Shell of electric vehicle and manufacturing method and mold thereof

Abstract

The invention discloses a shell of an electric vehicle and a manufacturing method and a die thereof, the shell of the electric vehicle comprises an iron main body and a plastic frame body, and the frame body and the main body are fixedly connected through die casting; the main body is made of iron or aluminum materials, and the frame body is made of nylon. The use amount of plastic can be greatly reduced, so that the safety of the electric vehicle is improved, and the occurrence rate of fire behavior is reduced.

Description

Technical Field

[0001] This invention relates to the field of electric vehicle technology, and in particular to an electric vehicle shell, its manufacturing method, and a mold. Background Technology

[0002] With the increasing demand for travel, electric bicycles, electric scooters, and other electric vehicles are being used more and more frequently in people's lives. Traditionally, the outer shell of electric vehicles is made of plastic parts processed by injection molding, which reduces the overall weight of the vehicle, lowers manufacturing costs, and keeps repair and replacement costs low. However, with the increase in the battery capacity of electric vehicles, fires during charging are becoming more frequent. Because the outer shell of electric vehicles is made of plastic, once a fire starts, it spreads rapidly and is difficult to extinguish, often damaging surrounding property and causing significant secondary damage to people and property. To mitigate or avoid damage caused by fires, improving battery safety is one aspect, but replacing the plastic outer shell of electric vehicles is even more urgent. Summary of the Invention

[0003] The purpose of this invention is to provide an outer shell for an electric vehicle, a method for manufacturing the same, and a mold, thereby solving the problem that existing plastic outer shells for electric vehicles are prone to catching fire and spreading the fire.

[0004] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0005] An electric vehicle shell includes a main body made of iron or aluminum and a plastic frame. The frame has a cutout with the same shape and size as the main body. The main body is set in the cutout of the frame, and the frame is fixedly connected to the main body by injection molding. The main body is also provided with auxiliary components that are fixedly connected to the frame.

[0006] The auxiliary components are through holes set at the connection between the main body and the frame; or inward notches opening at the edge of the main body; or barbs set on the surface of the main body and protruding from the surface of the main body; or barbs set in pairs on the upper and lower surfaces of the main body; the barbs are set at the connection between the main body and the frame.

[0007] The auxiliary components are through holes located at the connection between the main body and the frame, and barbs located on the surface of the main body and protruding from the surface of the main body.

[0008] The notch is an inward circular groove, or an elongated groove with an inward slanted opening, or an open parallelogram-shaped groove, or an elongated groove with the middle lower than the edge of the main body and rounded ends.

[0009] The edges of the main body are equipped with positioning components to prevent it from moving within the mold.

[0010] The positioning component is either a perforated ear that is positioned on the edge of the main body and is used for mold positioning, or a downwardly bent positioning insert that is positioned on the edge of the main body and is used for mold positioning.

[0011] The thickness of the main body is 0.3-1.5mm; the frame is made of nylon.

[0012] A method for manufacturing the aforementioned outer shell of an electric vehicle, comprising the following steps:

[0013] S1. Take a piece of iron and make it into a main body of the corresponding shape according to the shell of different parts of the electric vehicle.

[0014] S2, create auxiliary parts along the edge of the main body;

[0015] S3, the main body made in step S2 is placed into the corresponding mold for injection molding and casting, forming the outer shell of the electric vehicle that is fixedly connected to the outer edge of the main body and the plastic frame in one piece.

[0016] In step S2, a positioning component is positioned at the edge of the main body. This positioning component is a perforated ear that is positioned by a matching mold at the edge of the main body.

[0017] In step S2, a positioning component is provided on the edge of the main body. This positioning component is a downwardly bent positioning insert that is positioned on the edge of the main body in conjunction with the mold.

[0018] A mold for implementing the aforementioned method for manufacturing the outer shell of an electric vehicle, comprising an upper mold and a lower mold, the lower mold having a cavity plate, the cavity plate having a cavity for placing the main body of the outer shell of the electric vehicle and a flow channel for injection molding the frame of the outer shell of the electric vehicle, and a fixing member for preventing the main body from moving within the cavity.

[0019] The fixing element is a magnet installed inside the cavity.

