Roof cross beam assembly, frame and vehicle
By using non-metallic materials and carbon fiber skeleton structures in the roof beams, combining reinforcement ribs and three-dimensional grids, the lightweight and safety performance of the roof beams are achieved, and the weight increase caused by the safety performance improvement in the prior art is solved. The problem is applicable to the endurance needs of new energy vehicles.
Patent Information
- Application Number
- CN202421061267.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-05-15
- Publication Date
- 2024-12-17
- Estimated Expiration
- 2034-05-15
AI Technical Summary
In order to improve safety performance, the existing roof front beams have increased weight, making it difficult to achieve a lightweight design, which violates the needs of automobile energy consumption and energy conservation and emission reduction.
The roof beams made of non-metallic materials are used to improve mechanical strength by setting up a skeleton structure made of carbon fiber at the parts to be strengthened, and reinforcement ribs and three-dimensional mesh structures are distributed on the beam body, combining injection molding and sheet metal connection structures to achieve A balance of lightweight and safety performance.
On the premise of meeting safety performance, the roof beam is lighter, reducing the energy consumption of the whole vehicle, has a wider range of applications, and is low in cost, which is suitable for the endurance needs of new energy vehicles.
Smart Images
Figure CN222179647U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of vehicle engineering, and in particular to a roof crossbeam assembly, a vehicle frame, and a vehicle. Background Art
[0002] The front cross beam of the vehicle's roof mainly shares the lateral force of the front part, so as to ensure that the passenger compartment does not deform greatly when it is hit, thereby protecting the safety of passengers. In the related art, the front cross beam of the roof is generally formed by sheet metal welding, and there are also die-casting.
[0003] The front crossbeam of the roof is generally made of hot-formed steel + high-strength steel plate as the main material of the front crossbeam of the roof, which is welded after stamping to form a parts assembly. Therefore, with the increasing requirements for vehicle safety, the weight of the front crossbeam of the roof has also increased accordingly. However, the need for automobile energy consumption and energy conservation and emission reduction, as well as the pressure on the endurance of new energy vehicles, vehicles need lightweight design.
[0004] It can be seen that the safety performance and lightweight design of the roof beam are mutually constrained, and in order to improve the safety performance, the weight of the roof beam is often increased. Utility Model Content
[0005] In view of this, the utility model provides a roof crossbeam assembly, a frame and a vehicle to solve the problem of increasing the weight of the roof crossbeam in order to improve safety performance.
[0006] In a first aspect, the utility model provides a roof crossbar, comprising:
[0007] A beam body, wherein the beam body is a non-metallic part and has a portion and / or area to be strengthened;
[0008] The skeleton structure is arranged at the position to be strengthened and / or the area to be strengthened of the beam body, and the skeleton structure is made of carbon fiber.
[0009] Beneficial effects: Compared with the metal roof beam in the related art, the beam body adopts non-metallic material, which realizes the lightweight of the roof beam; in order to meet the safety requirements of the roof beam, a skeleton structure made of carbon fiber material is set at the to-be-reinforced part and / or the to-be-reinforced area of the beam body to improve the strength of the beam body. Since the tensile strength and shear strength of the carbon fiber material are high, the mechanical strength of the entire beam body is improved. With this arrangement, the roof beam can be lightweight while meeting the safety performance. Moreover, the use of the skeleton structure as a local reinforcement can significantly reduce the cost compared with the method of using carbon fiber materials over a large area.
[0010] In an optional embodiment, the skeleton structure includes: reinforcing ribs, and a plurality of the reinforcing ribs are distributed on the beam body.
[0011] Beneficial effect: Multiple reinforcing ribs are distributed at the load-bearing positions of the beam body, which reduces the amount of reinforcing ribs while improving the strength and rigidity of the beam body, and can effectively control costs.
[0012] In an optional embodiment, the reinforcing rib is made of carbon fiber filaments, and a plurality of the carbon fiber filaments are mixed and wound to form the reinforcing rib.
[0013] Beneficial effect: The carbon fiber filaments are made into reinforcing ribs through a mixed winding process, which further improves the tensile strength and toughness of the reinforcing ribs compared with the method of directly using carbon fiber blocks.
[0014] In an optional embodiment, the beam body forms a structure in which a middle portion is wide and two ends are narrow in its extension direction.
