Integrated stretch forming process for a storage basket for a vehicle

Abstract

The application discloses a kind of integral stretch forming process of vehicle storage basket, it is related to bicycle, electric bicycle and power-assisted vehicle accessory technical field, basket body is by single metal sheet material and is integrally formed by continuous stretching, the basket bottom, side wall and mouth along are single continuous material transition structure without splicing gap, without welding point, mouth along is folded outward and is edge crimped and is pressed to form reinforcing flange, basket cover is by metal wire material and is bent into shape and is by outer periphery closed frame and internal support silk constitutes grid-shaped cover body, basket cover is connected with basket body by welding type hinge component, hinge component includes first welding sheet, second welding sheet respectively welded on basket body and basket cover and is rotatably connected by hinged axle.The application is seamlessly integrally formed by basket body, eliminates splicing weak link, load is evenly transmitted, and deformation resistance and destruction resistance are strong, reinforcing flange of folding edge crimping improves mouth along rigidity, eliminates sharp edge, improves use safety and comfort.

Description

Technical Field

[0001] This invention relates to the field of bicycle, electric bicycle and e-bike accessories technology, specifically to an integral stretch forming process for a vehicle storage basket. Background Technology

[0002] Currently, most bicycle baskets on the market are manufactured using a multi-step molding and splicing process. These processes mainly include the following types: splicing of metal wire welded frames, riveting or welding of stamped parts, bonding or snap-fit ​​assembly of injection molded parts, and assembling of woven parts and frames.

[0003] The shortcomings of existing car storage baskets are: 1. Patent document CN204896045U discloses an integrally stretched basket. "This utility model relates to a metal storage basket, particularly an integrally stretched basket formed by integrally stretching a metal mesh. The basket is formed by integrally extending a flat metal mesh into a three-dimensional frame-like structure. Reinforcing ribs are imprinted on the bottom and the relatively wide sides of the basket. Through grooves are formed on the relatively narrow sides of the basket to create handles for easy lifting. Outer and inner lining edges are riveted to the upper edge of the basket opening and the inner edges of the through grooves on the narrow sides, respectively." The basket is made of sheet metal mesh, which is stretched or extended to form a three-dimensional frame basket. This results in a metal basket with high hardness, strong wear resistance, good plasticity, and durability. The basket can be formed in one piece, which reduces the number of processing steps and the processing difficulty compared to traditional processing methods. At the same time, it reduces the raw materials and lowers the manufacturing cost, resulting in a new type of metal basket that is structurally stable, cost-effective, and durable. However, the document states that the upper edge of the basket opening and the inner edge of the through grooves on both sides are riveted with outer and inner lining edges, respectively, which presents technical problems such as splicing nodes and weak riveting. Summary of the Invention

[0004] The purpose of this invention is to provide an integral stretch forming process for a vehicle storage basket, so as to solve the technical problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a car storage basket, comprising a basket body and a basket lid, wherein the basket body is integrally formed by continuous stretching of a single metal sheet and is composed of a basket bottom, side walls and a mouth rim; The bottom, side walls and rim of the basket are a single continuous material transition structure without splicing gaps or welding points. The four corners of the basket are rounded, and the rim is folded outward and rolled and pressed to form a reinforced folded edge. The basket cover is a grid-like cover formed by bending metal wire and consisting of an outer closed frame and an inner support wire; The basket lid and basket body are connected by a welded hinge assembly. The hinge assembly includes a first welded piece, a second welded piece, and a hinge shaft. The first welded piece is welded to the reinforcing flange outer wall of the basket body, and the second welded piece is welded to the outer closed frame of the basket lid. The first welded piece and the second welded piece are rotatably connected via the hinge shaft.

[0006] Preferably, during the stretching and forming process, the bottom wall thickness is greater than the side wall thickness, forming a differentiated wall thickness structure between the bottom impact-resistant zone and the side wall lightweight zone.

[0007] Preferably, the bottom of the basket body is provided with a concave-convex reinforcing rib structure directly pressed by a stretching die, and the reinforcing rib structure is distributed laterally along the bottom of the basket.

[0008] Preferably, the side wall of the basket is provided with decorative holes and mounting holes formed by three-dimensional laser cutting, and the cutting edges of the decorative holes and mounting holes have smooth, burr-free laser-melted flat surfaces.

[0009] Preferably, the basket body is made of aluminum alloy sheet or steel plate, and the basket cover is made of iron wire or steel wire.

