Automobile door
By adopting a car door design similar to a sandwich structure, combining sheet molded plastic door inner panel, polymer compound door outer panel and internal frame, the problem of heavy weight of traditional metal doors is solved, and the door is lightweight and high stiffness is achieved, meeting the lightweight needs of new energy vehicles.
Patent Information
- Application Number
- CN202420684915.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-04-03
- Publication Date
- 2025-03-21
- Estimated Expiration
- 2034-04-03
AI Technical Summary
Traditional metal doors are heavy and cannot meet the lightweight needs of new energy vehicles. At the same time, it is difficult to achieve lightweight doors while ensuring stiffness.
Car doors are designed with sandwich-like structures, including sheet-shaped molded door inner panels, polymer compound door outer panels and internal frames. The internal frame is used as a bearing component, the U-shaped beam has good stiffness, and the door inner panels and outer panels are made of composite materials to achieve light weight.
On the premise of ensuring stiffness, the doors are lighter and the doors are weight-reduced by 15-20%, better meeting the lightweight needs of new energy vehicles.
Smart Images
Figure CN222645773U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of automobile doors, and specifically provides an automobile door. Background Art
[0002] Traditional metal car doors are made entirely of metal sheets, which are stamped and formed according to the structure of different parts. All parts except the outer panels are connected by arc welding using a welding fixture, which requires about 2-3 welding cycles to form an inner panel assembly. Sealant is then applied around the outer panel using an edging fixture and combined with the inner panel assembly. The edges of the inner panel assembly are wrapped using edging to form a completed door assembly, which is then painted and finally the painted door assembly is assembled to the car door.
[0003] As the load-bearing component of the entire car door, the metal car door has good rigidity and can absorb more energy from side collisions. However, the overall weight of the metal car door is relatively large and cannot meet the lightweight requirements of new energy vehicles. Utility Model Content
[0004] In order to solve the above problems, the utility model provides a car door, which can realize the lightness of the car door under the premise of ensuring the rigidity.
[0005] The automobile door provided by the utility model comprises a sheet molding compound door inner panel, a polymer compound door outer panel, an internal frame and a window frame reinforcement; wherein the sheet molding compound door inner panel comprises an upper window frame area and a lower main body area, the window frame reinforcement is bonded and fixed to the upper window frame area, a reinforcing rib is formed in the lower main body area, the internal frame and the polymer compound door outer panel are bonded and fixed to the lower main body area in sequence from the inside to the outside; the internal frame comprises a U-shaped beam, a main cross beam and a door anti-collision beam, the two ends of the main cross beam are respectively welded to the two free ends of the U-shaped beam, and the door anti-collision beam is screwed on the U-shaped beam at an angle relative to the upper cross beam.
[0006] Preferably, the main crossbeam is integrally formed with the secondary crossbeam, and the ends of the secondary crossbeam are welded to the U-shaped beam.
[0007] Preferably, a door lock reinforcement is welded at a position on the U-shaped beam corresponding to the end of the secondary cross beam.
[0008] Preferably, a limiter reinforcement is welded on the U-shaped beam at a position corresponding to the higher end of the door anti-collision beam, a mounting part is welded at the bend of the U-shaped beam, and two hinge reinforcements are welded on both sides of the U-shaped beam at the higher end of the door anti-collision beam; the U-shaped beam is made of 6 series aluminum alloy square tube, the main crossbeam, hinge reinforcement, limiter reinforcement, door lock reinforcement, and mounting parts are all made of 5 series aluminum alloy plates, and the door anti-collision beam is made of high-strength steel plates.
[0009] Preferably, the material fiber of the sheet molding compound vehicle door inner panel is glass fiber or carbon fiber, and the material of the polymer compound vehicle door outer panel is a mixture of polypropylene and EPDM rubber.
[0010] Compared with the prior art, the utility model adopts a sandwich-like structure, dividing the vehicle door into a vehicle door inner panel, a vehicle door outer panel and an internal frame. The internal frame serves as the load-bearing component of the entire vehicle door. The U-shaped beam therein has good rigidity and can absorb more energy for side collisions. The use of composite materials for the vehicle door inner panel and the vehicle door outer panel can better achieve lightweighting, and the vehicle door can be reduced in weight by 15-20%. BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Figure 1 It is a structural schematic diagram of a door inner panel provided according to an embodiment of the utility model;
[0012] Figure 2 It is a schematic diagram of assembling a window frame reinforcement member and a door inner panel according to an embodiment of the utility model;
[0013] Figure 3 It is a structural schematic diagram of an internal frame provided according to an embodiment of the utility model;
[0014] Figure 4 It is a schematic diagram of the connection method of the internal frame provided according to an embodiment of the utility model;
[0015] Figure 5 It is a schematic diagram of assembling the internal frame and the inner door panel according to an embodiment of the utility model;
[0016] Figure 6 It is a schematic diagram of assembling a vehicle door outer panel and a vehicle door inner panel provided according to an embodiment of the utility model.
