A front wall outer panel assembly, a manufacturing method and a vehicle

Abstract

The application provides a front wall outer plate assembly, a preparation method and a vehicle. The front wall outer plate assembly comprises an outer skin and an inner lining plate. The outer skin is connected with the inner lining plate through sealing glue. A buffer cavity is formed between the outer skin and the inner lining plate. The outer skin and the inner lining plate are both made of modified polydicyclopentadiene material. The material selection and structure of the front wall outer plate assembly solve the technical problems of poor lightweight effect, poor NVH performance, low appearance quality and high manufacturing cost of the front wall outer plate in the prior art.

Description

Technical Field

[0001] This invention relates to the technical field of vehicle front bulkhead panels, and more specifically, to a front bulkhead panel assembly, a manufacturing method, and a vehicle. Background Technology

[0002] Commercial vehicle front bulkhead panels are typically manufactured using a high-temperature, high-pressure molding process with UPGF-SMC (unsaturated polyester glass fiber composite material). However, this process results in unavoidable technical shortcomings, including poor lightweighting, poor NVH performance, low aesthetic quality, and high manufacturing costs. Existing improvement solutions are mostly limited to single-dimensional adjustments, failing to simultaneously address the comprehensive requirements of lightweighting, high strength, high durability, and low noise.

[0003] There is currently no good solution to the technical problems of poor lightweighting effect, poor NVH performance, low appearance quality, and high manufacturing cost of the front bulkhead outer panel in existing technologies. Summary of the Invention

[0004] The main objective of this invention is to provide a front bulkhead outer panel assembly, a manufacturing method, and a vehicle to solve the technical problems of poor lightweighting effect, poor NVH performance, low appearance quality, and high manufacturing cost of the front bulkhead outer panel in the prior art.

[0005] To achieve the above objectives, according to one aspect of the present invention, a front bulkhead assembly is provided, the front bulkhead assembly including an outer skin and an inner liner, the outer skin being connected to the inner liner by a sealant, a buffer cavity being formed between the outer skin and the inner liner, wherein both the outer skin and the inner liner are made of modified polydicyclopentadiene material.

[0006] Furthermore, the modified polydicyclopentadiene has the following material properties: density ρ, tensile strength σt, flexural strength σb, unnotched impact strength K, temperature resistance range T, and water absorption rate W, wherein ρ ≤ 1.03 g / cm³. 3 , σt≥65MPa, σb≥90MPa, K≥25kJ / m 2 -40℃≤T≤120℃, W≤0.01%.

[0007] Furthermore, the outer skin has a first flange structure at its edge, and the inner liner has a second flange structure at its edge. The outer skin is connected to the inner liner through the first flange structure, and the first flange structure abuts against the second flange structure in the height direction of the outer skin.

[0008] Furthermore, the first flange structure includes flange A, which is formed at the upper edge of the outer skin and extends along the height direction of the outer skin; the second flange structure includes flange C, which is formed at the upper edge of the inner liner and extends along the thickness direction of the inner liner; flange A is connected to the inner liner, and the top of flange A abuts against flange C.

[0009] Furthermore, the first flange structure includes a flange B, which is formed at the lower edge of the outer skin. The flange B extends along the thickness direction of the outer skin, and the flange B and the outer skin enclose an installation space. A bending structure is formed at the lower edge of the inner liner, and part of the bending structure extends into the installation space and connects with the flange B.

[0010] Furthermore, the outer skin has a thickness of 2.5~3.5mm, the inner liner has a thickness of 3.0~4.0mm, and the sealant has a thickness of 0.8~1.2mm.

[0011] Furthermore, a connecting base is provided on the side of the inner liner facing away from the outer skin, and the connecting base is a protruding structure formed on the inner liner.

[0012] According to another aspect of the present invention, a method for preparing a front bulkhead outer panel assembly is provided. The front bulkhead outer panel assembly is the aforementioned front bulkhead outer panel assembly. The preparation method includes: injecting liquid raw material of modified polydicyclopentadiene into a mold cavity using a low-pressure reactive injection molding process to obtain an outer skin and an inner liner; performing plasma activation treatment on the bonding surfaces of the outer skin and the inner liner; applying sealant to the bonding surfaces after plasma activation treatment, and pressing the bonding surfaces of the outer skin and the inner liner together; and curing the pressed outer skin and the inner liner to obtain the front bulkhead outer panel assembly.