[0010] Preferably, a one-piece stretch forming process for a car storage basket is described, and the steps of this one-piece stretch forming process are as follows: S1. Laser blanking: Select a single metal sheet and cut it into a blank of a preset shape using a laser cutting device; S2, Double hydraulic stretching forming: The blank obtained in S1 is fed into the hydraulic press in sequence for the first preliminary stretching forming and the second deep stretching forming, forming a continuous seamless trough-shaped container with the bottom, side walls and mouth edge folded outward to form a reinforced flange. During the second stretching, the stretching parameters of the hydraulic press are adjusted to make the wall thickness of the bottom of the basket greater than the wall thickness of the side walls. S3, 3D laser precision cutting: Using 3D laser cutting equipment, the excess material after forming in S2 is precisely removed, and decorative holes and mounting holes are simultaneously cut on the side wall; S4. Edge curling reinforcement: Use an edge curling machine to curl and compact the outer edge of the reinforcing flange formed in S2 to form a smooth and reinforced edge; S5. Hinge welding: The basket cover is provided, the first welding piece of the hinge assembly is welded to the outer wall of the reinforcing flange of the basket body, the second welding piece is welded to the frame of the basket cover, and the two are hinged by a hinge shaft so that the basket cover can be flipped open and closed to cover the edge of the basket body. S6. Surface coating: Apply a coating to the outer surface of the welded vehicle storage basket.

[0011] Preferably, in step S2, while performing the second deep stretching and shaping, a hydraulic press mold is used to press out transversely distributed concave-convex reinforcing ribs on the bottom surface of the basket.

[0012] Preferably, the welding method in S5 is resistance spot welding or argon arc welding.

[0013] Preferably, the surface coating of S6 is an electrostatic powder coating or an electrophoretic coating process.

[0014] Compared with the prior art, the beneficial effects of the present invention are: 1. This invention effectively eliminates the splicing nodes and weak points of traditional baskets by installing a basket body formed by continuous stretching of a single metal sheet, without splicing gaps or welding points. This creates a single continuous material transition structure between the bottom, side walls, and rim of the basket, allowing the load to be evenly transferred through the continuous material, significantly improving the overall resistance to deformation and damage. At the same time, the reinforced folded edge at the rim, which is folded outward and rolled and pressed, improves the structural rigidity and impact deformation resistance at the rim of the basket body, and eliminates sharp edges, improving the safety and comfort of the user. 2. This invention achieves a reasonable distribution of the bottom impact-resistant zone and the side lightweight zone by installing a differential wall thickness structure with the bottom wall thickness being greater than the side wall thickness. While ensuring the impact resistance of the bottom heavy-load area, it achieves reasonable thinning of the side wall material. At the same time, the combination of aluminum alloy or steel plate basket body and iron wire or steel wire basket cover significantly reduces the weight of the basket, which is beneficial to the lightweight design of the whole vehicle and the improvement of riding and handling performance. 3. The present invention has installed concave and convex reinforcing ribs at the bottom of the basket, which are integrally formed with the bottom of the basket through a stretching mold to form a skeleton similar to "ribs". This effectively enhances the bending stiffness of the basket when subjected to vertical heavy loads, prevents the bottom of the basket from plastically sagging under long-term load, and improves the full-load service life of the basket. 4. This invention, by installing decorative holes and mounting holes cut by three-dimensional laser cutting, and with a smooth, burr-free laser-melted flat surface at the cutting edge, completely avoids the hidden dangers of micro-cracks, stress concentration and edge burrs caused by traditional stamping or drilling processes, improves the fatigue life of the structure, and at the same time gives the basket a more streamlined and high-end appearance, improving the overall quality and added value of the product. 5. This invention uses a welded hinge assembly, with the first and second welding pieces firmly welded to the basket body and basket cover respectively, and the two are rotatably connected by a hinge shaft. Compared with traditional bolt fixing or riveting solutions, it has higher connection strength and excellent anti-vibration loosening performance, making the basket cover open and close reliably and smoothly during vehicle bumps, and the appearance is neat with no exposed fasteners, avoiding safety problems caused by loose connections. Attached Figure Description

[0015] Figure 1 This is a three-dimensional structural diagram of the vehicle storage basket of the present invention; Figure 2 This is a top view of the vehicle storage basket of the present invention; Figure 3 This is a bottom view of the structure of the vehicle storage basket of the present invention; Figure 4 This is a side view of the vehicle storage basket structure of the present invention; Figure 5 This is a rear view schematic diagram of the vehicle storage basket of the present invention; Figure 6 This is a schematic diagram of the process steps for the integral stretching molding of the vehicle storage basket of the present invention.

