Improved structure of composite material front machine cover

Abstract

The utility model provides an improved structure of a composite material front machine cover, which comprises an inner plate and an outer plate, both the inner plate and the outer plate are made of composite materials, welding ribs are arranged on the inner plate or the outer plate, and the inner plate and the outer plate are welded together by melting the welding ribs in a welding mode and cooling and solidifying. The front machine cover has the advantages that compared with a front machine cover formed by metal stamping, the light weight effect is good, and the process is simpler; compared with a plastic front machine cover in a bonding mode, the welding mode is adopted to replace a bonding technology, the technology is simple, the production takt is fast, the product cost is low, the light weight effect is better, the energy absorption foam interlayer is additionally arranged between the inner plate and the outer plate of the front machine cover, the light weight effect is achieved, and meanwhile damage to pedestrians after collision can be effectively reduced.

Description

Technical Field

[0001] This utility model belongs to the field of automotive hood technology, specifically relating to an improved structure of a composite material front hood. Background Technology

[0002] With increasingly stringent requirements for vehicle emissions and range, lightweighting has become an essential step, and replacing traditional metal materials with composite materials as a lightweighting solution is becoming a trend. Currently, the mainstream method for manufacturing front hoods is metal (steel, aluminum, etc.) stamping. The advantage of steel stamping is low cost, but the disadvantage is its heavy weight. The advantages of aluminum stamping are its light weight and good pedestrian protection, while its disadvantage is its high cost. The trend of replacing steel with plastic in automotive body panels is towards lightweighting, and the use of in-mold coloring technology during injection molding, such as ColorForm, has become a more environmentally friendly, lower-cost, and simpler surface treatment solution than painting. Currently, metal stamping for hoods is costly and has poor lightweighting effects. Plastic hoods with bonded inner and outer panels require multiple steps in the adhesive bonding process: cleaning, flame treatment (to increase surface energy), applying adhesive, pressing, heat curing, and settling. Some adhesives also require a primer before application. This process is complex and time-consuming. The complex bonding process, coupled with the high cost of adhesives, leads to slow production cycles and high product costs. Furthermore, since the inner and outer panels are only bonded with adhesive at the joint, there is no corresponding cushioning structure when a pedestrian's head hits the outer hood panel after a collision, resulting in significant head injuries. Utility Model Content

[0003] The technical problem to be solved by this utility model is to provide an improved composite material front hood structure that is lightweight and simple to manufacture, in light of the current state of the technology.

[0004] The technical solution adopted by this utility model to solve the above-mentioned technical problems is as follows: an improved structure of a composite material front hood, including an inner plate and an outer plate, characterized in that the inner plate and the outer plate are both made of composite materials, and welding ribs are arranged on the inner plate or the outer plate. The inner plate and the outer plate are welded together by melting the welding ribs and cooling and solidifying them.

[0005] Preferably, in the above-mentioned improved composite material hood structure, the welding ribs are arranged on the periphery or middle area of ​​the inner or outer plate.

[0006] Preferably, in the aforementioned improved composite material hood structure, the welding method is one of infrared welding, vibration friction welding, or laser welding. In this patent, both the inner and outer panels are made of plastic composite materials, and welding is used instead of adhesive bonding to achieve a solution for connecting and fixing the inner and outer panels. This not only achieves the goal of cost reduction and weight reduction but also simplifies the process.

[0007] Preferably, in the above-mentioned improved composite material hood structure, an energy-absorbing foam interlayer is filled between the inner panel and the outer panel.

[0008] Preferably, in the aforementioned improved composite material hood structure, the energy-absorbing foam interlayer is foamed from PUR polyurethane, EPP polypropylene, EPDM ethylene propylene rubber, or EVA ethylene-vinyl acetate copolymer. In this patent, the energy-absorbing foam interlayer can be fixed to the inner or outer panel via adhesive and / or snap-fit. When a pedestrian's head impacts the outer panel of the hood, the impact force is transferred through the outer panel to the energy-absorbing foam interlayer, thus reducing head injury to the pedestrian.

