Novel carbon fiber composite non-bearing type chassis

Abstract

The invention relates to a novel carbon fiber composite non-bearing type chassis, and belongs to the technical field of automobiles. The chassis mainly comprises a frame body made of a carbon fiber composite material, an independent suspension arranged in front of the frame and a rear steel plate spring non-independent suspension arranged behind the frame. A composite material adopted by the frame body is composed of glass fiber felt, carbon fibers, unsaturated polyester resin and methyl ethyl ketone peroxide. Optimized layout of the independent suspension is achieved through a lateral installation frame body, a front suspension supporting beam, a thrust rod, a lower swing arm and other components, and the connection rigidity of the rear suspension is improved through specific front and rear lifting lug base assemblies. A special suspension support and a suspension pad are further designed between the frame and the vehicle body to block vibration transmission. Compared with a traditional metal chassis, on the basis that the weight is greatly reduced and the fuel economy is improved, the stress of a suspension mounting point is reduced by 10%, the rigidity of a rear suspension connecting part is improved by 20%, and the vibration noise in a vehicle can be remarkably reduced by 12 dB.

Description

Technical Field

[0001] This invention belongs to the field of vehicle frame technology, specifically relating to a novel carbon fiber composite material non-load-bearing chassis. Background Technology

[0002] In the automotive industry, with increasingly stringent environmental and energy-saving requirements, lightweighting has become a crucial development trend for improving fuel economy and reducing emissions. As the core load-bearing component of a vehicle, weight reduction in the chassis is essential for enhancing overall vehicle performance.

[0003] Traditional non-load-bearing chassis typically use rigid frames made of steel or other metal materials, welded or stamped together. While metal materials offer good strength and rigidity, meeting the mechanical performance requirements of the chassis as the support base for the entire vehicle, their significant weight increases the vehicle's curb weight, directly limiting further improvements in fuel economy and negatively impacting the vehicle's handling agility.

[0004] In recent years, novel carbon fiber composites, represented by carbon fiber and glass fiber, have gradually gained attention in the field of automotive lightweighting due to their high specific strength, high specific modulus, excellent corrosion resistance, and fatigue resistance. However, applying these materials to non-load-bearing rigid chassis frames that need to withstand complex alternating loads still faces many challenges: 1. Difficulty in structural integration: Non-load-bearing chassis require the installation of complex mechanisms such as independent suspension or leaf spring suspension, and the connection methods of traditional metal frames are difficult to directly transfer to carbon fiber composite components.

[0005] 2. Balancing performance and cost is challenging: How to balance stiffness requirements and manufacturing efficiency while ensuring frame strength through reasonable material ratios and cross-sectional design.

[0006] 3. Complex manufacturing process: Large-sized and complex-shaped chassis components have extremely high requirements for molding process. If traditional pressing process is used, the equipment cost is expensive and the yield rate is difficult to guarantee.

[0007] In view of this, this solution was developed. Summary of the Invention

[0008] In view of the shortcomings of the prior art, the technical problem to be solved by the present invention is to provide a novel carbon fiber composite non-load-bearing chassis that is lighter and stronger.

[0009] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is: a novel carbon fiber composite material non-load-bearing chassis, including a frame body, an independent suspension disposed in front of the frame body, and a rear leaf spring non-independent suspension disposed behind the frame body; the frame body is made of carbon fiber composite material. The independent suspension includes two sets of lateral mounting frames, a front suspension crossbeam, and a strut connecting rod. The two lateral mounting frames are installed on both sides of the front end of the vehicle frame body. The lateral mounting frame includes a front suspension support beam, a thrust rod, a lower control arm, a front support, and a front strut. The front support is connected to the side wall of the mounting frame, and the outward-facing side of the front support has a mounting notch. The front strut is installed within the mounting notch and faces downward. The front suspension support beam is installed at the bottom of the vehicle frame body and at the front end of the front support. The lower surface of the front suspension support beam has a mounting seat. The lower control arm is connected to the lower surface of the vehicle frame body and is located below the front support. One end of the thrust rod is connected to the mounting seat, and the other end of the thrust rod is connected to the lower control arm. The lower end of the front strut is connected to the lower control arm. The two front supports are connected by a strut connecting rod, and the two front suspension support beams are connected by a front suspension crossbeam.