[0016] In the diagram: 1. Basket body; 2. Basket lid; 3. Hinge assembly; 4. Basket bottom; 5. Side wall; 6. Edge; 8. Reinforcing rib; 9. Decorative hole; 10. Mounting hole; 11. Outer closed frame; 12. Internal support wire; 13. First welding piece; 14. Second welding piece; 15. Hinge shaft. Detailed Implementation

[0017] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0018] In the description of this invention, it should be noted that the terms "upper," "lower," "inner," "outer," "front end," "rear end," "both ends," "one end," and "the other end," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0019] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed," "equipped with," "connected," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0020] Example 1: Please refer to Figure 1 , Figure 2 , Figure 3 , Figure 4 and Figure 5 This invention provides a car storage basket, comprising a basket body 1 and a basket lid 2. The basket body 1 is integrally formed from a single metal sheet (e.g., a 5052 aluminum alloy sheet or a high-strength steel sheet with a thickness of 0.8mm-1.5mm) through continuous stretching. The basket body 1 is composed of a basket bottom 4, side walls 5, and an opening rim 6. The basket bottom 4, side walls 5, and opening rim 6 form a single continuous material transition structure without splicing gaps or welding points. The four corners of the basket body 1 are rounded to effectively avoid stress concentration at sharp corners and meet the safety requirements when the vehicle is in motion. The opening rim 6 of the basket body 1 is folded outwards and rolled. The machine-rolled and compacted edges form a thickened and reinforced flange. Due to the special nature of the stretching process, during the forming process, the hydraulic press parameters are adjusted to make the wall thickness of the bottom 4 of the basket greater than that of the side wall 5 (for example, the bottom thickness is 1.2 mm, and the side wall 5 thickness is 0.9 mm), creating a differentiated wall thickness structure between the impact-resistant bottom zone and the lightweight side wall 5 zone. The bottom 4 of the basket also features concave-convex reinforcing ribs 8 directly pressed by the stretching die. These reinforcing ribs 8 are laterally distributed, forming a "ribbed" skeleton, greatly enhancing the bending stiffness of the basket 1 under load. On wall 5, several decorative holes 9 and mounting holes 10 are cut out using a three-dimensional laser cutting device. The laser-cut edges have a smooth, burr-free laser-melted flat surface. Compared with traditional stamping and drilling processes, laser cutting eliminates micro-cracks and burrs on the cutting edges, further avoiding the hidden danger of stress concentration. The cover 2 is formed by bending metal wire (such as Φ3mm-4mm steel wire or iron wire), and consists of an outer closed frame 11 and an inner support wire 12 forming a grid-like cover, which ensures both breathability and visibility, and achieves lightweight design. The outer closed frame 11 has a specific shape. Matching the contour of the rim 6 of the basket body 1, the basket body 1 and the basket cover 2 are connected by a welded hinge assembly 3. The hinge assembly 3 includes a first welded piece 13, a second welded piece 14 and a hinge shaft 15. The first welded piece 13 is welded to the outer wall of the reinforcing flange of the basket body 1, and the second welded piece 14 is welded to the outer closed frame 11 of the basket cover 2. The first welded piece 13 and the second welded piece 14 are rotatably connected by the hinge shaft 15. The material of the basket body 1 is preferably aluminum alloy plate (such as 3003 or 5052 alloy) or high-strength steel plate, and the material of the basket cover 2 is preferably iron wire or steel wire.