[0020] When performing S3, the iron body is first placed into the cavity of the lower mold, where magnets fix the body in place. Then, the upper and lower molds are closed for injection molding.

[0021] The lower mold also has a positioning post in the flow channel and a positioning component on the edge of the main body. The positioning component is a perforated ear that is positioned on the edge of the main body to cooperate with the mold positioning. When implementing S3, the main body of the electric vehicle shell is first placed into the cavity of the lower mold, and the positioning post is inserted into the perforation of the ear.

[0022] The lower mold also has a slot in the flow channel and a positioning component on the edge of the main body. The positioning component is a downwardly bent positioning insert that is set on the edge of the main body and is used to position the mold. When performing S3, the main body of the electric vehicle shell is first placed into the cavity of the lower mold and its positioning insert is inserted into the slot.

[0023] In view of the above technical features, the present invention has the following beneficial effects: 1. The main body of the outer shell is made of iron or aluminum metal, and the frame is made of plastic, which greatly reduces the amount of plastic used. In the event of a fire, the fire intensity is much lower than that of existing plastic shells; 2. The main body is made of iron or aluminum, which provides greater strength than existing plastic shells; 3. The frame of the outer shell is made of nylon, which is heat-resistant and has a high ignition point. In the event of a fire, it is not easily combustible, and it is not easily deformed during the painting process; 4. The safety of electric vehicles is greatly improved. Even if a fire occurs, the fire will not spread because of the small amount of plastic used, and the use of heat-resistant nylon further reduces secondary damage from the fire. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the structure of the outer shell of the electric vehicle of the present invention, according to one embodiment.

[0025] Figure 2 This is a schematic diagram of the frame structure of an embodiment of the electric vehicle shell of the present invention.

[0026] Figure 3 This is a schematic diagram of the main body of the outer shell of the electric vehicle of the present invention, according to one embodiment.

[0027] Figure 4 yes Figure 3 Enlarged view of point A in the middle.

[0028] Figure 5 This is a schematic diagram of the main body of Embodiment 2 of the present invention.

[0029] Figure 6 yes Figure 5 Enlarged view of point B in the middle.

[0030] Figure 7 This is a schematic diagram of the main body of Embodiment 3 of the present invention.

[0031] Figure 8 yes Figure 7 Enlarged view of point C in the middle.

[0032] Figure 9 This is a schematic diagram of the main body of Embodiment 4 of the present invention.

[0033] Figure 10 yes Figure 9 Enlarged view of point D in the middle.

[0034] Figure 11 This is a schematic diagram of the main body of Embodiment 5 of the present invention.

[0035] Figure 12 yes Figure 11 Enlarged view of point E in the middle.

[0036] Figure 13 This is an exploded view of the structure of Embodiment Six of the present invention.

[0037] Figure 14 This is an exploded view of the structure of Embodiment Seven of the present invention.

[0038] Figure 15 This is one of the mold structure diagrams of the present invention.

[0039] Figure 16 This is the second mold structure diagram of the present invention.

[0040] Figure 17 yes Figure 16 Enlarged view of point F in the middle.

[0041] Figure 18 This is the third mold structure diagram of the present invention.

[0042] Figure 19 yes Figure 18 A magnified view of point G in the middle.

[0043] In the diagram: 1-Main body; 11-Through hole; 12-Barb; 13-Notch; 2-Frame; 21-Hollow; 3-Ear; 31-Perforation; 4-Positioning insert; 5-Upper mold; 6-Lower mold; 61-Cavity plate; 62-Cavity; 63-Runway; 7-Magnet; 8-Positioning post; 9-Slot. Detailed Implementation

[0044] The present invention will be further described below with reference to specific embodiments. It should be understood that these embodiments are for illustrative purposes only and are not intended to limit the scope of the invention. Furthermore, it should be understood that after reading the teachings of this invention, those skilled in the art can make various alterations or modifications to the invention, and these equivalent forms also fall within the scope defined by the appended claims.

[0045] This invention discloses an outer shell for an electric vehicle. It should be noted that the outer shell of an electric vehicle includes outer shells of different parts such as the front windshield shell, the front storage box shell, and the outer shell around the seat bucket, which are well known to those skilled in the art. Therefore, the electric vehicle shell described in this invention is a general term for the outer shells of various parts of existing electric vehicles.

