Flange composite material tubular beam and instrument board cross beam assembly adopting same

Abstract

The utility model belongs to the technical field of instrument panel cross beams, and particularly relates to a flange composite material tubular beam and an instrument panel cross beam assembly adopting the same, the flange composite material tubular beam comprises a steel pipe and a composite material wrapping the outer surface of the steel pipe, an injection molding integrated forming process is adopted, and a flange is arranged on the outer surface of the steel pipe in the length direction; the cross section is circular or elliptical, and the wall thickness is 0.8-1mm. The flange structure is formed on the surface of the steel pipe through the hot steam expansion technology, a traditional surface treatment or knurling slotting technology is replaced, shaping of the meshing structure is completed in the tubular beam forming stage, the machining technology is simplified, the machining cost is reduced, the steel pipe and the composite material are integrally formed, and through the metal and nonmetal combined structure design, the machining efficiency is improved. The problems that a traditional instrument panel cross beam is prone to corrosion, complex in machining process, high in machining cost and too large in weight are solved, the production efficiency and the qualified rate of products are remarkably improved, and the double requirements for light weight and high performance of modern automobiles are met.

Description

Technical Field

[0001] The utility model belongs to the technical field of instrument panel cross beams, and more specifically, relates to a flange composite pipe beam and an instrument panel cross beam assembly using the pipe beam. Background Art

[0002] The automotive instrument panel cross beam is a key structural component for supporting human-machine interface control devices and decorative parts, and is also an important part for protecting drivers and passengers in the vehicle. Its strength and stiffness are the primary indicators for measuring its performance. With the pursuit of a high-quality lifestyle by people and the in-depth penetration of ecological thinking and the concept of sustainable development, higher requirements are also imposed on materials and processing and forming technologies. Against the background of the rapid development of the automotive industry, the demand for vehicle lightweighting is increasing day by day. Materials with energy conservation, environmental protection, light weight, and high mechanical properties are more favored than non-economical materials.

[0003] Currently, the mainstream design scheme for automotive instrument panel cross beams is mainly the all-steel stamping and welding type. This design technology is mature and can relatively easily meet the requirements for safety and collision performance. However, the all-steel instrument panel cross beam assembly has a large mass and poor lightweighting effect, and cannot meet the strict requirements for vehicle lightweighting of some vehicle models. To solve this problem, a metal-plastic hybrid instrument panel cross beam has emerged. This hybrid cross beam can not only meet the performance index requirements but also achieve the goal of vehicle lightweighting.

[0004] However, even the metal-plastic hybrid cross beam still has some deficiencies. Currently, most metal-plastic hybrids use aluminum alloy pipes, and plastics are injection-molded on the outside of the aluminum alloy pipes to form an integral structure. Although the aluminum alloy pipe is lighter in mass than the traditional all-steel stamping and welding formed instrument panel cross beam, the material cost is high and the processing procedures are cumbersome. For example, for the aluminum alloy pipe beam shown in the attached drawings of the specification, before injection molding on the outer surface of the aluminum alloy pipe beam, its surface needs to be treated or a process such as rolling and grooving (such as the groove line a1 in Figure 1-2 is required to enhance the bonding between the aluminum alloy pipe beam and the injection molding material. Due to the aluminum alloy pipe beam compared to the all-steel one, the manufacturing cost is high. Figure 2 In general, the existing all-steel stamping and welding type instrument panel cross beam is technically mature, safe and reliable, but it has a large weight and poor lightweighting effect, and it is difficult to meet the high requirements of the modern automotive industry for lightweighting, energy conservation and environmental protection. Although the metal-plastic hybrid cross beam has improved in terms of lightweighting, it still faces problems such as complex manufacturing processes and high costs. Therefore, developing an instrument panel cross beam structure that can meet various performance requirements while having the advantages of lightweighting and affordability is an urgent problem to be solved in the current automotive industry.

[0005] Summary of the Utility Model

[0006] ​In view of the deficiencies of the prior art, the present application proposes a flanged composite tube beam for solving the above problems and an instrument panel crossbeam assembly using such a tube beam.