[0021] Example 2: Please refer to Figure 6 The present invention provides an integral stretch forming process for a car storage basket, the steps of which are as follows: S1. Laser cutting: Select a single metal sheet, place the metal sheet flat on the worktable of the laser cutting machine, program it according to the preset blank unfolding shape, and use high-power laser cutting equipment to cut out the blank with the set contour and shape. Laser cutting ensures that the edges are flat and clean, providing high-quality flat blanks for subsequent stretching processes. S2, Double Hydraulic Stretching Forming: The blank obtained in S1 is fed into a hydraulic press. First, the blank edge is pressed by the blank pressure ring to perform the first preliminary stretching forming, so that the blank is shallowly drawn into a primary blank with a preliminary three-dimensional shape. Then, the primary blank is transferred to the secondary stretching die for the second deep stretching and shaping. In the second deep stretching, by precisely controlling the stretching die gap, blank pressure force and stretching speed (for example, stretching speed of 10-30mm / s and blank pressure force of 30-60 tons), the sheet metal produces sufficient plastic flow and is formed into a continuous seamless groove-shaped container with the bottom 4, side walls 5 and mouth 6 folded outward to form a reinforced flange. Meanwhile, in this step, by controlling the material flow, the wall thickness of the bottom 4 of the formed basket is made to be greater than the wall thickness of the side wall 5, forming the aforementioned differentiated wall thickness structure. Furthermore, during the second deep stretching and shaping, the hydraulic press mold presses out transversely distributed concave and convex reinforcing ribs 8 on the surface of the bottom 4, so that the reinforcing ribs 8 and the basket body 1 are formed synchronously and integrally. S3, 3D laser precision cutting: Using a laser cutting device equipped with a 3D cutting head, the semi-finished product formed in S2 is precisely processed. First, along the waste cutting line reserved in the blank, the excess waste generated by stretching and forming is removed. Second, decorative holes 9 and mounting holes 10 are simultaneously cut on the side wall 5. Since 3D laser cutting is a non-contact processing, the cutting edge forms a smooth and burr-free laser melting and cutting surface. The power and speed of laser cutting are precisely set according to the thickness of the plate to ensure the quality of the cutting surface. S4. Edge Rolling Reinforcement: Using an edge rolling machine, the outer edge of the reinforced flange formed by the outward turning of the flange 6 in S2 is rolled and compacted. The edge rolling machine uses rollers to circulate along the flange contour, rolling and flattening the outer edge of the flange inward to form a smooth reinforced edge with a teardrop or circular cross-section and a smooth surface. This increases the rigidity and impact resistance of the flange 6, while eliminating sharp edges and improving user safety. S5. Hinge Welding: Provide a pre-prepared basket cover 2 through wire bending forming process. Align and attach the first welding piece 13 of the hinge assembly 3 to the reinforcing flange outer wall of the basket body 1. Align and attach the second welding piece 14 to the outer closed frame 11 of the basket cover 2. Use welding processes such as resistance spot welding or argon arc welding to firmly weld the first welding piece 13 and the second welding piece 14 to the basket body 1 and the basket cover 2 respectively. After welding, the first welding piece 13 and the second welding piece 14 are hinged together through the hinge shaft 15 to realize the flip opening and closing of the basket cover 2. S6. Surface Coating: The welded vehicle storage basket is coated on its outer surface. In this embodiment, electrostatic powder coating or electrophoretic coating is preferred. After the assembled storage basket is degreased, derusted and phosphated, it is sent into the spraying chamber or electrophoresis tank. A uniform and firm coating (coating thickness preferably 60-100μm) is formed on its inner and outer surfaces by electrostatic powder coating or cathodic electrophoresis. Finally, it is cured and baked at high temperature to obtain excellent anti-corrosion and wear resistance and beautiful decorative effect. Finally, the finished product is packaged and stored.

[0022] The working principle involves installing a basket 1, formed from a single metal sheet through continuous stretching, without seams or welds. This effectively eliminates the splicing nodes and weak points of traditional baskets, creating a continuous material transition structure between the bottom 4, side walls 5, and rim 6. Loads are evenly transferred through this continuous material, significantly improving overall resistance to deformation and damage. Simultaneously, the reinforced rim 6, with its outward folding and rolled edges, enhances the structural rigidity and impact resistance at the rim 6 of the basket 1, eliminating sharp edges and improving overall structural integrity. To enhance user safety and comfort, a differential wall thickness structure is implemented where the bottom wall (4) is thicker than the side wall (5). This achieves a reasonable distribution between the bottom impact-resistant zone and the lightweight side wall (5). While ensuring the impact resistance of the heavy-duty bottom area, the side wall material is appropriately thinned. Furthermore, the combination of an aluminum alloy or steel plate basket body (1) and a wire or steel wire basket cover (2) significantly reduces the basket's weight, contributing to overall lightweight design and improved riding handling. The installation of concave-convex reinforcing ribs (8) on the bottom (4) further enhances the reinforcing effect. The basket 8 and basket bottom 4 are integrally formed through a stretching mold to create a "rib"-like skeleton, effectively enhancing the bending stiffness of the basket 1 under vertical heavy loads and preventing plastic sagging deformation of the basket bottom 4 under long-term load conditions. This improves the full-load service life of the basket. The installation of decorative holes 9 and mounting holes 10, which are three-dimensionally laser-cut with smooth, burr-free laser-melted surfaces, completely avoids the micro-cracks, stress concentrations, and edge burrs caused by traditional stamping or drilling processes, thus improving structural fatigue life and providing... The design of the basket is more streamlined and high-end, improving the overall quality and added value of the product. By installing a welded hinge assembly 3, the first welding piece 13 and the second welding piece 14 are firmly welded to the basket body 1 and the basket cover 2 respectively, and the two are rotatably connected by the hinge shaft 15. Compared with the traditional bolt fixing or riveting solution, it has higher connection strength and excellent anti-vibration loosening performance, so that the basket cover 2 can open and close reliably and smoothly during vehicle bumps, and the appearance is clean with no exposed fasteners, avoiding safety problems caused by loose connection.