[0046] like Figure 1-14 As shown, an electric vehicle shell includes a main body 1 made of iron or aluminum and a plastic frame 2. The frame 2 is fixedly connected to the main body 1 by injection molding. In this way, the amount of plastic used in the electric vehicle shell is greatly reduced, and the fire will not be large in the event of a fire.

[0047] Preferably, the thickness of the main body 1 is 0.3-1.5mm. Using iron material to make the main body 1 can control costs, while using aluminum material to make the main body 1 can make it lighter than iron material. The thinness of the main body 1 can reduce the weight of the entire shell.

[0048] Furthermore, the plastic used for frame 2 is made of nylon. Nylon is heat-resistant, has a high ignition point, and is not easily combustible. In the event of a fire, nylon will significantly reduce secondary damage. Moreover, the use of nylon for frame 2 makes the outer shell less prone to deformation during painting.

[0049] like Figure 2 , 13 As shown in Figures 1 and 14, the frame 2 has a cutout 21 that is the same shape and size as the main body 1, and the main body 1 is set at the cutout 21 of the frame 2.

[0050] like Figure 3-12 As shown, the main body 1 is also provided with auxiliary components that are fixedly connected to the frame 2.

[0051] The auxiliary component is a through hole 11 located at the connection between the main body 1 and the frame 2. Multiple through holes 11 can be evenly arranged along the edge of the main body 1. The function of the through holes 11 is that during the injection molding process, plastic can fill the through holes 11, making the frame 2 and the main body 1 more firmly connected and preventing them from falling off.

[0052] like Figure 3 , Figure 4 As shown, the auxiliary component is a barb 12 that is set on the surface of the main body 1 and protrudes from the surface of the main body 1. The barb 12 is set on the upper or lower surface of the main body 1, or in pairs on the upper and lower surfaces of the main body 1. Its function is that during the injection molding process, the plastic will firmly wrap around the barb 12, making the combination between the main body 1 and the frame 2 more secure and preventing it from falling off.

[0053] Barbs 12 are provided at the connection between the main body 1 and the frame 2. Multiple or pairs can be evenly provided along the edge of the main body 1.

[0054] Furthermore, a through hole 11 and a barb 12 can be provided at the connection between the main body 1 and the frame 2.

[0055] like Figure 5-12 As shown, the auxiliary component can also be an inwardly facing notch 13 located on the main body 1 and opening at the edge of the main body; the notch 13 can be as follows: Figure 5 , Figure 6 The inward circular groove shown, or as... Figure 9 , Figure 10 The elongated groove shown has an inwardly angled opening, or as... Figure 11 , Figure 12 The parallelogram-shaped groove with the opening shown, or as... Figure 7 , Figure 8 The image shows a long, narrow groove that is lower in the middle than the edge of the main body 1 and has rounded ends. This embodiment is actually a variation of the through hole 11 embodiment, and its function is the same as that of the through hole 11. Similarly, during the injection molding process, the plastic can fill the notch 13, making the frame 2 more firmly attached to the main body 1 and preventing it from falling off.

[0056] To prevent the main body 1 from shifting during mold closing and injection molding, positioning components are provided on the edges of the main body 1 to prevent it from moving within the mold.

[0057] like Figure 13 As shown, the positioning component is an ear 3 with a through hole 31 that is set on the edge of the main body 1 and is positioned in conjunction with the mold. Correspondingly, a positioning post 8 that cooperates with the ear 3 is provided in the mold. The positioning post 8 passes through the through hole 31 of the ear 3 to position the main body 1 in the mold.

[0058] like Figure 14 As shown, the positioning component is a downwardly bent positioning insert 4 set on the edge of the main body 1. Correspondingly, a slot 9 that mates with the positioning insert 4 is provided in the mold. The positioning insert 4 is inserted into the slot 9 to position the main body 1 in the mold.

[0059] A method for manufacturing the outer shell of an electric vehicle as described above, comprising the following steps:

[0060] S1. Take a piece of iron or aluminum and make it into a main body 1 of the corresponding shape according to the outer shell of different parts of the electric vehicle.