[0017] The accompanying drawings include: door inner panel 1, annular reinforcement rib 101, gluing position 102, window frame reinforcement 2, gluing position 201, internal frame 3, U-beam 301, main cross beam 302, door anti-collision beam 303, secondary cross beam 304, hinge reinforcement 305, limiter reinforcement 306, door lock reinforcement 307, mounting part 308, gluing position 309, door inner panel assembly 4, gluing position 401, door outer panel 5. DETAILED DESCRIPTION
[0018] Hereinafter, embodiments of the present utility model will be described with reference to the accompanying drawings. In the following description, the same modules are represented by the same reference numerals. In the case of the same reference numerals, their names and functions are also the same. Therefore, the detailed description thereof will not be repeated.
[0019] In order to make the purpose, technical solution and advantages of the utility model more clear, the utility model is further described in detail below in conjunction with the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described here are only used to explain the utility model and do not constitute a limitation of the utility model.
[0020] like Figure 1-Figure 6 As shown, an embodiment of the utility model provides a car door, including a door inner panel 1, a window frame reinforcement 2, an internal frame 3 and a door outer panel 4; wherein, the door inner panel 1 includes an upper window frame area and a lower main body area, the window frame reinforcement 2 is bonded and fixed to the upper window frame area, an annular reinforcement rib 101 is formed in the lower main body area, and the internal frame 3 and the door outer panel 4 are bonded and fixed to the lower main body area in sequence from the inside to the outside.
[0021] The door inner panel 1 is made of sheet molding compound, and the fiber in the sheet molding compound can be glass fiber or carbon fiber. The production process of the door inner panel 1 is as follows: lay the sheet molding compound flat in the mold, close the mold and heat it to 280-300°C to form the sheet molding compound, and take out the door inner panel 1 after opening the mold. The thickness of the door inner panel 1 is 2.5-3.5mm. The lower main body area of the door inner panel 1 is formed into an annular reinforcing rib 101 through the mold, which is used as the support position of the internal frame 3. The upper window frame area and the lower main body area of the door inner panel 1 are distributed with multiple glue coating positions 102 along the contour, and the width of the glue coating position is ≥10mm.
[0022] The window frame reinforcement 2 is made of 5 series or 6 series aluminum alloy profiles and is formed by stamping. The window frame reinforcement 2 is used as a reinforcement structure of the vehicle door window frame and is bonded to the upper window frame area of the vehicle door inner panel 1 by structural adhesive. The gluing position 201 of the window frame reinforcement 2 corresponds to the gluing position 102 of the upper window frame area. The gluing width of the gluing position 201 and the gluing position 102 are both 6-8mm, and the gluing thickness is 3-4mm. Then, the window frame reinforcement 2 is bonded to the upper window frame area of the vehicle door inner panel 1 by a bonding tool.
[0023] The internal frame 3 includes a U-shaped beam 301, a main cross beam 302, a door anti-collision beam 303, a secondary cross beam 304, a hinge reinforcement 305, a limiter reinforcement 306, a door lock reinforcement 307, and a mounting member 308. The main cross beam 302, the secondary cross beam 304, the hinge reinforcement 305, the limiter reinforcement 306, the door lock reinforcement 307, and the mounting member 308 are respectively welded to the U-shaped beam 301, and the door anti-collision beam 303 is screwed to the U-shaped beam 301.
[0024] The U-shaped beam 301 is formed by hydraulic forming using a 6-series aluminum alloy profile. The specific production process is as follows: first, the 6-series aluminum alloy square tube is bent into a U-shaped square tube by a tube bending machine, and then the U-shaped square tube is placed in a hydraulic forming mold, the hydraulic forming mold is closed, and high-pressure water is injected into the U-shaped square tube. The water pressure reaches 80MPa, so that the outer surface of the U-shaped square tube is completely fitted with the inner surface of the hydraulic forming mold, and the two ends of the hydraulically formed U-shaped square tube are cut to form the U-shaped beam 301. The U-shaped beam 301 uses a 6-series aluminum alloy profile to improve the overall rigidity of the internal frame and absorb more energy for side collisions.
[0025] The main beam 302 and the secondary beam 304 are integrally stamped from 5 series aluminum alloy profiles through a stamping process. Both ends of the main beam 302 are welded to the two free ends of the U-shaped beam 301 , and the free end of the secondary beam 304 is welded to a position close to a free end of the U-shaped beam 301 .