[0007] To achieve the technical objectives of the present utility model, the following technical solutions will be adopted:

[0008] On the one hand, the present utility model provides a flanged composite tube beam, comprising:

[0009] A steel tube, on the outer surface of which there is provided at least one flange along its length direction;

[0010] A composite material, which is wrapped on the outer surface of the steel tube;

[0011] The steel tube and the composite material are integrally formed by injection molding;

[0012] The cross-section of the steel tube is of a circular or elliptical structure, and the flange is formed by a hot steam expansion process of the steel tube;

[0013] The thickness of the steel tube is 0.8 - 1 mm.

[0014] Further, there are two flanges provided on the outer surface of the steel tube along its length direction.

[0015] Further, the composite material is a glass fiber reinforced plastic.

[0016] On the other hand, the present utility model provides an instrument panel crossbeam assembly using a flanged composite tube beam, comprising a tube beam body and a bracket assembly provided on the tube beam body.

[0017] Further, the tube beam body comprises a steel tube and a composite material wrapped on the outer surface of the steel tube.

[0018] Further, the bracket assembly comprises an instrument panel mounting bracket, a steering column mounting bracket, a front bulkhead connecting bracket, an air conditioner mounting bracket, a safety airbag mounting bracket and a floor connecting bracket provided at corresponding positions of the tube beam body.

[0019] The beneficial effects of the present utility model are:

[0020] First, the inner tube of the composite material pipe beam of the present utility model is a steel pipe, and its surface is provided with flanges. The composite material is wrapped on the outer surface of the steel pipe. The flanges provide more stable support for the composite material, preventing it from slipping or falling off during use. Compared with traditional aluminum alloy materials, the steel pipe has higher hardness and strength, can withstand greater loads, reduces the risk of rupture during high-pressure die swelling, thereby improving production efficiency and product qualification rate; the flanges on the steel pipe are formed by a hot steam swelling process, replacing the traditional metal pipe surface treatment or rolling and grooving process, reducing processing costs, not only ensuring a firm bond between the steel pipe and the composite material, but also improving the durability and reliability of the pipe beam structure; the thickness of the steel pipe is 0.8 - 1 mm, and compared with the aluminum alloy pipe, its thickness is 1 / 3 of the thickness of the aluminum alloy pipe. Since the density of the aluminum alloy material is about 1 / 3 of the density of the steel material, using this wall thickness steel pipe structure can not only meet the structural strength but also maintain the same lightweight effect as the aluminum-plastic instrument panel crossbeam.

[0021] Second, in the preferred implementation, the composite material of the present utility model uses glass fiber reinforced plastic, which has high strength, corrosion resistance, heat resistance, and high impact resistance.

[0022] Third, the instrument panel crossbeam assembly using the flange composite material pipe beam of the present utility model, compared with the traditional all-steel instrument panel crossbeam, the flange steel pipe beam composite material structure significantly reduces the weight, improves the fuel economy and driving performance of the vehicle. Compared with the aluminum alloy pipe beam composite material structure, it reduces the overall material cost and manufacturing process complexity, improves production efficiency. Through the combination of steel and composite materials, the impact resistance and stiffness of the structure are significantly improved, ensuring the protection of drivers and passengers under various working conditions. Description of the Drawings

[0023] Figure 1 is a schematic structural diagram of the pipe beam body in the instrument panel crossbeam assembly of the prior art;

[0024] Figure 2 is Figure 1 the A - A cross-sectional view of

[0025] Figure 3 is a schematic structural diagram of the pipe beam body in the instrument panel crossbeam assembly of the embodiment of the present utility model;

[0026] Figure 4 is Figure 3 the B - B cross-sectional view of

[0027] Figure 5 is a schematic structural diagram of the instrument panel crossbeam assembly of the embodiment of the present utility model;

[0028] Figure 6 is Figure 5 the C - C cross-sectional view of

[0029] Among them, 1 is the pipe beam body; 10 is the steel pipe; 100 is the flange; 11 is the injection molding part; 2 is the instrument panel mounting bracket; 3 is the steering column mounting bracket; 4 is the front bulkhead connecting bracket; 5 is the air conditioner mounting bracket; 6 is the airbag mounting bracket; 7 is the floor connecting bracket; a1 is the groove line. Specific implementation mode

[0030] In order to enable those skilled in the art to better understand the technical solution of the present application, the following will further describe the present utility model in detail with reference to the accompanying drawings and embodiments.

