Forming tool, vehicle body component and vehicle
By designing molds and core material components, the problems of composite material layer deformation and insert displacement were solved, achieving efficient molding and improved precision of vehicle body components.
Patent Information
- Application Number
- CN202520445940.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-03-14
- Publication Date
- 2026-01-16
- Estimated Expiration
- 2035-03-14
AI Technical Summary
During the molding process of vehicle body components, composite material layers are prone to deformation and inserts are prone to displacement, leading to molding defects.
The molding tooling includes a mold and a core material assembly. The mold is equipped with a molding cavity for laying the composite material layer. The core material assembly consists of at least two core material blocks and is equipped with auxiliary positioning holes. The core material blocks can be placed sequentially in the receiving cavity to reduce deformation and displacement.
It effectively reduces defects in the molded body components, improves operational convenience and molding accuracy, and reduces deformation and displacement of composite material layers and inserts.
Smart Images
Figure CN223803134U_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The application belongs to the technical field of vehicles, and particularly relates to a forming tool, a vehicle body component and a vehicle. BACKGROUND
[0002] Since composite materials (such as carbon fibers) have the characteristics of lightweight, high strength and high rigidity, in the related art, the inserts of composite materials (such as carbon fiber materials) and metals are formed into vehicle body components through co-curing to meet the requirement of lightweight of vehicles. Figure 1 As shown in the prior art, the inserts need to be fixed on an integrated core material first, and then the composite material layers are wound outside the integrated core material, and then the integrated core material with the wound composite material layers is transported into a mold, so that the composite material layers and the inserts are co-cured in the mold to form the vehicle body component.
[0003] However, when the integrated core material with the wound composite material layers is transported and placed in the mold, the composite material layers are prone to deformation due to their own gravity or other factors, and the inserts are prone to displacement, which leads to defects in the formed vehicle body component. CONTENT OF THE INVENTION
[0004] The purpose of the embodiments of the application is to provide a forming tool, a vehicle body component and a vehicle, which can solve the problem that in the related art, the composite material layers are prone to deformation and the inserts are prone to displacement in the forming process of the vehicle body component, which leads to defects in the vehicle body component.
[0005] In a first aspect, the embodiments of the application provide a forming tool, which comprises:
[0006] a mold, provided with a forming cavity, a cavity wall of the forming cavity being used for laying a composite material layer, so that the composite material layer surrounds a containing cavity;
[0007] a core material assembly, comprising at least two core material blocks, and at least one of the core material blocks is provided with an auxiliary positioning hole used for positioning an insert;
[0008] In the case that the composite material layer is laid on the cavity wall of the forming cavity and surrounds the containing cavity, each of the core material blocks can be placed in the containing cavity in sequence, so that the composite material layer and the insert can be formed into a vehicle body component.
[0009] In the embodiment of the present application, the composite material layer can be laid on the cavity wall of the forming cavity in the process without being wound on the core assembly in advance, so that the deformation of the composite material layer in the transfer process can be eliminated. In addition, since the core assembly includes at least two core blocks, the core block provided with the auxiliary positioning hole and in contact with the side wall of the accommodating cavity can be placed first, and then the core block without the auxiliary positioning hole or other core blocks can be placed, so that the displacement of the insert caused by the transfer and placement of the core assembly can be reduced, and the extrusion of the composite material layer in the insertion direction of the core assembly during the placement can be reduced, so that the deformation of the composite material layer in the insertion direction of the core assembly can be reduced, and the defects of the formed vehicle body component can be effectively reduced.
[0010] Optionally, the mold includes a first mold and a second mold, the first mold is provided with a forming groove, and the second mold is detachably connected with the first mold to form the forming cavity with the forming groove and the second mold.
[0011] The groove wall of the forming groove is used for laying the part of the composite material layer, so that the part of the composite material layer surrounds the accommodating groove.
[0012] Each of the core blocks can be distributed in the accommodating groove along a first direction, and the second mold is used for being in contact with the remaining part of the composite material layer, and the first direction is perpendicular to the direction from the second mold to the first mold.