[0026] The door anti-collision beam 303 is formed by stamping a high-strength steel plate with a yield strength of 980 MPa through a stamping process. The door anti-collision beam 303 is connected to the U-shaped beam 301 relative to the main cross beam 302 through bolts.
[0027] There are two hinge reinforcements 305, which are respectively stamped from 5 series aluminum alloy plates through a stamping process. The two hinge reinforcements 305 are respectively welded to the U-shaped beam 301 on both sides of the higher end of the door anti-collision beam 303, one of the hinge reinforcements 305 is close to the end of the U-shaped beam 301, and the other hinge reinforcement 305 is close to the bending part of the U-shaped beam 301.
[0028] The stopper reinforcement 306 is formed by stamping a 5 series aluminum alloy plate through a stamping process, and the stopper reinforcement 306 is welded to a position on the U-shaped beam 301 corresponding to the higher end of the door anti-collision beam 303 .
[0029] The door lock reinforcement 307 is stamped from a 5 series aluminum alloy plate through a stamping process, and the door lock reinforcement 307 is welded to a position on the U-shaped beam 301 corresponding to the end of the secondary cross beam 304 .
[0030] The mounting member 308 is formed by stamping a 5 series aluminum alloy plate through a stamping process, and the mounting member 308 is welded at the bending position of the U-shaped beam 301 .
[0031] Structural adhesive is applied to both ends of the main cross beam 302 , the free end of the secondary cross beam 304 , both ends of the door anti-collision beam 303 , and the glue coating positions 309 on the two hinge reinforcements 305 , the limiter reinforcement 306 , and the door lock reinforcement 307 , respectively, so as to bond the U-shaped beam 3 to the lower main body area of the door inner panel 1 .
[0032] In order to improve the connection strength between the internal frame 3 and the door inner panel 1, screw holes are respectively processed on the mounting part 308, the two hinge reinforcements 305, the door lock reinforcement 307 and one end of the door anti-collision beam 303, which are connected to the lower main area of the door inner panel 1 by bolts.
[0033] The door inner panel 1 is connected to the window frame reinforcement 2 and the U-shaped beam 301 to form a door inner panel assembly 4. A gluing position 401 is distributed on the periphery of the internal frame 3 in the lower main area of the door inner panel assembly 4. Structural glue is applied at the gluing position 401 to achieve bonding with the door outer panel 5.
[0034] The door outer panel 5 is made of a mixture of polypropylene and EPDM rubber, which is filled into a mold by an injection molding machine, and the door outer panel 5 is taken out after the mold is opened. The thickness of the door outer panel 5 is 2.5-2.8 mm. The door outer panel 5 is bonded to the door inner panel assembly 4 to form a car door.
[0035] Since the vehicle door inner panel 1 and the vehicle door outer panel 5 are made of composite materials, the vehicle door can be made lighter in weight.
[0036] The above content describes in detail the structure of the automobile door provided by the embodiment of the utility model. The embodiment of the utility model also provides a method for manufacturing the automobile door, which specifically includes the following steps:
[0037] S1: Produce sheet molding compound door inner panel, polymer compound door outer panel, inner frame and window frame reinforcement respectively.
[0038] S2: Structural adhesive is applied to a designated position of an upper window frame area of the sheet molding compound door inner panel, and the window frame reinforcement is bonded to the upper window frame area.
[0039] S3: Structural adhesive is applied to the designated positions of the lower main body area of the sheet molding compound door inner panel and the designated positions of the inner frame, and the inner frame and the polymer compound door outer panel are sequentially bonded and fixed to the lower main body area from the inside to the outside.
[0040] In a specific example of the present invention, the process of making the internal frame in step S1 is as follows:
[0041] The U-shaped beam, main beam, secondary beam, door anti-collision beam, door lock reinforcement, hinge reinforcement, limiter reinforcement and mounting parts are manufactured respectively; among them, the U-shaped beam is hydraulically formed by a hydraulic forming process using a 6-series aluminum alloy profile; the main beam and secondary beam are integrally stamped by a stamping process using a 5-series aluminum alloy profile; the door anti-collision beam, door lock reinforcement, hinge reinforcement, limiter reinforcement and mounting parts are independently stamped by a stamping process using a 5-series aluminum alloy profile;
[0042] The main crossbeam and the secondary crossbeam are welded to the U-shaped frame respectively, the two ends of the main crossbeam are welded to the two free ends of the U-shaped beam, and the free end of the secondary crossbeam is welded to a position close to one free end of the U-shaped beam;
[0043] Screw the door anti-collision beam on the U-beam at an angle relative to the upper crossbeam;
[0044] Welding the door lock reinforcement to the U-beam at a position corresponding to the end of the secondary crossbeam;
[0045] The stopper reinforcement is welded to the U-beam at a position corresponding to the higher end of the door anti-collision beam;
[0046] Weld the mounting parts to the bend of the U-beam;
[0047] Two hinge reinforcements are welded to the U-beam on both sides of the higher end of the door anti-collision beam.