[0013] Furthermore, the curing temperature is 55~65℃, the curing time is 40~60min; and / or, the alignment and pressing pressure is 0.3~0.8MPa.

[0014] According to another aspect of the invention, a vehicle is provided, the vehicle including the aforementioned front bulkhead assembly.

[0015] Applying the technical solution of this invention, both the outer skin and the inner liner are made of modified polydicyclopentadiene material. The density of modified polydicyclopentadiene material is lower than that of unsaturated polyester glass fiber composite material, which helps to achieve a lightweight design of the front bulkhead assembly. Modified polydicyclopentadiene material has excellent toughness and low-temperature performance, solving the problems of easy cracking and low-temperature brittle fracture, which helps to improve the durability and appearance quality of the front bulkhead. The outer skin is connected to the inner liner through sealant, so that a closed buffer cavity is formed between the outer skin and the inner liner. This buffer cavity can absorb the energy of vehicle vibration, significantly suppress high-frequency resonance of the panel surface, eliminate abnormal noise, and improve the NVH performance of the front bulkhead. In the manufacturing process of the front bulkhead, the modified polydicyclopentadiene material can be formed using a low-pressure process, without residual internal stress, avoiding warping deformation, simplifying post-processing procedures, and reducing manufacturing costs. The material selection and structural composition of the front bulkhead assembly in the above solution solve the technical problems of poor lightweight effect, poor NVH performance, low appearance quality, and high manufacturing cost of the front bulkhead assembly in the prior art. Attached Figure Description

[0016] The accompanying drawings, which form part of this application, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0017] Figure 1 A cross-sectional schematic diagram of the front bulkhead assembly in this application is shown;

[0018] Figure 2 An exploded view of the front bulkhead assembly in this application is shown;

[0019] Figure 3 A flowchart illustrating the preparation method of the front bulkhead assembly in this application is shown.

[0020] The above figures include the following reference numerals:

[0021] 1. Outer skin;

[0022] 11. Flanged edge A; 12. Flanged edge B; 13. Installation space;

[0023] 2. Inner lining board;

[0024] 21. Flanged edge C; 22. Bending structure;

[0025] 3. Buffer chamber. Detailed Implementation

[0026] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0027] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0028] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such terms can be used interchangeably where appropriate so that the embodiments of this application described herein can be implemented, for example, in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0029] Exemplary embodiments according to this application will now be described in more detail with reference to the accompanying drawings. However, these exemplary embodiments may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. It should be understood that these embodiments are provided so that the disclosure of this application is thorough and complete, and that the concept of these exemplary embodiments is fully conveyed to those skilled in the art. In the drawings, for clarity, the thickness of layers and regions may be exaggerated, and the same reference numerals are used to denote the same devices, and therefore their description will be omitted.

[0030] Combination Figures 1 to 2 As shown, according to a specific embodiment of this application, a front bulkhead assembly is provided.

[0031] Specifically, the front bulkhead assembly includes an outer skin 1 and an inner liner 2. The outer skin 1 is connected to the inner liner 2 by a sealant, and a buffer cavity 3 is formed between the outer skin 1 and the inner liner 2. Both the outer skin 1 and the inner liner 2 are made of modified polydicyclopentadiene material.

[0032] In the embodiments of this application, both the outer skin 1 and the inner liner 2 are made of modified polydicyclopentadiene material. The density of modified polydicyclopentadiene material is lower than that of unsaturated polyester glass fiber composite material, which helps to achieve a lightweight design of the front bulkhead assembly. Modified polydicyclopentadiene material has excellent toughness and low-temperature performance, solving the problems of easy cracking and low-temperature brittle fracture, which helps to improve the durability and appearance quality of the front bulkhead. The outer skin 1 is connected to the inner liner 2 by sealant, so that a closed buffer cavity 3 is formed between the outer skin 1 and the inner liner 2. The buffer cavity 3 can absorb the vibration energy of driving, greatly suppress the high-frequency resonance of the panel surface, eliminate abnormal noise, and improve the NVH performance of the front bulkhead. In the manufacturing process of the front bulkhead, the modified polydicyclopentadiene material can be formed using a low-pressure process, without residual internal stress, avoiding warping deformation, simplifying post-processing procedures, and reducing manufacturing costs. The material selection and structural composition of the front bulkhead assembly in the above solution solve the technical problems of poor lightweight effect, poor NVH performance, low appearance quality, and high manufacturing cost of the front bulkhead assembly in the prior art.