[0010] Furthermore, the front support includes a first top plate, two first side plates and a first back plate. The first top plate is connected to the upper end of the first back plate, and the two first side plates are respectively connected to the two sides of the first top plate and the first back plate. The first top plate, the two first side plates and the first back plate surround to form an installation notch, and the first top plate is provided with a first installation hole.

[0011] Furthermore, the front suspension support beam includes a first base plate and a support plate. The first base plate is connected to the lower part of the vehicle frame body, and the first support plate is connected to the outer side of the first base plate and connected to the side of the vehicle frame body. The mounting seat has a shaft hole, one end of the thrust rod extends into the shaft hole, and the other end of the thrust rod is horizontally hinged to the lower control arm.

[0012] Furthermore, the rear leaf spring non-independent suspension includes two sets of rear mounting brackets, which are installed on both sides of the rear end of the vehicle frame body. Each rear mounting bracket includes a front rear suspension hanger assembly, a rear rear suspension hanger assembly, and a leaf spring suspension. The front rear suspension hanger assembly and the rear rear suspension hanger assembly are located on the side of the vehicle frame body and are spaced apart. The two ends of the leaf spring suspension are hinged to the front rear suspension hanger assembly and the rear rear suspension hanger assembly respectively through hinge plates on both sides.

[0013] Furthermore, the vehicle frame body and the vehicle body bottom longitudinal beam are connected by a vehicle body suspension bracket and a connector. The vehicle body suspension bracket is connected to one side of the vehicle frame body. The vehicle body suspension bracket includes a second top plate, a second back plate and two second side plates. The second top plate is connected to the upper end of the second back plate, and the two second side plates are respectively connected to the two sides of the second top plate and the second back plate. The connector passes through the vehicle body bottom longitudinal beam and the second top plate and is connected to the bolt. A vehicle body suspension pad is provided between the vehicle body bottom longitudinal beam and the second top plate and is sleeved on the periphery of the connector.

[0014] Furthermore, the carbon fiber composite material is composed of 30-35% glass mat, 22-25% carbon fiber, 40-45% 994# pre-accelerated phthalic unsaturated polyester resin, and 1-2% BUTANOX-M-50 peroxide methyl ethyl ketone.

[0015] Furthermore, the frame body includes crossbeams and longitudinal beams, which are arranged in a matrix pattern under horizontal projection. The manufacturing processes for the crossbeams and longitudinal beams are as follows: S1. Connect the mold to the water temperature machine heating system; S2. The prepared carbon fiber composite material is laid flat on the mold in sequence; S3. Lay a layer of release cloth on the carbon fiber composite material, and the release cloth completely covers the carbon fiber composite material. S4. Lay a layer of flow guide cloth on the release cloth, and then lay flow guide tubes on the flow guide cloth; S5. Apply sealing strips around the laid material to form a closed loop; S6. Lay a vacuum bag film on the release cloth, and attach the bag film to the sealing strip around the edges to form a sealed cavity with the mold that encloses all the laid material. S7. Install the vacuum valve, quick coupling, and vacuum tubing; S8. Pour in the prepared vinyl resin until the resin completely impregnates the carbon fiber composite material; S9. Start the water temperature controller heating system and wait for the product to cure.

[0016] Compared with the prior art, the present invention has the following beneficial effects: 1. This invention uses a carbon fiber composite material, composed of carbon fiber, fiberglass mat, and unsaturated polyester resin, to replace traditional metal materials in the manufacture of the vehicle frame. Due to the extremely high specific strength and low density of the carbon fiber composite material, it can significantly reduce weight compared to a traditional metal frame, thereby reducing the vehicle's curb weight, significantly improving fuel economy, and reducing carbon emissions.

[0017] 2. Through the coordinated design of the lateral mounting frame, front suspension support beam, and thrust rod, the layout of the suspension mounting points has been optimized, reducing the stress at the independent suspension mounting points by 10%, effectively reducing stress concentration, and enhancing connection strength.

[0018] 3. The rear suspension front hanger assembly, rear suspension rear hanger assembly, and leaf spring suspension designed for the rear leaf spring non-independent suspension improve the support capacity of the leaf spring suspension, increasing the stiffness of the connection between the rear suspension and the vehicle frame by 20%, thus ensuring the vehicle's driving safety under heavy loads and complex road conditions.