[0048] In another specific example of the present invention, the production process of the U-shaped beam is as follows: first, a 6 series aluminum alloy square tube is bent into a U-shaped square tube by a tube bending machine, and then the U-shaped square tube is placed in a hydraulic forming mold, the hydraulic forming mold is closed and high-pressure water is injected into the U-shaped square tube, so that the outer surface of the U-shaped square tube is completely fitted with the inner surface of the hydraulic forming mold, and the two ends of the U-shaped square tube after hydraulic forming are cut to form a U-shaped beam.
[0049] In another specific example of the present invention, step S3 specifically includes the following steps:
[0050] Structural adhesive is applied to both ends of the main cross beam, the free end of the secondary cross beam, both ends of the door anti-collision beam, the door lock reinforcement, the two hinge reinforcements, and the stopper reinforcement, respectively, to bond the U-shaped beam to the lower main body area of the sheet molding compound door inner panel;
[0051] The mounting member, two hinge reinforcement members, the door lock reinforcement member and one end of the door anti-collision beam are respectively screwed to the lower main body area of the sheet molding compound door inner panel by bolts;
[0052] Structural adhesive is coated on the periphery of the inner frame at the lower main area of the sheet molding compound door inner panel, and the polymer compound door outer panel is bonded to the lower main area of the sheet molding compound door inner panel.
[0053] In another specific example of the present invention, the process of making a sheet molding compound door inner panel in step S1 is as follows: the process of making a sheet molding compound door inner panel in step S1 is as follows: spreading the sheet molding compound in the mold, and after closing the mold, the clamping force is 2000T, the holding time is 10-15s, the heating temperature is 280-300°C, the cooling time is 15-20s, so that the sheet molding compound is formed, and the sheet molding compound door inner panel is taken out after opening the mold; the process of making a polymer compound door outer panel in step S1 is as follows: filling a mixture of polypropylene and ethylene propylene diene rubber into the mold by an injection molding machine, the clamping force is 1600T, the holding time is 10-15s, the cooling time is 10-15s, so that the mixture is formed, and the polymer compound door outer panel is taken out after opening the mold.
[0054] Although the embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and cannot be understood as limiting the present invention. A person skilled in the art may change, modify, replace and modify the above embodiments within the scope of the present invention.
[0055] The above specific implementation methods of the utility model do not constitute a limitation on the protection scope of the utility model. Any other corresponding changes and modifications made according to the technical concept of the utility model should be included in the protection scope of the claims of the utility model.
Claims
1. A car door, characterized in that: Including sheet molding compound door inner panels, polymer compound door outer panels, internal frames and window frame reinforcements; among which, The sheet molding compound door inner panel comprises an upper window frame region and a lower main body region, the window frame reinforcement is bonded and fixed to the upper window frame region, a reinforcing rib is formed in the lower main body region, and the internal frame and the polymer compound door outer panel are bonded and fixed to the lower main body region in sequence from the inside to the outside; The internal frame comprises a U-shaped beam, a main cross beam and a door anti-collision beam. The two ends of the main cross beam are respectively welded to the two free ends of the U-shaped beam. The door anti-collision beam is screwed on the U-shaped beam at an angle relative to the main cross beam.
2. The automobile door according to claim 1, characterized in that: The main crossbeam is integrally formed with a secondary crossbeam, and ends of the secondary crossbeam are welded to the U-shaped beam.
3. The automobile door according to claim 2, characterized in that: A door lock reinforcement is welded on the U-shaped beam at a position corresponding to the end of the secondary cross beam.
4. The automobile door according to claim 3, characterized in that: A limiter reinforcement is welded on the U-shaped beam at a position corresponding to the higher end of the door anti-collision beam, a mounting piece is welded at the bending part of the U-shaped beam, and two hinge reinforcements are respectively welded on both sides of the higher end of the door anti-collision beam on the U-shaped beam; the U-shaped beam is made of 6 series aluminum alloy square tube, the main crossbeam, the hinge reinforcement, the limiter reinforcement, the door lock reinforcement and the mounting piece are all made of 5 series aluminum alloy plate, and the door anti-collision beam is made of high-strength steel plate.
Citation Information
Cited By
Automobile door and manufacturing method thereof
CN118107355A