[0015] Beneficial effects: The structure that is wide in the middle and narrow at both ends is based on layout needs. After the middle part is widened, installation parts such as lidar and antennas can be set inside the roof beam, and the narrow structure at both ends is easier to assemble, overcoming the limitation of installation size. On the other hand, the widening of the middle part can effectively improve the rigidity of the roof beam.
[0016] In an optional embodiment, the beam body is an injection molded part, and the skeleton structure is embedded in the beam body.
[0017] Beneficial effect: The skeleton structure is embedded in the beam body and is integrally injection molded with the beam body. Compared with a separate setting method, the connection reliability is higher and the integrity is better.
[0018] In an optional embodiment, a three-dimensional grid structure is distributed on the beam body.
[0019] Beneficial effects: The three-dimensional grid structure is distributed on the beam body, which can ensure the strength of the beam body while further realizing lightweight design; and the three-dimensional grid structure can also suppress vibration and noise and improve NVH modal performance.
[0020] In an optional embodiment, a connection structure is provided on the beam body, and the connection structure includes sheet metal parts provided at both ends of the beam body.
[0021] Beneficial effects: a connection structure is arranged on the beam body, so as to facilitate the connection with surrounding matching parts and improve the convenience of assembling the roof cross beam; and the connection structure includes sheet metal parts, so there is no need to change the original connection relationship between the roof cross beam and the surrounding matching parts, and the structure of the surrounding parts does not need to be adjusted, which saves time and effort while effectively controlling costs; in addition, different connection structures can be configured according to the vehicle model and installation requirements, and the scope of application is wider.
[0022] In an optional embodiment, the connection structure is bonded to the beam body; or, the connection structure and the beam body are integrally injection molded.
[0023] Beneficial effects: The method of bonding the connection structure to the beam body has a relatively simple process; the method of integrally injecting the connection structure and the beam body has a relatively high connection reliability, and the specific connection method between the connection structure and the beam body can be selected according to needs during application.
[0024] In a second aspect, the utility model further provides a vehicle frame, comprising the roof crossbar assembly described in any one of the above items.
[0025] Beneficial effects: The vehicle frame includes the roof crossbeam assembly of the utility model, and the mechanical properties of the beam body are improved through the skeleton structure, thereby ensuring the safety performance and achieving the lightweight of the vehicle frame.
[0026] In a third aspect, the utility model further provides a vehicle, comprising the above-mentioned frame.
[0027] Beneficial effects: The utility model achieves lightweight frame while meeting the frame safety performance, thereby achieving lightweight of the entire vehicle, reducing vehicle energy consumption, meeting the needs of energy conservation and emission reduction, and improving the endurance of new energy vehicles. The idea of composite reinforcement of the skeleton structure also provides ideas and references for the lightweight design of other parts of the vehicle, creating conditions for further lightweighting of the vehicle. BRIEF DESCRIPTION OF THE DRAWINGS
[0028] In order to more clearly illustrate the specific implementation methods of the utility model or the technical solutions in the prior art, the drawings required for use in the specific implementation methods or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some implementation methods of the utility model. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.
[0029] Figure 1 A front perspective view of a roof crossbar according to an embodiment of the utility model;
[0030] Figure 2 A rear perspective view of a roof crossbar according to an embodiment of the utility model;
[0031] Figure 3 A schematic diagram of the distribution of reinforcing ribs in a beam body according to an embodiment of the utility model;
[0032] Figure 4 It is a schematic diagram of the exploded structure of a beam body and a connecting structure of an embodiment of the utility model;
[0033] Figure 5It is a schematic diagram of the exploded structure of a beam body and reinforcing ribs in an embodiment of the utility model;
[0034] Figure 6 The present invention is a schematic diagram of a cross-sectional structure of a beam body according to an embodiment of the present invention.
[0035] Description of reference numerals:
[0036] 1. Beam body;
[0037] 2. Strengthen the ribs;
[0038] 3. Connection structure. DETAILED DESCRIPTION
[0039] In order to make the purpose, technical solution and advantages of the embodiment of the utility model clearer, the technical solution in the embodiment of the utility model will be clearly and completely described below in conjunction with the drawings in the embodiment of the utility model. Obviously, the described embodiment is a part of the embodiment of the utility model, not all the embodiments. Based on the embodiment of the utility model, all other embodiments obtained by those skilled in the art without creative work are within the scope of protection of the utility model.