[0009] Preferably, in the aforementioned improved composite material hood structure, a metal hinge reinforcement plate is installed in the hinge mounting area of ​​the inner panel, and a metal door lock reinforcement plate is installed in the door lock mounting area of ​​the inner panel. The metal hinge reinforcement plate and the metal door lock reinforcement plate are installed on the inner panel by insert injection molding, riveting, or screwing. In this patent, the assembly of a metal hinge reinforcement plate in the hinge mounting area and a metal door lock reinforcement plate in the door lock mounting area (using insert injection molding, riveting, or screwing, etc.) are added to the inner panel to enhance the strength of the hinge and door lock areas of the hood.

[0010] Preferably, in the aforementioned improved composite material hood structure, reinforcing ribs are arranged on the inner panel. These reinforcing ribs enhance the overall rigidity of the inner panel.

[0011] Preferably, in the aforementioned improved composite material hood structure, the inner panel is one of PP+LGF30, PP+LGF40, SMC, or CFRTP continuous fiber reinforced thermoplastic composite materials. Here, the PP+LGF30 or PP+LGF40 inner panel is produced by injection molding, while the SMC or CFRTP inner panel is produced by compression molding. Furthermore, CFRTP can be continuous glass fiber or carbon fiber, exhibiting low density, high rigidity, and superior lightweighting.

[0012] Preferably, in the aforementioned improved composite material hood structure, the outer panel is one of PP+EPDM-TD20, PP+EPDM-TD25, PP+EPDM-TD30, or TPO thermoplastic elastomer. Here, the outer panel material is PP+EPDM-TD20, PP+EPDM-TD25, PP+EPDM-TD30, or TPO thermoplastic elastomer, etc. Through injection molding, the outer panel material has a low modulus, making it easily deformable upon pedestrian collision, reducing head injuries.

[0013] Preferably, in the above-mentioned improved structure of a composite material hood, the outer surface of the outer panel has a body color layer, which is formed by reaction injection and adsorption onto the outer surface of the outer panel through PUR polyurethane or PUA polyurea coating.

[0014] The outer surface treatment of the outer panel can be achieved by spraying paint on the exterior surface after injection molding to achieve the body color; alternatively, ColorForm can be used to integrally mold a thermoplastic matrix such as PP+EPDM-TD20, PP+EPDM-TD25, PP+EPDM-TD30 or thermoplastic elastomer TPO in the injection mold, and then directly inject a PUR polyurethane or PUA polyurea coating onto the matrix surface in the mold for reaction injection molding (RIM). This coating adheres to the outer surface of the outer panel, forming a colored outer panel part, thus eliminating the need for painting. This simplifies the secondary surface treatment (painting) process, reduces costs, and is more environmentally friendly. Furthermore, the elastomer PUR polyurethane or PUA polyurea coating on the product surface has strong self-healing capabilities, allowing it to recover instantly from minor collisions and scratches. If the coating is thick, it can also reduce head injuries to pedestrians after a collision.

[0015] Compared with the prior art, the advantages of this utility model are that it has a better lightweight effect and simpler process than metal stamping forming of the front hood; compared with the adhesive form of plastic front hood, the welding form replaces the adhesive process, which is simple, quick to produce, low product cost, and has a better lightweight effect. Adding an energy-absorbing foam interlayer between the inner and outer panels of the front hood can effectively reduce the injury to pedestrians after collision while achieving the lightweight effect. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall structure of the improved composite material hood.

[0017] Figure 2 This is a schematic diagram of the inner panel structure of the improved composite material front hood.

[0018] Figure 3 yes Figure 2 A schematic diagram of the AA-direction structure;

[0019] Figure 4This is a schematic diagram of the welded structure of the inner and outer panels. Detailed Implementation

[0020] The following are specific embodiments of the present invention, which are described in conjunction with the accompanying drawings. However, the present invention is not limited to these embodiments.

[0021] In the diagram, inner panel 100; outer panel 200; body color layer 300; welding rib 400; reinforcing rib 500; energy-absorbing foam interlayer 600; metal hinge reinforcing plate 700; metal door lock reinforcing plate 800.