[0019] 4. This invention incorporates a specific suspension bracket designed between the vehicle frame and the longitudinal beams of the vehicle body, along with a matching vehicle body suspension pad. This combination effectively blocks and absorbs vibration transmission between the frame and the body. Tests have shown that in-vehicle vibration noise can be reduced by 12dB, significantly improving the quietness and comfort of the ride. Attached Figure Description

[0020] Figure 1 This is a three-dimensional structural diagram of the location where the independent suspension is installed in this invention; Figure 2 This is a three-dimensional structural diagram of the non-independent suspension position of the leaf spring after installation in this invention; Figure 3 This is a front view structural diagram of the location where the vehicle body suspension pad is installed in this invention.

[0021] The markings in the diagram are: 1. Vehicle frame body; 2. Independent suspension; 21. Lateral mounting bracket; 211. Front suspension support beam; 2111. First base plate; 2112. Support plate; 2113. Mounting seat; 212. Thrust rod; 213. Lower control arm; 214. Front support; 215. Front strut; 22. Front suspension crossbeam; 23. Strut connecting rod; 3. Rear leaf spring non-independent suspension; 31. Rear suspension front hanger assembly; 32. Rear suspension rear hanger assembly; 33. Leaf spring suspension; 4. Vehicle body suspension pad. Detailed Implementation

[0022] To make the above features and advantages of the present invention more apparent and understandable, specific embodiments are described below in conjunction with the accompanying drawings for detailed explanation.

[0023] like Figures 1-3 As shown, this embodiment provides a novel carbon fiber composite non-load-bearing chassis, including a frame body 1, an independent suspension 2 disposed in front of the frame body 1, and a rear leaf spring non-independent suspension 3 disposed behind the frame body 1.

[0024] The frame body 1 is made of carbon fiber composite material. This carbon fiber composite material consists of 30-35% glass felt, 22-25% carbon fiber, 40-45% 994# pre-accelerated phthalic unsaturated polyester resin, and 1-2% BUTANOX-M-50 methyl ethyl ketone peroxide. Specifically, the parameters are 30% glass felt, 25% carbon fiber, 43% 994# pre-accelerated phthalic unsaturated polyester resin, and 2% BUTANOX-M-50 methyl ethyl ketone peroxide. Utilizing the high specific strength and low density characteristics of carbon fiber composite material, a significant weight reduction is achieved compared to traditional metal frames, resulting in a substantial improvement in the vehicle's fuel economy and a reduction in carbon emissions.

[0025] The independent suspension 2 includes two sets of lateral mounting frames 21, a front suspension crossbeam 22, and a strut connecting rod 23. The two lateral mounting frames 21 are installed on both sides of the front end of the vehicle frame body 1.

[0026] The lateral mounting frame 21 includes a front suspension support beam 211, a thrust rod 212, a lower control arm 213, a front support 214, and a front strut 215. The front support 214 is connected to the side wall of the mounting frame and has an installation notch on its outward-facing side. The front strut 215 is installed in the installation notch and faces downward. The front suspension support beam 211 is installed at the bottom of the frame body 1 and is located at the front end of the front support 214. The lower surface of the front suspension support beam 211 has a mounting seat 2113. The lower control arm 213 is connected to the lower surface of the frame body 1 and is located below the front support 214. One end of the thrust rod 212 is connected to the mounting seat 2113, and the other end of the thrust rod 212 is connected to the lower control arm 213. The lower end of the front strut 215 is connected to the lower control arm 213. The two front supports 214 are connected by a strut connecting rod 23, and the two front suspension support beams 211 are connected by a front suspension crossbeam 22.

[0027] The front support 214 has the following specific structure: The front support 214 includes a first top plate, two first side plates and a first back plate. The first top plate is connected to the upper end of the first back plate, and the two first side plates are respectively connected to the two sides of the first top plate and the first back plate. The first top plate, the two first side plates and the first back plate surround to form an installation notch, and a first installation hole is provided on the first top plate.