[0033] It should be further explained that the outer skin 1 is connected to the inner liner 2 through sealant, which eliminates stress concentration at the mechanical connection point and helps to improve the shear stiffness and bending stiffness of the front bulkhead assembly. The sealant forms a viscoelastic medium, which can effectively dissipate vibration energy and suppress high-frequency resonance of the skin. Compared with mechanical connection (rigid transmission of vibration), this method significantly reduces driving noise and abnormal noise, and improves driving comfort. The outer skin 1 is connected to the inner liner 2 through sealant, and a closed buffer cavity 3 is formed between the outer skin 1 and the inner liner 2, which blocks rainwater and dust from entering the gap between the outer skin 1 and the inner liner 2, avoiding the water seepage, dust accumulation and corrosion problems common in traditional mechanical connections.

[0034] For example, the sealant is a high-toughness polyurethane structural adhesive.

[0035] For example, the modified polydicyclopentadiene material contains one or more of the following: chopped glass fibers, inorganic mineral fillers, elastomer toughening agents, and polar modifiers.

[0036] Furthermore, the modified polydicyclopentadiene has the following material properties: density ρ, tensile strength σt, flexural strength σb, unnotched impact strength K, temperature resistance range T, and water absorption rate W, wherein ρ ≤ 1.03 g / cm³. 3 , σt≥65MPa, σb≥90MPa, K≥25kJ / m 2 -40℃≤T≤120℃, W≤0.01%.

[0037] In the embodiments of this application, the low density of modified polydicyclopentadiene significantly reduces the weight of the front bulkhead assembly, which helps improve the vehicle's fuel economy; the high tensile strength and high flexural strength of modified polydicyclopentadiene help ensure the structural rigidity and deformation resistance of the front bulkhead assembly; the high impact strength and wide temperature range of modified polydicyclopentadiene ensure that the front bulkhead assembly does not crack in extreme cold or deform at high temperatures, which helps it adapt to all climatic conditions; the low water absorption of modified polydicyclopentadiene eliminates the risk of hydrolysis and delamination, which helps improve weather resistance and durability.

[0038] Furthermore, the outer skin 1 has a first flange structure on its edge, and the inner liner 2 has a second flange structure on its edge. The outer skin 1 is connected to the inner liner 2 through the first flange structure, and the first flange structure abuts against the second flange structure in the height direction of the outer skin 1.

[0039] In the embodiments of this application, the outer skin 1 is connected to the inner liner 2 via a first flange structure. The first flange structure increases the limited connection area between the outer skin 1 and the inner liner 2, improving the sealing performance of the front bulkhead assembly edge. The first flange structure abuts against the second flange structure in the height direction of the outer skin 1, forming a mechanical limit to prevent relative displacement or delamination between the outer skin 1 and the inner liner 2 in the vertical direction, ensuring connection reliability under long-term vibration.

[0040] Specifically, such as Figure 1 As shown, the first flange structure includes flange A11, which is formed at the upper edge of the outer skin 1 and extends along the height direction of the outer skin 1; the second flange structure includes flange C21, which is formed at the upper edge of the inner liner 2 and extends along the thickness direction of the inner liner 2. Flanged flange A11 is connected to the inner liner 2, and the top of flange A11 abuts against flange C21.

[0041] Flanged edge A11 extends along the height, and flanged edge C21 extends along the thickness. The two abut against each other and form an L-shaped structural constraint, effectively limiting the vertical displacement and warping deformation of the outer skin 1 relative to the inner liner 2, ensuring assembly accuracy. Under long-term vehicle vibration conditions, the above-mentioned abutment structure improves the fatigue resistance and structural stability of the front bulkhead outer panel assembly, reducing the risk of abnormal noise or delamination caused by loosening.