[0022] like Figure 1 As shown, this improved composite material hood structure includes an inner panel 100 and an outer panel 200, both made of composite materials. The inner panel 100 is one of PP+LGF30, PP+LGF40, SMC, or CFRTP continuous fiber reinforced thermoplastic composite materials. The PP+LGF30 or PP+LGF40 inner panel 100 is manufactured using injection molding, while the SMC or CFRTP inner panel 100 is manufactured using compression molding. The CFRTP can be a continuous glass fiber reinforced composite material. Fiber or carbon fiber has low material density, good rigidity and strength, and better lightweight effect. The outer plate 200 is one of PP+EPDM-TD20, PP+EPDM-TD25, PP+EPDM-TD30 or TPO thermoplastic elastomer. The material of the outer plate 200 is PP+EPDM-TD20, PP+EPDM-TD25, PP+EPDM-TD30 or TPO thermoplastic elastomer, etc. Through the injection molding process, the outer plate 200 material has a low modulus, which makes it easy to deform when a pedestrian collides, reducing head injury.

[0023] As a preferred option, a body color layer 300 is applied to the outer surface of the outer panel 200. The body color layer 300 of the outer panel 200 is applied using a spray painting process, and the welding area needs to be masked during the spray painting process. Alternatively, the in-mold coloring process ColorForm, which is applied during the injection molding process, is also used as a more environmentally friendly, lower-cost, and simpler surface treatment solution to replace the spray painting process. Here, the body color layer 300 is applied to the outer surface of the outer panel 200 by reacting and injecting a PUR polyurethane or PUA polyurea coating. This coating adheres to the outer panel 200, forming a colored outer panel 200 part. The elastomer PUR polyurethane or PUA polyurea coating on the product surface has a strong self-healing ability, and minor collisions and scratches can be recovered instantly. If the coating is thicker, it can also reduce head injuries to pedestrians after a collision.

[0024] like Figure 2 as well as Figure 3As shown, in this patent, welding ribs 400 are arranged on the inner plate 100 or the outer plate 200. The inner plate 100 and the outer plate 200 are welded together by melting the welding ribs 400 and cooling and solidifying them. The welding ribs 400 are arranged around or in the middle area of ​​the inner plate 100 or the outer plate 200. Figure 4 As shown, the welding method is one of infrared welding, vibration friction welding, or laser welding. Both the inner panel 100 and the outer panel 200 in this patent are made of plastic composite materials. Welding is used instead of adhesive bonding to connect and fix the inner and outer panels 200, achieving not only cost reduction and weight reduction but also simplifying the process.

[0025] Here, the welding rib 400 is designed on the inner panel 100 or the outer panel 200. The welding rib 400 is formed integrally with the inner panel 100 or the outer panel 200 by multiple ribs (the number of welding ribs 400 can be 1, 2, 3 or more depending on the product performance requirements). The welding rib 400 and the welding area of ​​the outer panel 200 (or inner panel 100) of the other part are heated and melted through infrared welding (vibration friction welding or laser welding) and fused together to form the front hood welding assembly.

[0026] There are three welding methods:

[0027] Infrared welding: Infrared rays are used to heat the welding ribs 400 of the inner plate 100 (or outer plate 200) and the welding area of ​​the outer plate 200 or the inner plate 100, causing the surface temperature to rise and the material to melt. Pressure is then applied to the welding area to tightly bond the inner plate 100 and the outer plate 200 together. The molten material is then allowed to cool and solidify, welding the inner plate 100 and the outer plate 200 together. Vibration friction welding: The inner plate 100 and the outer plate 200 are pressed together by a tooling fixture. The two plates reciprocate at high frequency, generating frictional heat that melts the welding ribs 400. After cooling and solidification, the inner and outer plates 200 are welded together.

[0028] Laser welding: The inner plate 100 is a light-transmitting layer, and the outer plate 200 is a light-absorbing layer. Welding ribs 400 are designed on the inner plate 100 (or outer plate 200). First, the inner plate 100 and outer plate 200 are clamped together by pressure. The laser passes through the light-transmitting layer of the inner plate 100, and the energy is absorbed by the light-absorbing layer of the outer plate 200, causing it to heat up and melt. The welding ribs 400 expand due to high temperature and the energy is conducted to the light-transmitting part of the inner plate 100, where they fuse together. The laser heating stops, but the clamping force is maintained, and the molten zone cools and welds together. The advantages of using laser welding are fast production cycle, low energy consumption, and high dimensional accuracy.