[0061] S2, create auxiliary parts on the edge of the main body 1;

[0062] like Figure 3-6 As shown, the auxiliary component can be a through hole 11 provided at the connection between the main body 1 and the frame 2; or, it can be a barb 12 provided on the surface of the main body 1 and protruding from the surface of the main body 1. The barb 12 can be provided on the upper or lower surface of the main body 1, or it can be provided in pairs on the upper and lower surfaces of the main body 1; the auxiliary component can also be a through hole 11 and a barb 12 provided at the connection between the main body 1 and the frame 2.

[0063] Furthermore, such as Figure 13-14 As shown, the edge of the main body 1 is provided with a positioning component to prevent the main body 1 from moving in the mold during mold closing and injection molding. This positioning component is an ear 3 with a through hole 31 that is provided on the edge of the main body 1 and is positioned to cooperate with mold positioning; or, the positioning component is a downwardly bent positioning insert 4 that is provided on the edge of the main body 1 and is positioned to cooperate with mold positioning.

[0064] S3, the main body 1 made in step S2 is placed into the corresponding mold for injection molding and casting, forming the outer shell of the electric vehicle that is fixedly connected to the outer edge of the main body 1 and the plastic frame 2 in one piece.

[0065] A mold for implementing the aforementioned method of manufacturing the outer shell of an electric vehicle, such as... Figure 15-19 As shown, it includes an upper mold 5 and a lower mold 6. The lower mold 6 is provided with a cavity plate 61. The cavity plate 61 is provided with a cavity 62 for placing the main body 1 of the electric vehicle shell and a flow channel 63 for injection molding the frame 2 of the electric vehicle shell. The cavity 62 is provided with a fixing member to prevent the main body 1 from moving.

[0066] Preferably, the fixing element is a magnet 7 disposed in the cavity 62, used to attract the iron body 1.

[0067] When implementing step S3, the iron body 1 is first placed into the cavity 62 of the lower mold 6. The magnet 7 in the cavity 62 attracts and fixes the body 1. Then, the upper mold 5 and the lower mold 6 are closed. The body 1 will not shift during the mold closing process. Then, injection molding is performed to make a frame 2 on the edge of the body 1. The frame 2 is fixedly connected to the body 1 to form the shell of the electric vehicle.

[0068] The cavity 62 of the mold is designed according to the shape of the outer shell of different parts of the electric vehicle. Therefore, to make the outer shell of the entire electric vehicle, multiple different molds are needed. The only difference between these molds is the shape of the cavity 62. The manufacturing method and structure of the outer shell are the same.

[0069] like Figure 16 , Figure 17 As shown, a positioning post 8 is also provided in the flow channel 63 of the lower mold 6. When implementing S3, the main body 1 of the electric vehicle shell with the ear 3 is first placed into the cavity 62 of the lower mold 6. The positioning post 8 is inserted into the through hole 31 of the ear 3 to further position the main body 1 in the cavity 62 without moving. After injection molding, the ear 3 is wrapped in the frame 2. A small hole is left on the lower surface of the frame 2 at the position of the positioning post 8.

[0070] like Figure 18 , Figure 19 As shown, another positioning method of the main body 1 in the mold is provided. The flow channel 63 of the lower mold 6 is also provided with a slot 9. When implementing S3, the main body 1 of the electric vehicle shell with positioning insert 4 is first placed into the cavity 62 of the lower mold 6. The positioning insert 4 is inserted into the slot 9, which further positions the main body 1 in the cavity 62 without moving. After injection molding, the upper end of the positioning insert 4 is wrapped in the frame 2, and a part of the lower end of the positioning insert 4 protrudes from the lower surface of the frame 2.

[0071] The above description is merely a preferred embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. The outer shell of an electric vehicle, characterized in that: It includes a main body (1) made of iron or aluminum and a plastic frame (2). The frame (2) has a cutout (21) that is the same shape and size as the main body (1). The main body (1) is set at the cutout (21) of the frame (2). The frame (2) is fixedly connected to the main body (1) by injection molding. The main body (1) is also provided with auxiliary components that are fixedly connected to the frame (2).

2. The outer shell of the electric vehicle as described in claim 1, characterized in that: The auxiliary components are through holes (11) provided at the connection between the main body (1) and the frame (2); or inward notches (13) opening at the edge of the main body (1); or barbs (12) provided on the surface of the main body (1) and protruding from the surface of the main body (1); or barbs (12) provided in pairs on the upper and lower surfaces of the main body (1); the barbs (12) are provided at the connection between the main body (1) and the frame (2).