[0042] Specifically, such as Figure 1 As shown, the first flange structure includes a flange B12, which is formed at the lower edge of the outer skin 1. The flange B12 extends along the thickness direction of the outer skin 1, and the flange B12 and the outer skin 1 enclose an installation space 13. A bending structure 22 is formed at the lower edge of the inner liner 2, and part of the bending structure 22 extends into the installation space 13 and is connected to the flange B12.

[0043] The bending structure 22 of the inner liner 2 extends into the installation space 13 and is connected to the flange B12. The outer skin 1 and the inner liner 2 form a mechanical interlock, which effectively resists shear force and prevents interlayer peeling.

[0044] Furthermore, the outer skin 1 has a thickness of 2.5~3.5mm, the inner liner 2 has a thickness of 3.0~4.0mm, and the sealant has a thickness of 0.8~1.2mm.

[0045] In the embodiments of this application, the outer skin 1 has a thickness of 2.5~3.5mm, which ensures the smoothness of the outer skin 1 surface and its resistance to local impacts while effectively controlling its weight; the inner liner 2 has a thickness of 3.0~4.0mm, which can be combined with reinforcing ribs to provide sufficient overall bending stiffness and assembly support; the sealant has a thickness of 0.8~1.2mm, which ensures sufficient bonding area to transmit shear force and utilizes the viscoelasticity of the sealant layer to form effective damping buffer, thereby optimizing NVH performance.

[0046] Furthermore, a connecting base is provided on the side of the inner liner 2 facing away from the outer skin 1, and the connecting base is a protruding structure formed on the inner liner 2.

[0047] In the embodiments of this application, the integrally molded connecting base serves as a stress concentration point, increasing the contact area with the vehicle body bracket, effectively dispersing the stress during bolt tightening, and preventing cracking or deformation caused by stress concentration. The integrated design of the connecting base eliminates the connection risks associated with welding or riveting, ensuring structural integrity.

[0048] Furthermore, such as Figure 2 As shown, the inner liner 2 has a reinforcing structure formed on the side near the outer skin 1. This reinforcing structure consists of multiple reinforcing ribs formed on the inner liner 2.

[0049] According to another specific embodiment of this application, a method for manufacturing a front bulkhead outer panel assembly is provided, wherein the front bulkhead outer panel assembly is the same as the front bulkhead outer panel assembly described in the above embodiment, such as... Figure 3 As shown, the preparation method includes the following steps:

[0050] Step S1: Using a low-pressure reactive injection molding process, liquid raw material of modified polydicyclopentadiene is injected into the mold cavity to obtain the outer skin 1 and the inner liner 2.

[0051] Specifically, the RIM reaction injection mold is cleaned, and the mold cavity is uniformly sprayed with a release agent and dried to ensure that the cavity is clean and smooth; the liquid raw material of modified polydicyclopentadiene is subjected to vacuum degassing treatment to remove air bubbles inside the raw material; the liquid modified polydicyclopentadiene is injected into the mold cavity using a low-pressure reaction injection molding process to obtain the outer skin 1 and the inner liner 2, which are then naturally cooled and shaped.

[0052] Step S2: Perform plasma activation treatment on the bonding surfaces of the outer skin 1 and the inner liner 2.

[0053] Specifically, the bonding surfaces of the outer skin 1 and the inner liner 2 are sanded and dust-removed, and then subjected to plasma activation treatment to improve adhesion. The power of the ion activation treatment is 800-1200W, and the processing speed is 300-500mm / s, ensuring uniform activation of the bonding surfaces and increasing the bonding strength by more than 30%.

[0054] Step S3: Apply sealant to the bonding surface after plasma activation treatment, and align and press the bonding surface of the outer skin 1 with the bonding surface of the inner liner 2.

[0055] Specifically, an automated gluing device is used to uniformly apply polyurethane structural adhesive to the entire bonding surface, and a special tooling fixture is used to accurately align and press the outer skin 1 and the inner liner 2 together.

[0056] Step S4: Curing treatment is performed on the pressed outer skin 1 and inner liner 2 to obtain the front bulkhead outer panel assembly.