[0029] The two plastic parts to be welded are a light-transmitting part (inner panel 100) and a light-absorbing part (outer panel 200). The light-transmitting part requires that the material has a certain transmittance to the laser, and the light-absorbing part requires that the material can absorb the laser. First, the light-transmitting part and the light-absorbing part are clamped together by pressure. Then, the short-wave infrared laser is directed to the area to be welded. The laser beam passes through the light-transmitting part and reaches the light-absorbing part. After being absorbed by the light-absorbing part, it is heated and melted. The high temperature expansion of the molten area of ​​the light-absorbing part is conducted to the light-transmitting part and they fuse together. The laser stops heating, and the clamping force is maintained. The molten area cools and welds together.

[0030] Alternatively, as a preferred embodiment, the inner panel 100 is provided with reinforcing ribs 500. These reinforcing ribs 500 enhance the overall rigidity of the inner panel 100. An energy-absorbing foam interlayer 600 is filled between the inner panel 100 and the outer panel 200. The energy-absorbing foam interlayer 600 is made of PUR polyurethane, EPP polypropylene, EPDM ethylene propylene rubber, or EVA ethylene-vinyl acetate copolymer. Before welding the inner panel 100 and the outer panel 200, the energy-absorbing foam interlayer 600 is fixed to the inner panel 100 or the outer panel 200 by adhesives and / or snap-fits. After welding, the energy-absorbing foam absorbs heat and absorbs moisture. The foam interlayer 600 is fixed between the inner panel 100 and the outer panel 200. This allows it to buffer and absorb energy when a pedestrian's head hits the outer panel 200 during a collision, reducing injury. A metal hinge reinforcement plate 700 is installed in the hinge mounting area of ​​the inner panel 100, and a metal door lock reinforcement plate 800 is installed in the door lock mounting area of ​​the inner panel 100. The metal hinge reinforcement plate 700 and the metal door lock reinforcement plate 800 are installed on the inner panel 100 by insert injection molding, riveting, or screwing. In this patent, the assembly of the metal hinge reinforcement plate 700 in the hinge mounting area and the assembly of the metal door lock reinforcement plate 800 in the door lock mounting area (using insert injection molding, riveting, or screwing, etc.) are added to the inner panel 100 to strengthen the hinge and door lock areas of the front hood.

[0031] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0032] The embodiments described above are merely examples of several implementations of this utility model, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the utility model patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, and these modifications and improvements all fall within the protection scope of this utility model.

Claims

1. An improved structure for a composite material front hood, comprising an inner panel and an outer panel, characterized in that, Both the inner and outer panels are made of composite materials. Welding ribs are arranged on the inner or outer panels. The inner and outer panels are welded together by melting the welding ribs and cooling and solidifying them.

2. The improved composite material hood structure as described in claim 1, characterized in that, The welding ribs are arranged around or in the middle area of ​​the inner or outer plate.

3. The improved composite material hood structure as described in claim 2, characterized in that, The welding method is one of infrared welding, vibration friction welding, or laser welding.

4. The improved composite material hood structure as described in claim 1, characterized in that, An energy-absorbing foam interlayer is filled between the inner and outer panels.

5. The improved composite material hood structure as described in claim 4, characterized in that, The energy-absorbing foam interlayer is made of PUR polyurethane, EPP polypropylene, EPDM ethylene propylene rubber, or EVA ethylene-vinyl acetate copolymer.

6. The improved composite material hood structure as described in claim 1, characterized in that, The inner panel has a metal hinge reinforcement plate installed in the hinge mounting area and a metal door lock reinforcement plate installed in the door lock mounting area. The metal hinge reinforcement plate and the metal door lock reinforcement plate are installed on the inner panel by insert injection molding, riveting or screwing.

7. The improved composite material hood structure as described in claim 1, characterized in that, The inner plate is provided with reinforcing ribs.

8. The improved composite material hood structure as described in claim 1, characterized in that, The inner panel is one of PP+LGF30, PP+LGF40, SMC or CFRTP continuous fiber reinforced thermoplastic composite materials.

9. The improved composite material hood structure as described in claim 1, characterized in that, The outer panel is one of PP+EPDM-TD20, PP+EPDM-TD25, PP+EPDM-TD30 or TPO thermoplastic elastomer.

10. The improved composite material hood structure as described in claim 1, characterized in that, The outer surface of the outer panel has a body color layer, which is formed by reaction injection and adsorption onto the outer surface of the outer panel through PUR polyurethane or PUA polyurea coating.

Images