[0040] In the description of the utility model, it should be noted that, unless otherwise specified, "multiple" means two or more; the orientations or positional relationships indicated by the terms "upper", "lower", "left", "right", "inner", "outer", "front end", "rear end", "head", "tail", etc. are based on the orientations or positional relationships shown in the drawings, and are only for the convenience of describing the utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the utility model. In addition, the terms "first", "second", "third", etc. are only used for descriptive purposes and cannot be understood as indicating or implying relative importance.
[0041] In the description of the present invention, it is also necessary to explain that, unless otherwise clearly specified and limited, the terms "installation", "connection", and "connection" should be understood in a broad sense, for example, it 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. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to the specific circumstances.
[0042] Combine the following Figures 1 to 6 , describing an embodiment of the utility model.
[0043] According to an embodiment of the present utility model, on the one hand, as Figure 1 and Figure 2As shown, a roof beam assembly is provided, comprising:
[0044] The beam body 1 is provided with a skeleton structure, and at least the beam body 1 is a non-metallic beam;
[0045] The connecting structure 3 is arranged at both ends of the beam body 1 and is used to connect the roof cross beam to surrounding matching parts. At least the beam body 1 of the roof cross beam is a non-metallic beam, which realizes the lightweight of the roof cross beam, and the skeleton structure is arranged on the beam body 1 so that the roof cross beam can meet the safety requirements at the same time, thus realizing that the roof cross beam meets the safety requirements and the need of lightweight at the same time.
[0046] Specifically, a plurality of reinforcing ribs 2 are distributed at the load-bearing positions of the beam body 1 to form a skeleton structure. The distribution form of the reinforcing ribs 2 in the beam body 1 is shown in FIG. Figure 3 The explosion structure of the stiffener 2 and the beam body 1 can be seen in Figure 5 .
[0047] As a reinforcing structure, the ribs 2 need to have properties such as tensile strength and tensile modulus that are equal to or higher than those of conventional metal materials such as aluminum alloy and high-strength steel. Therefore, their cost is generally higher than that of metal materials used to manufacture the roof cross beams. Therefore, the ribs 2 are distributed at the load-bearing positions of the beam body 1, which can reduce the amount of the ribs 2 used, thereby ensuring performance while achieving the purpose of controlling costs.
[0048] In one embodiment, Figure 6 As shown, the cross section of the beam body 1 includes:
[0049] Arched segment;
[0050] The side wings are arranged obliquely at the side edges of the arched section, and each side wing has a plurality of bending sections. The reinforcing ribs 2 are arranged at the junction of at least some adjacent bending sections.
[0051] The cross section of the beam body 1 has an arched section and side wings on both sides. This arrangement facilitates placement of mounting components in the cavity formed by the arched section, while the bent sections formed on the side wings can improve the rigidity of the beam body 1.
[0052] Figure 6 Only one implementation method of the cross section of the beam body 1 is given. In actual application, the design can be optimized according to force calculation and software simulation. The cross-sectional shape and size of the reinforcing ribs 2 in the figure are also different, and are mainly set according to the force conditions. In some embodiments, the cross-sections of multiple reinforcing ribs 2 can also be set to have the same structure and size. In this case, only one mold needs to be opened to manufacture the reinforcing ribs 2, which can reduce the mold cost.
[0053] In one embodiment, Figure 1 and Figure 2As shown, the beam body 1 forms a structure in which the middle portion is wide and the two ends are narrow in its extending direction.
[0054] The structure that is wide in the middle and narrow at both ends is based on layout needs. After the middle part is widened, mounting parts such as laser radar can be installed inside the roof beam, and the narrow structure at both ends is easier to assemble, overcoming the limitation of installation size. On the other hand, widening the middle part can effectively improve the stiffness of the roof beam.
[0055] In one embodiment, Figure 1 As shown, the reinforcing ribs 2 are extended along the length direction of the beam body 1 , and the bending shape of the reinforcing ribs 2 is adapted to the bending shape of the profile of the beam body 1 .
[0056] The bending shape of the reinforcing rib 2 is adapted to the bending shape of the profile of the beam body 1 , and in the extension direction of the beam body 1 , the reinforcement consistency of various parts of the beam body 1 is better.
[0057] In one embodiment, the beam body 1 is an injection molded part, and the skeleton structure is compounded with the beam body 1 .