[0057] Specifically, the pressed semi-finished product is fed into a constant temperature curing device and allowed to cool naturally after curing. The tooling fixtures are removed, and the edges are trimmed and the holes are cleaned. The appearance, bonding strength, and dimensional accuracy of the assembly are inspected, and defective products with delamination, debonding, or deformation are removed to complete the finished product preparation.

[0058] In the embodiments of this application, the outer skin 1 and inner liner 2 are prepared using a low-pressure reactive injection molding process. The low molding temperature and pressure eliminate residual internal stress, effectively preventing warping, deformation, and hole misalignment of the parts, ensuring extremely high dimensional stability and assembly accuracy. Furthermore, the low-pressure, low-temperature molding also imparts excellent damping characteristics to the parts, optimizing NVH performance. The bonding surfaces of the outer skin 1 and inner liner 2 are ion-activated to increase the surface energy of the bonding surfaces, thereby enhancing the interfacial adhesion of the sealant. The dense surfaces of the outer skin 1 and inner liner 2 eliminate the need for heavy polishing, simplifying post-processing steps and reducing energy consumption and production costs. The above-mentioned preparation method achieves a balance between lightweight, high strength, high reliability, and low manufacturing cost, solving the technical problems of poor lightweight effect, poor NVH performance, low appearance quality, and high manufacturing cost in the prior art for front panel.

[0059] Furthermore, the curing temperature is 55~65℃, the curing time is 40~60min; and / or, the alignment and pressing pressure is 0.3~0.8MPa.

[0060] In the embodiments of this application, the curing temperature is 55~65℃ and the curing time is 40~60min, which ensures that the polyurethane structural adhesive is fully cross-linked and cured to achieve maximum bonding strength, while avoiding thermal deformation or aging of the modified polydicyclopentadiene caused by high temperature, thus balancing strength and dimensional stability.

[0061] Example 1

[0062] The front bulkhead assembly for heavy-duty commercial vehicles is a high-spec version. Both the outer skin 1 and the inner liner 2 are made of modified polydicyclopentadiene. The outer skin 1 is 3mm thick and features water channels, windshield mounting slots, lamp holes, and mounting flanges, achieving an A-class appearance. The inner liner 2 is 3.5mm thick, with trapezoidal reinforcing ribs on the inner side that are 10mm high and spaced 50mm apart. The four corners and mounting base of the inner liner 2 are thickened by 2mm. Polyurethane structural adhesive is used as the sealant, with a coating thickness of 1mm.

[0063] The preparation steps for the front bulkhead outer panel assembly are as follows:

[0064] 1. Mold pretreatment: Clean the RIM reactive injection mold, spray the release agent evenly, and dry at 50℃ and let it stand.

[0065] 2. Raw material processing: The modified polydicyclopentadiene two-component raw material is mixed in the specified proportion and vacuum degassed for 5 minutes;

[0066] 3. Low-pressure molding: The molding temperature is 50℃ and the molding pressure is 0.5MPa. The outer skin 1 and the inner liner 2 are injection molded separately and then naturally cooled for 15 minutes to set.

[0067] 4. Ion activation treatment: The bonding surfaces of the outer skin 1 and the inner liner 2 are activated by a 1000W plasma device at a speed of 400mm / s.

[0068] 5. Glue application and pressing: Glue is applied evenly using automatic equipment, and special tooling is used to precisely align and press the outer skin 1 and inner liner 2 together.

[0069] 6. Constant temperature curing: Place the pressed outer skin 1 and inner liner 2 at a constant temperature of 60℃ for 50 minutes, and then let them cool naturally to room temperature.

[0070] 7. Post-processing: trimming and cleaning holes, testing dimensions and adhesion performance, and warehousing.

[0071] The performance test results are as follows: compared with the original SMC assembly, the weight is reduced by 33%, the bending stiffness is increased by 46%, there is no damage in the -40℃ low temperature impact, no corrosion stratification in the 500h salt spray test, and the driving resonance noise is reduced by 5dB, which fully meets the high-intensity and all-condition use requirements of heavy commercial vehicles.