[0028] The specific structure of the front suspension support beam 211 is as follows: The front suspension support beam 211 includes a first base plate 2111 and a support plate 2112. The first base plate 2111 is connected to the lower part of the vehicle frame body 1, and the first support plate 2112 is connected to the outer side of the first base plate 2111 and to the side of the vehicle frame body 1. The mounting seat 2113 has a shaft hole, one end of the thrust rod 212 extends into the shaft hole, and the other end of the thrust rod 212 is horizontally hinged to the lower control arm 213. This optimized layout effectively disperses the dynamic load during suspension operation and avoids stress concentration at the connection points. Testing showed that this design reduced the stress at the suspension mounting points by 10%, significantly enhancing the connection strength and service life of the front of the chassis.

[0029] The rear leaf spring non-independent suspension 3 includes two sets of rear mounting brackets, which are installed on both sides of the rear end of the vehicle frame body 1. Each rear mounting bracket includes a front rear suspension hanger assembly 31, a rear rear suspension hanger assembly 32, and a leaf spring suspension 33. The front rear suspension hanger assembly 31 and the rear rear suspension hanger assembly 32 are located on the sides of the vehicle frame body 1 and are spaced apart. The leaf spring suspension 33 is hinged to the front rear suspension hanger assembly 31 and the rear rear suspension hanger assembly 32 at both ends via hinge plates on both sides. This specific hanger assembly design improves the stability of the leaf spring support. Compared to conventional designs, the stiffness of its connection points is increased by 20%, ensuring vehicle safety under heavy loads and complex operating conditions, as well as the torsional rigidity of the vehicle frame.

[0030] The chassis body 1 is connected to the longitudinal beams of the vehicle body using a chassis suspension bracket and connectors. The chassis suspension bracket is connected to one side of the chassis body 1 and includes a second top plate, a second back plate, and two second side plates. The second top plate is connected to the upper end of the second back plate, and the two second side plates are respectively connected to the sides of the second top plate and the second back plate. The connectors pass through the longitudinal beams of the vehicle body and the second top plate and are connected to bolts. A chassis suspension pad 4 is provided between the longitudinal beams of the vehicle body and the second top plate, fitted around the periphery of the connector. The chassis suspension pad 4 is fitted inside the bracket. This suspension system utilizes the damping properties of composite materials and buffer pads to efficiently absorb and block the transmission of vibrations from the road surface. Test data shows that this design significantly reduces in-vehicle vibration noise by approximately 12 dB, greatly improving the quietness and ride comfort of the cockpit.

[0031] The frame body 1 includes crossbeams and longitudinal beams, and the vertical cross-section of the crossbeams and longitudinal beams is C-shaped; the crossbeams and longitudinal beams are spliced ​​together to form a rectangular frame, and multiple reinforcing intermediate beams are also set between the two crossbeams; This embodiment provides the manufacturing process for the crossbeam and longitudinal beam as follows: S1. Connect the mold to the water temperature machine heating system; S2. The prepared carbon fiber composite material is laid flat on the mold in sequence; S3. Lay a layer of release cloth on the carbon fiber composite material, and the release cloth completely covers the carbon fiber composite material. S4. Lay a layer of flow guide cloth on the release cloth, and then lay flow guide tubes on the flow guide cloth; S5. Apply sealing strips around the laid material to form a closed loop; S6. Lay a vacuum bag film on the release cloth, and attach the bag film to the sealing strip around the edges to form a sealed cavity with the mold that encloses all the laid material. S7. Install the vacuum valve, quick coupling, and vacuum tubing; S8. Pour in the prepared vinyl resin until the resin completely impregnates the carbon fiber composite material; S9. Start the water temperature controller heating system and wait for the product to cure.

[0032] The foregoing has shown and described the basic principles and main features of the present invention, as well as its advantages. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the present invention. Various changes and modifications can be made to the present invention without departing from its spirit and scope. All such changes and modifications fall within the scope of the present invention as claimed, which is defined by the appended claims and their equivalents.