3. The outer shell of the electric vehicle as described in claim 2, characterized in that: The auxiliary components are a through hole (11) provided at the connection between the main body (1) and the frame (2) and a barb (12) provided on the surface of the main body (1) and protruding from the surface of the main body (1).

4. The outer shell of the electric vehicle as described in claim 2, characterized in that: The notch (13) is an inward circular groove, or an elongated groove with an opening that slopes inward, or an open parallelogram-shaped groove, or an elongated groove with the middle lower than the edge of the main body (1) and rounded ends.

5. The outer shell of the electric vehicle as described in claim 1, characterized in that: The edges of the main body (1) are provided with positioning parts to prevent it from moving in the mold.

6. The outer shell of the electric vehicle as described in claim 4, characterized in that: The positioning component is an ear (3) with a perforation (31) that is positioned in conjunction with the mold on the edge of the main body (1), or a downwardly bent positioning insert (4) that is positioned in conjunction with the mold on the edge of the main body (1).

7. The outer shell of the electric vehicle as described in claim 1, characterized in that: The thickness of the main body (1) is 0.3-1.5mm; the frame (2) is made of nylon.

8. A method for manufacturing the outer shell of an electric vehicle as described in claim 1, 2, 3, 4, 5, 6, or 7, characterized in that: The steps for its production are as follows: S1. Take an iron or aluminum sheet and make it into a body of the corresponding shape according to the outer shell of different parts of the electric vehicle (1). S2, make auxiliary parts on the edge of the main body (1); S3, the main body (1) made in step S2 is placed into the corresponding mold for injection molding and casting, forming the outer shell of the electric vehicle with the outer edge of the main body (1) and the plastic frame (2) fixedly connected.

9. The method for manufacturing the outer shell of an electric vehicle as described in claim 8, characterized in that: In step S2, a positioning component is provided on the edge of the main body (1). The positioning component is an ear (3) with a perforation (31) that is positioned on the edge of the main body (1) in conjunction with the mold.

10. The method for manufacturing the outer shell of an electric vehicle as described in claim 8, characterized in that: In step S2, a positioning component is provided on the edge of the main body (1). The positioning component is a downwardly bent positioning insert (4) that is positioned on the edge of the main body (1) in conjunction with the mold.

11. A mold for implementing the method of manufacturing the outer shell of an electric vehicle as described in claim 8, characterized in that: It includes an upper mold (5) and a lower mold (6). The lower mold (6) is provided with a cavity plate (61). The cavity plate (61) is provided with a cavity (62) for placing the main body (1) of the electric vehicle shell and a flow channel (63) for injection molding the frame (2) of the electric vehicle shell. The cavity (62) is provided with a fixing member to prevent the main body (1) from moving.

12. The mold as described in claim 11, characterized in that: The fixing element is a magnet (7) installed inside the cavity (62).

13. The mold as described in claim 12, characterized in that: When implementing S3, the iron body (1) is first placed into the cavity (62) of the lower mold (6), and the magnet (7) in the cavity (62) fixes the body (1). Then the upper mold (5) and the lower mold (6) are closed and injection molded.

14. The mold as described in claim 11, characterized in that: A positioning post (8) is also provided in the flow channel (63) of the lower mold (6), and a positioning component is provided on the edge of the main body (1). The positioning component is an ear (3) with a perforation (31) that is positioned on the edge of the main body (1) in conjunction with the mold. When implementing S3, the main body (1) of the electric vehicle shell is first placed into the cavity (62) of the lower mold (6), and the positioning post (8) is inserted into the perforation (31) of the ear (3).

15. The mold as described in claim 11, characterized in that: The lower mold (6) has a slot (9) in the flow channel (63) and a positioning component is provided on the edge of the main body (1). The positioning component is a downwardly bent positioning insert (4) that is set on the edge of the main body (1) to cooperate with the mold positioning. When implementing S3, the main body (1) of the electric vehicle shell is first placed into the cavity (62) of the lower mold (6), and its positioning insert (4) is inserted into the slot (9).

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