[0072] Example 2

[0073] The front bulkhead assembly adapted for mass production in medium and light commercial vehicles uses modified polydicyclopentadiene material for both the outer skin 1 and the inner liner 2. The outer skin 1 is 2.5mm thick and features water channels, windshield mounting slots, lamp holes, and mounting flanges, achieving an A-class appearance. The inner liner 2 is 3mm thick, with 8mm high trapezoidal reinforcing ribs on the inner side and a 40mm spacing between them. The four corners and mounting base of the inner liner 2 are thickened by 1.5mm. Polyurethane structural adhesive is used as the sealant, with a coating thickness of 0.8mm.

[0074] The preparation steps for the front bulkhead outer panel assembly are as follows:

[0075] 1. Mold pretreatment: Clean the RIM reactive injection mold, spray the release agent evenly, and dry at 50℃ and let it stand.

[0076] 2. Raw material processing: The modified polydicyclopentadiene two-component raw material is mixed in the specified proportion and vacuum degassed for 5 minutes;

[0077] 3. Low-pressure molding: The molding temperature is 45℃ and the molding pressure is 0.4MPa. The outer skin 1 and the inner liner 2 are injection molded separately and then naturally cooled for 15 minutes to set.

[0078] 4. Ion activation treatment: The bonding surfaces of the outer skin 1 and the inner liner 2 are activated using a 900W plasma device at a speed of 400mm / s.

[0079] 5. Glue application and pressing: Glue is applied evenly using automatic equipment, and special tooling is used to precisely align and press the outer skin 1 and inner liner 2 together.

[0080] 6. Constant temperature curing: Place the pressed outer skin 1 and inner liner 2 at a constant temperature of 55℃ for 40 minutes, and then let them cool naturally to room temperature.

[0081] 7. Post-processing: trimming and cleaning holes, testing dimensions and adhesion performance, and warehousing.

[0082] The performance test results are as follows: Compared with the original SMC assembly, the weight is reduced by 29%, and the mechanical strength, NVH performance and weather resistance are all better than traditional SMC parts. The production cycle is faster and the cost is lower, making it suitable for mass production of medium and light commercial vehicles.

[0083] According to another specific embodiment of this application, a vehicle is provided, the vehicle including the front bulkhead assembly described in the above embodiments.

[0084] As can be seen from the above description, the embodiments of the present invention achieve the following technical effects:

[0085] 1. The material density ρ of modified polydicyclopentadiene is ≤ 1.03 g / cm³. 3 With a density far lower than that of unsaturated polyester glass fiber composites, the overall weight of the assembly is reduced by 28% to 35% without compromising structural strength or ensuring fully universal assembly interfaces. This effectively reduces the vehicle's curb weight, fuel consumption, and range, aligning with the trend of lightweighting in commercial vehicles.

[0086] 2. Both the outer skin 1 and the inner liner 2 are made using a low-pressure molding process, with no residual internal stress from molding. They do not warp, deform, or crack under long-term vibration and alternating hot and cold conditions.

[0087] 3. Modified polydicyclopentadiene material has excellent low-temperature toughness and does not crack in extremely cold environments of -40℃, solving the problem of traditional parts being easily damaged at low temperatures; at the same time, it has excellent acid and alkali resistance, salt spray resistance, and anti-aging properties, and its service life far exceeds that of parts made of unsaturated polyester glass fiber composite materials, greatly reducing after-sales maintenance costs.

[0088] 4. The outer skin 1 is connected to the inner liner 2 by sealant, so that a closed buffer cavity 3 is formed between the outer skin 1 and the inner liner 2. The structural damping coefficient is greatly improved, which can effectively absorb and attenuate the driving vibration energy, suppress the high frequency resonance of the panel, reduce the driving noise of the front of the vehicle by 3-6dB, and significantly improve the driving comfort.

[0089] 5. Low-pressure and low-temperature molding replaces high-temperature and high-pressure molding, reducing equipment energy consumption, extending mold life, and reducing failure rate; modified polydicyclopentadiene molded parts have a smooth and dense surface, with no exposed glass fiber or orange peel-like pits, eliminating the need for heavy grinding and leveling, simplifying post-processing, and significantly improving yield, making them suitable for large-scale mass production.