Claims

1. A novel carbon fiber composite non-load-bearing chassis, characterized in that: It includes a frame body, an independent suspension located at the front of the frame body, and a rear leaf spring non-independent suspension located at the rear of the frame body; the frame body is made of carbon fiber composite material. The independent suspension includes two sets of lateral mounting frames, a front suspension crossbeam, and a strut connecting rod. The two lateral mounting frames are installed on both sides of the front end of the vehicle frame body. The lateral mounting frame includes a front suspension support beam, a thrust rod, a lower control arm, a front support, and a front strut. The front support is connected to the side wall of the mounting frame, and the outward-facing side of the front support has a mounting notch. The front strut is installed within the mounting notch and faces downward. The front suspension support beam is installed at the bottom of the vehicle frame body and at the front end of the front support. The lower surface of the front suspension support beam has a mounting seat. The lower control arm is connected to the lower surface of the vehicle frame body and is located below the front support. One end of the thrust rod is connected to the mounting seat, and the other end of the thrust rod is connected to the lower control arm. The lower end of the front strut is connected to the lower control arm. The two front supports are connected by a strut connecting rod, and the two front suspension support beams are connected by a front suspension crossbeam.

2. The novel carbon fiber composite non-load-bearing chassis according to claim 1, characterized in that: The front support includes a first top plate, two first side plates and a first back plate. The first top plate is connected to the upper end of the first back plate, and the two first side plates are respectively connected to the sides of the first top plate and the first back plate. The first top plate, the two first side plates and the first back plate surround to form an installation notch, and the first top plate is provided with a first installation hole.

3. The novel carbon fiber composite non-load-bearing chassis according to claim 1, characterized in that: The front suspension support beam includes a first base plate and a support plate. The first base plate is connected to the lower part of the vehicle frame body, and the first support plate is connected to the outer side of the first base plate and connected to the side of the vehicle frame body. The mounting seat has a shaft hole, one end of the thrust rod extends into the shaft hole, and the other end of the thrust rod is horizontally hinged to the lower control arm.

4. The novel carbon fiber composite non-load-bearing chassis according to claim 1, characterized in that: The rear leaf spring non-independent suspension includes two sets of rear mounting brackets, which are installed on both sides of the rear end of the vehicle frame body. Each rear mounting bracket includes a front rear suspension hanger assembly, a rear rear suspension hanger assembly, and a leaf spring suspension. The front rear suspension hanger assembly and the rear rear suspension hanger assembly are located on the side of the vehicle frame body and are spaced apart. The two ends of the leaf spring suspension are hinged to the front rear suspension hanger assembly and the rear rear suspension hanger assembly respectively through hinge plates on both sides.

5. The novel carbon fiber composite non-load-bearing chassis according to claim 1, characterized in that: The vehicle frame body and the longitudinal beam of the vehicle body are connected by a vehicle body suspension bracket and a connector. The vehicle body suspension bracket is connected to one side of the vehicle frame body. The vehicle body suspension bracket includes a second top plate, a second back plate and two second side plates. The second top plate is connected to the upper end of the second back plate. The two second side plates are respectively connected to the two sides of the second top plate and the second back plate. The connector passes through the longitudinal beam of the vehicle body and the second top plate and is connected to the bolt. A vehicle body suspension pad is provided between the longitudinal beam of the vehicle body and the second top plate and is sleeved on the periphery of the connector.

6. The novel carbon fiber composite non-load-bearing chassis according to claim 1, characterized in that: The carbon fiber composite material is composed of 30-35% glass mat, 22-25% carbon fiber, 40-45% 994# pre-accelerated phthalic unsaturated polyester resin and 1-2% BUTANOX-M-50 peroxide methyl ethyl ketone.

7. A novel carbon fiber composite non-load-bearing chassis according to claim 6, characterized in that: The frame body includes crossbeams and longitudinal beams, which are arranged in a matrix under the horizontal projection. The manufacturing processes for the crossbeams and longitudinal beams are as follows: S1. Connect the mold to the water temperature machine heating system; S2. The prepared carbon fiber composite material is laid flat on the mold in sequence; S3. Lay a layer of release cloth on the carbon fiber composite material, and the release cloth completely covers the carbon fiber composite material. S4. Lay a layer of flow guide cloth on the release cloth, and then lay flow guide tubes on the flow guide cloth; S5. Apply sealing strips around the laid material to form a closed loop; S6. Lay a vacuum bag film on the release cloth, and attach the bag film to the sealing strip around the edges to form a sealed cavity with the mold that encloses all the laid material. S7. Install the vacuum valve, quick coupling, and vacuum tubing; S8. Pour in the prepared vinyl resin until the resin completely impregnates the carbon fiber composite material; S9. Start the water temperature controller heating system and wait for the product to cure.

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