[0023] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A car storage basket, comprising a basket body (1) and a basket lid (2), characterized in that: The basket (1) is formed by continuous stretching of a single metal sheet and consists of a basket bottom (4), side walls (5) and mouth edge (6); The bottom (4), side wall (5) and mouth edge (6) of the basket are a single continuous material transition structure without splicing gaps or welding points. The four corners of the basket body (1) are rounded transitions, and the mouth edge (6) is folded outward and rolled and pressed to form a reinforced folded edge. The basket cover (2) is a grid-like cover made of metal wire bent into shape and consisting of an outer closed frame (11) and an inner support wire (12); The basket cover (2) is connected to the basket body (1) by a welded hinge assembly (3). The hinge assembly (3) includes a first welded piece (13), a second welded piece (14) and a hinge shaft (15). The first welded piece (13) is welded to the reinforcing flange outer wall of the basket body (1), and the second welded piece (14) is welded to the outer closed frame (11) of the basket cover (2). The first welded piece (13) and the second welded piece (14) are rotatably connected by the hinge shaft (15).

2. The vehicle storage basket according to claim 1, characterized in that: When the basket (1) is stretched and formed, the wall thickness of the bottom (4) is greater than the wall thickness of the side wall (5), forming a differential wall thickness structure between the bottom impact resistance zone and the side wall (5) lightweight zone.

3. A car storage basket according to claim 1, characterized in that: The bottom (4) of the basket body (1) is provided with a concave-convex reinforcing rib (8) structure directly pressed by a stretching mold, and the reinforcing rib (8) structure is distributed laterally along the bottom (4).

4. A car storage basket according to claim 1, characterized in that: The side wall (5) of the basket (1) is provided with decorative holes (9) and mounting holes (10) formed by three-dimensional laser cutting, and the cutting edges of the decorative holes (9) and mounting holes (10) have smooth, burr-free laser-melted flat surfaces.

5. A car storage basket according to claim 1, characterized in that: The basket body (1) is made of aluminum alloy plate or steel plate, and the basket cover (2) is made of iron wire or steel wire.

6. The integral stretch forming process for a vehicle storage basket according to any one of claims 1-5, characterized in that, The steps of the one-piece stretch forming process for this car storage basket are as follows: S1. Laser blanking: Select a single metal sheet and cut it into a blank of a preset shape using a laser cutting device; S2, Double hydraulic stretching: The blank obtained in S1 is fed into the hydraulic press in sequence for the first preliminary stretching and the second deep stretching and shaping, forming a continuous seamless trough-shaped container with the bottom (4), side wall (5) and mouth edge (6) folded outward to form a reinforced flange. During the second stretching, the wall thickness of the bottom (4) is made greater than the wall thickness of the side wall (5) by adjusting the stretching parameters of the hydraulic press. S3, Three-dimensional laser precision cutting: Using a three-dimensional laser cutting device, the excess material formed in S2 is precisely removed, and decorative holes (9) and mounting holes (10) are simultaneously cut on the side wall (5). S4. Edge curling reinforcement: Use an edge curling machine to curl and compact the outer edge of the reinforcing flange formed in S2 to form a smooth and reinforced edge; S5, Hinge welding: Provide the basket cover (2), weld the first welding piece (13) of the hinge assembly (3) to the outer wall of the reinforcing flange of the basket body (1), weld the second welding piece (14) to the frame of the basket cover (2), and hinge the two together through the hinge shaft (15) so that the basket cover (2) can be flipped open and closed to cover the edge (6) of the basket body (1); S6. Surface coating: Apply a coating to the outer surface of the welded vehicle storage basket.

7. The integral stretching molding process for a vehicle storage basket according to claim 6, characterized in that: In S2, while performing the second deep stretching and shaping, a horizontally distributed concave-convex reinforcing rib (8) is pressed onto the surface of the bottom (4) of the basket by a hydraulic press mold.

8. The integral stretching molding process for a vehicle storage basket according to claim 6, characterized in that: The welding method in S5 is resistance spot welding or argon arc welding.

9. The integral stretching molding process for a vehicle storage basket according to claim 6, characterized in that: The surface coating of S6 is electrostatic powder coating or electrophoretic coating process.

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