[0090] 6. The outer boundary, mounting hole position, assembly benchmark and overlap size of the front bulkhead outer panel assembly in this application are completely consistent with the original parts. There is no need to change the body matching structure. It can be directly replaced and installed on the vehicle without additional mold opening and modification. The difficulty of industrialization is low.

[0091] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0092] In addition to the above, it should be noted that the terms "one embodiment," "another embodiment," and "embodiment" used in this specification refer to specific features, structures, or characteristics described in connection with that embodiment, which are included in at least one embodiment described in the general description of this application. The appearance of the same expression in multiple places in the specification does not necessarily refer to the same embodiment. Furthermore, when a specific feature, structure, or characteristic is described in connection with any embodiment, the intention is to suggest that implementing such a feature, structure, or characteristic in conjunction with other embodiments also falls within the scope of this invention.

[0093] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0094] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A front bulkhead outer panel assembly, characterized in that, The front bulkhead assembly includes an outer skin (1) and an inner liner (2). The outer skin (1) is connected to the inner liner (2) by a sealant. A buffer cavity (3) is formed between the outer skin (1) and the inner liner (2). Both the outer skin (1) and the inner liner (2) are made of modified polydicyclopentadiene material.

2. The front bulkhead outer panel assembly according to claim 1, characterized in that, The modified polydicyclopentadiene has the following material properties: density ρ, tensile strength σt, flexural strength σb, unnotched impact strength K, temperature resistance range T, and water absorption rate W, wherein ρ ≤ 1.03 g / cm³. 3 , σt≥65MPa, σb≥90MPa, K≥25kJ / m 2 -40℃≤T≤120℃, W≤0.01%.

3. The front bulkhead outer panel assembly according to claim 1, characterized in that, The outer skin (1) has a first flange structure on its edge, and the inner liner (2) has a second flange structure on its edge. The outer skin (1) is connected to the inner liner (2) through the first flange structure. The first flange structure abuts against the second flange structure in the height direction of the outer skin (1).

4. The front bulkhead outer panel assembly according to claim 3, characterized in that, The first flange structure includes a flange A (11), which is formed at the upper edge of the outer skin (1) and extends along the height direction of the outer skin (1); The second flange structure includes a flange C (21), which is formed at the upper edge of the inner liner (2). The flange C (21) extends along the thickness direction of the inner liner (2). The flange A (11) is connected to the inner liner (2), and the top of the flange A (11) abuts against the flange C (21).

5. The front bulkhead outer panel assembly according to claim 3 or 4, characterized in that, The first flange structure includes flange B (12), which is formed at the lower edge of the outer skin (1). The flange B (12) extends along the thickness direction of the outer skin (1), and the flange B (12) and the outer skin (1) enclose an installation space (13). The lower edge of the inner liner (2) is formed with a bent structure (22), part of which extends into the installation space (13) and is connected to the flange B (12).

6. The front bulkhead outer panel assembly according to claim 1, characterized in that, The outer skin (1) has a thickness of 2.5~3.5mm, the inner liner (2) has a thickness of 3.0~4.0mm, and the sealant has a thickness of 0.8~1.2mm.

7. The front bulkhead outer panel assembly according to claim 1, characterized in that, The inner liner (2) has a connecting base on the side opposite to the outer skin (1), and the connecting base is a protruding structure formed on the inner liner (2).

8. A method for manufacturing a front bulkhead outer panel assembly, characterized in that, The front outer panel assembly is the front outer panel assembly according to any one of claims 1-7, and the manufacturing method includes: The modified polydicyclopentadiene liquid raw material was injected into the mold cavity using a low-pressure reaction injection molding process to obtain the outer skin (1) and inner liner (2). Plasma activation treatment is performed on the bonding surfaces of the outer skin (1) and the inner liner (2); Apply sealant to the bonding surface after plasma activation treatment, and press the bonding surface of the outer skin (1) and the bonding surface of the inner liner (2) together. The outer skin (1) and the inner liner (2) after being pressed together are cured to obtain the front outer panel assembly.

9. The preparation method according to claim 8, characterized in that, The curing temperature is 55~65℃, the curing time is 40~60min; and / or, the alignment and pressing pressure is 0.3~0.8MPa.

10. A vehicle, characterized in that, The vehicle includes the front bulkhead assembly as described in any one of claims 1-7.

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