[0031] The orientation terms such as up, down, left, right, front and back in this application document are established based on the positional relationship shown in the accompanying drawings. If the accompanying drawings are different, the corresponding positional relationship may also change accordingly. Therefore, it should not be understood as a limitation of the protection scope.

[0032] In this application, the terms "installation", "connection", "engagement", "connection", "fixation", etc. should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, an integral connection, a mechanical connection, an electrical connection or a connection that can communicate with each other, a direct connection, an indirect connection through an intermediate medium, a connection inside two components, or an interaction relationship between two components. For those of ordinary skill in the art, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0033] Embodiment 1

[0034] As shown in the specification appendix Figure 3-4 , the present utility model discloses a flange composite pipe beam, which includes a steel pipe 10 and a composite material wrapped on the outer surface of the steel pipe 10. A flange 100 is arranged on the outer surface of the steel pipe 10 along its length direction.

[0035] Preferably, the cross-section of the steel pipe 10 is a circular or elliptical structure.

[0036] The flange 100 is a part of the steel pipe 10 and is formed by a steel pipe hot steam expansion process. This process uses hot steam pressure to expand the steel pipe in a specific area to form a flange.

[0037] The flange 100 enhances the bonding force between the composite material and the steel pipe by increasing the friction and contact area on the surface of the steel pipe 10.

[0038] Preferably, two flanges 100 are provided.

[0039] Preferably, the thickness of the steel pipe 10 is 0.8 - 1 mm. Compared with the aluminum alloy pipe, its thickness is 1 / 3 of the thickness of the aluminum alloy pipe. Since the density of the aluminum alloy material is about 1 / 3 of the density of the steel material, using the steel pipe 10 structure with this wall thickness can not only meet the structural strength but also maintain the same lightweight effect as the aluminum-plastic instrument panel crossbeam.

[0040] Preferably, the composite material is glass fiber reinforced plastic, which has high strength, corrosion resistance, heat resistance, and high impact resistance.

[0041] The steel pipe 10 and the composite material are integrally formed. The specific manufacturing process is as follows:

[0042] Steel pipe forming process: First, preheat the steel pipe 10, then place it in a hot gas expansion mold, and at the same time introduce high-temperature and high-pressure gas (such as nitrogen or helium). Under the action of the gas, the gas temperature and pressure inside the steel pipe 10 rise rapidly, and the steel pipe 10 expands and deforms, causing a flange 100 to form along the length direction of the outer surface of the steel pipe 10. After expansion, gradually reduce the gas temperature and pressure to keep the steel pipe 10 in an expanded state at a relatively high temperature. Finally, use the method of natural cooling or forced cooling to make the steel pipe 10 return to normal temperature to obtain the required steel pipe 10.

[0043] Steel pipe composite process: Place the formed steel pipe 10 in an injection mold, mix the composite material in proportion to ensure uniformity, and inject the mixed composite material into the mold. The injection process controls the fluidity and curing time of the material by heating the mold or using a heater to make the composite material wrap around the outer surface of the steel pipe 10. After injection molding, place the mold at an appropriate temperature and pressure to ensure that the composite material is fully cured. After curing is completed, carefully disassemble the mold and take out the steel pipe 10 wrapped with the composite material.

[0044] Using the structure of this embodiment, the inner pipe of the pipe beam is made of steel pipe. Compared with the traditional aluminum alloy material, it has higher hardness and strength, can withstand greater loads, reduces the risk of cracking during high-pressure in-mold expansion, thereby improving production efficiency and product qualification rate; the flange provides more stable support for the composite material to prevent it from slipping or falling off during use. This flange formed by the hot gas expansion process replaces the traditional metal pipe surface treatment or rolling and grooving process, reduces processing costs, not only ensures the firm bonding between the steel pipe and the composite material but also improves the durability and reliability of the pipe beam structure.