[0058] Compared with the method of setting up the frame structure separately, the frame structure is combined with the beam body 1, which has better integrity and higher reliability.
[0059] Specifically, the beam body 1 can be injection molded using one or more common injection molding materials such as PA6 material and PP material.
[0060] In one embodiment, a three-dimensional grid structure is distributed on the beam body 1 .
[0061] The three-dimensional grid structure is distributed on the beam body 1, which can ensure the strength of the beam body 1 while further reducing the weight. The specific shape of the grid can also be simulated and designed through software.
[0062] In one embodiment, the connection structure 3 is a sheet metal part, and each connection structure 3 is provided with a mounting structure.
[0063] The connection structure 3 is a sheet metal part, and there is no need to change the connection relationship between the roof cross beam and the surrounding matching parts. The assembly is achieved through the upper mounting structure of the connection structure 3, which is convenient for installation and has a wider range of applications.
[0064] Specifically, Figure 1 As shown, the mounting structure may be a mounting hole, a mounting step or the like.
[0065] In one embodiment, the reinforcing rib 2 is made of carbon fiber filaments, and at least two carbon fiber filaments are mixed and wound to form the reinforcing rib 2 .
[0066] Carbon fiber materials have high tensile strength, high modulus, low creep, strong designability, and excellent corrosion resistance. The reinforcing ribs 2 are formed by mixed winding of carbon fiber filaments. The winding method further improves the strength of the reinforcing ribs 2. The reinforcing ribs 2 with excellent performance improve the mechanical properties of the entire roof beam. Moreover, the reinforcing ribs 2 are used as local reinforcements, which greatly reduces costs compared to the method of using carbon fiber materials over a large area.
[0067] In this embodiment, the density of the high-performance carbon fiber composite material is in the range of 1.5 g / cm 3 -2.0g / cm 3 (The density of high-strength steel is 7.85g / cm 3 , the density of aluminum alloy is 2.7g / cm 3 ), the tensile strength of high-performance carbon fiber composite materials can reach 5000-7000MPa, which is higher than high-strength steel and aluminum alloy. The following table shows the parameters of tensile strength and tensile modulus of high-performance carbon fiber composite materials in this embodiment, which shows that its tensile modulus is also relatively high. In addition, high-performance carbon fiber composite materials have low creep, strong designability, and a wide variety of optional carbon fiber models. There are many types of resins used as import materials, and carbon fiber composite materials can also adopt layered structures. They also have strong anti-rust ability and are suitable as skeleton materials for roof beams.
[0068] High Strength Steel 7 series aluminum alloy High-performance carbon fiber <![CDATA[Density / (g / cm 3 )]]> 7.85 2.7 1.5-2.0 Tensile strength / MPa 1000-2000 500 5000-7000 Tensile modulus / GPa 210 75 200-700
[0069] In one embodiment, the connection structure 3 is bonded to the beam body 1 .
[0070] The connection structure 3 is bonded to the beam body 1 , and the connection process is relatively simple.
[0071] In some other embodiments, the connection structure 3 and the beam body 1 are integrally injection molded.
[0072] The connection structure 3 and the beam body 1 are integrally injection-molded, and the connection reliability is high. In actual application, the connection method of the connection structure 3 and the beam body 1 can be selected according to needs. Figure 4 The explosion structure of the connection structure 3 and the beam body 1 is given.
[0073] According to an embodiment of the present utility model, on the other hand, a vehicle frame is provided, comprising a door panel and a roof crossbeam, wherein the roof crossbeam is connected to the door panel via a connecting structure 3 .
[0074] The vehicle frame adopts the roof cross beam of the utility model, which realizes the lightweight of the vehicle frame and has the same technical effect as the roof cross beam, which will not be described in detail here.
[0075] According to an embodiment of the present utility model, on the other hand, a vehicle is provided, comprising the above-mentioned frame.
[0076] The utility model not only meets the safety performance of the frame, but also realizes the lightweight of the frame, thereby realizing the lightweight of the entire vehicle, thereby reducing the energy consumption of the vehicle, meeting the needs of energy conservation and emission reduction, and improving the endurance of new energy vehicles. The idea of composite reinforcement of the reinforcing rib 2 also provides ideas and references for the lightweighting of other parts of the vehicle, creating conditions for further lightweighting of the vehicle.
[0077] According to an embodiment of the present utility model, in another aspect, a molding method of a roof crossbar assembly is provided, the molding method comprising the following steps:
[0078] The carbon fiber filaments are mixed and wound, and resin is introduced through a thermal curing process to form a reinforcing rib 2;
[0079] The reinforcing ribs 2 are integrally injection molded to form the beam body 1;
[0080] The connecting structure 3 is bonded to both ends of the beam body 1 to form a roof cross beam; or, the reinforcing rib 2 and the connecting structure 3 are integrally injection-molded to form a roof cross beam.
[0081] First, the carbon fiber filaments are mixed and wound, and resin is introduced through a thermal curing process to form a reinforcing rib 2, and then the reinforcing rib 2 is compound injection molded to form the beam body 1. The reinforcing rib 2 has high strength and good mechanical properties, which improves the safety performance of the beam body 1. In addition, the injection molded beam body 1 is light in weight, and the roof crossbeam meets the safety performance while achieving lightweight; the connecting structure 3 can be bonded to the beam body 1, and the process is simple; the connecting structure 3 can also be integrally injection molded with the beam body 1, which can simplify the process steps.
[0082] The utility model uses high-performance carbon fiber filaments for mixed winding, and uses a thermosetting process to introduce resin to form a composite material; then, a secondary injection molding process is used to integrally mold the sheet metal part (connecting structure 3) and the carbon fiber part (reinforcement rib 2) to form a composite front roof beam. Taking advantage of the high strength of carbon fiber composite materials, the skeleton structure composite beam body 1 is supported and reinforced by the reinforcement rib 2. Specifically, the beam body 1 and the reinforcement rib 2 are solidified through the injection molding process after the injection molding is cooled, and the reinforcement rib 2 is embedded in the beam body 1; at the same time, a three-dimensional grid reinforcement structure is added in the middle area of the beam body 1 to strengthen the structure and increase its bending resistance and rigidity.
[0083] The setting of the sheet metal connection structure 3 does not need to change the connection method with the surrounding parts, and the connection reliability is high. During injection molding, the weight ratio of the sheet metal is controlled, and the composite material structure is optimized to maximize weight reduction. CAE is used for topological optimization to analyze the fiber arrangement and layer structure of the material, the design of the connection structure 3, and the structural distribution of related parts to optimize product performance and lightweight.
[0084] Although the embodiments of the present invention are described in conjunction with the accompanying drawings, those skilled in the art may make various modifications and variations without departing from the spirit and scope of the present invention, and such modifications and variations are all within the scope defined by the appended claims.
Claims
1. A roof beam assembly, characterized in that: include: A beam body (1), wherein the beam body (1) is a non-metallic part having a portion and / or an area to be strengthened; A skeleton structure is arranged at the position to be reinforced and / or the area to be reinforced of the beam body (1), and the skeleton structure is made of carbon fiber.
2. The roof beam assembly according to claim 1, characterized in that: The skeleton structure comprises: reinforcing ribs (2), a plurality of the reinforcing ribs (2) being distributed on the beam body (1).
3. The roof crossbar assembly according to claim 2, characterized in that: The reinforcing rib (2) is made of carbon fiber filaments, and a plurality of the carbon fiber filaments are mixed and wound to form the reinforcing rib (2).
4. The roof crossbar assembly according to claim 1, characterized in that: The beam body (1) forms a structure in its extending direction that is wide in the middle and narrow at both ends.
5. The roof crossbar assembly according to claim 1, characterized in that: The beam body (1) is an injection-molded part, and the skeleton structure is embedded in the beam body (1).
6. The roof crossbar assembly according to claim 1, characterized in that: A three-dimensional grid structure is distributed on the beam body (1).
7. The roof crossbar assembly according to any one of claims 1 to 6, characterized in that: A connection structure (3) is provided on the beam body (1), and the connection structure (3) comprises sheet metal parts provided at both ends of the beam body (1).
8. The roof crossbar assembly according to claim 7, characterized in that: The connection structure (3) is bonded to the beam body (1); or, the connection structure (3) and the beam body (1) are integrally injection molded.
9. A vehicle frame, characterized in that: The invention comprises the roof crossbar assembly according to any one of claims 1 to 8.
10. A vehicle, characterized in that: Comprising the frame described in claim 9.