[0045] Embodiment 2

[0046] As shown in the attached specification Figure 5-6, this utility model describes an instrument panel crossbeam assembly using a flange composite material pipe beam, which includes a pipe beam body 1 and a bracket assembly arranged on the pipe beam body 1. The bracket assembly includes an instrument panel mounting bracket 2, a steering column mounting bracket 3, a front panel connecting bracket 4, an air conditioner mounting bracket 5, a safety airbag mounting bracket 6 and a floor connecting bracket 7, and these brackets are installed at corresponding positions on the pipe beam 10.

[0047] The pipe beam body 1 is a flange composite material pipe beam integrally formed by the composite material and the steel pipe 10 in Embodiment 1. The pipe beam body 1 includes a steel pipe 10 and an injection molding part 11.

[0048] In one implementation, the bracket assembly is made of a metal material with corrosion resistance, high hardness and high strength. After the pipe beam body 1 is manufactured, the bracket assembly is installed at the corresponding position on the pipe beam body 1.

[0049] In another implementation, some brackets in the bracket assembly use metal materials as the main materials and are installed on the steel pipe that has not been injection molded after bulging. Through the injection molding process, the composite material is wrapped on the metal main material brackets and the steel pipe to improve the impact resistance and corrosion resistance.

[0050] In another implementation, some brackets in the bracket assembly adopt an injection molding process. Corresponding bracket grooves are provided at the corresponding positions of the steel pipe of the injection mold, and corresponding brackets are formed on the steel pipe through injection molding. These brackets are integrally formed with the injection molding part 11 wrapped on the outer surface of the steel pipe, and have higher position accuracy compared with independent brackets.

[0051] Adopting the structure of this embodiment, compared with the traditional all-steel instrument panel crossbeam, the flange steel pipe beam composite material structure significantly reduces the weight, improves the fuel economy and driving performance of the vehicle. Compared with the aluminum alloy pipe beam composite material structure, it reduces the overall material cost and manufacturing process complexity, improves the production efficiency. Through the combination of steel and composite materials, the impact resistance and stiffness of the structure are significantly improved, ensuring the protection of drivers and passengers under various working conditions.

[0052] The above are only the embodiments of this utility model. Common knowledge such as specific structures and characteristics known in the solutions is not described in detail here. For those skilled in the art, it is obvious that this application is not limited to the details of the above exemplary embodiments, and can be implemented in other specific forms without departing from the spirit or basic characteristics of this application. Therefore, from any point of view, the embodiments should be regarded as exemplary and non-limiting. The scope of this application is defined by the appended claims rather than the above description. Therefore, all changes falling within the meaning and scope of the equivalent elements of the claims are intended to be included in this application. Any reference signs in the claims should not be regarded as limiting the claimed rights.

Claims

1. A flange composite material tubular beam, characterized in that: include: A steel pipe (10) having at least one flange (100) disposed on its outer surface along its length direction; A composite material wrapped around the outer surface of the steel pipe (10); The steel pipe (10) and the composite material are integrally formed by injection molding; The cross section of the steel pipe (10) is a circular or elliptical structure, and the flange (100) is formed by a hot steam expansion process of the steel pipe; The thickness of the steel pipe (10) is 0.8-1 mm.

2. The flange composite material tubular beam according to claim 1, characterized in that: The outer surface of the steel pipe (10) is provided with two flanges (100) along its length direction.

3. The flange composite material tubular beam according to claim 1, characterized in that: The composite material is glass fiber reinforced plastic.

4. An instrument panel cross beam assembly using the flange composite material tube beam according to any one of claims 1 to 3, characterized in that: It comprises a pipe beam body (1) and a bracket assembly arranged on the pipe beam body (1).

5. The instrument panel cross beam assembly according to claim 4, characterized in that: The tube beam body (1) comprises a steel tube (10) and a composite material wrapped around the outer surface of the steel tube.

6. The instrument panel cross beam assembly according to claim 4, characterized in that: The bracket assembly comprises a dashboard mounting bracket, a steering column mounting bracket, a front enclosure connecting bracket, an air conditioner mounting bracket, an air bag mounting bracket and a floor connecting bracket, which are arranged at corresponding positions of the tube beam body (1).

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