[0013] In this way, the composite material layer can be laid on the cavity wall of the forming cavity, and the core blocks can be placed in the accommodating groove formed by the composite material layer. In addition, since each of the core blocks can be distributed in the accommodating groove along the first direction, the operator has a wider operation space, the operator can easily put the core blocks into the accommodating groove from the groove opening of the accommodating groove, the operation process is more intuitive, the position of the core blocks can be easily observed and adjusted, and in addition, compared with the mode that each of the core blocks is distributed along the direction from the second mold to the first mold, the deformation of the composite material layer in the direction from the second mold to the first mold and the displacement of the insert in the direction from the second mold to the first mold are less likely to occur during the placement of the core blocks, so that the deformation of the composite material layer and the displacement of the insert can be reduced.
[0014] Optionally, the side of the core block adjacent to the first groove wall of the forming groove and away from the first groove wall is provided with an inclined surface, the first groove wall is adjacent to the groove opening of the forming groove, and the inclined surface extends along the direction from the second mold to the first mold and is inclined to the direction away from the first groove wall.
[0015] In this way, the space left at the slot opening after placing the core material block adjacent to the first slot wall of the forming groove is large enough to facilitate the insertion of other core material blocks into the accommodating groove, and the inclined surface can guide the insertion of other core material blocks, thereby further facilitating the insertion of other core material blocks into the accommodating groove, and improving the operation convenience, and the tolerance between the core material blocks can be reduced.
[0016] Optionally, the at least two core material blocks comprise a first core material block, a second core material block and a third core material block which are sequentially butted in the first direction, the sides of the first core material block and the third core material block away from each other are used to fit with two slot walls of the accommodating groove in the first direction, and the side of the first core material block close to the second core material block and the side of the third core material block close to the second core material block are provided with the inclined surface, and the width of the second core material block in the first direction gradually decreases in the direction from the second mold to the first mold.
[0017] In this way, the core material assembly can adapt to the form of the vehicle body member provided with inserts on one side or both sides, and for the form provided with inserts on both sides, the core material blocks on both sides (i.e. the first core material block and the third core material block) can be placed first, and the core material block in the middle (i.e. the second core material block) can be placed later, so that the inserts can be placed in the mold without being unable to be placed during the process, and the number of core material blocks can be minimized to reduce the forming error.
[0018] Optionally, the two sides of the core material block in the direction from the second mold to the first mold are respectively provided with a first supporting surface and a second supporting surface, the first supporting surface is used to contact the composite material layer at the slot opening of the forming groove, and the second supporting surface is used to contact the composite material layer at the slot bottom of the forming groove.
[0019] In this way, the cross section of the core material block can be trapezoidal or similar to the trapezoidal structure, thereby improving the bending strength of the core material block, so that the core material block is not easy to be broken under force.
[0020] Optionally, the butting surface of at least one of the two adjacent core material blocks is provided with a smooth coating.
[0021] In this way, the surface roughness of the butting surface can be significantly reduced, and the butting surface of the core material block is smoother and more flat, so that only a small force needs to be applied when inserting the core material block, and the core material block can be smoothly inserted into the predetermined position, thereby greatly reducing the difficulty of the insertion operation.
[0022] Optionally, a fixing portion is arranged on the cavity wall of the forming cavity, and the fixing portion is used to fix the insert.
[0023] In this way, the stability of the embedded part can be further improved, and displacement of the embedded part can be further prevented.
[0024] In a second aspect, the embodiments of the present application further provide a vehicle body component, which comprises a component main body formed by a composite material layer and an embedded part through the forming tool described above.
[0025] The vehicle body component provided in the embodiments of the present application has the same beneficial effects as the forming tool described above, and thus will not be described here again.
[0026] Optionally, the vehicle body component further comprises a reinforcing part inside the component main body, wherein the reinforcing part comprises a core material assembly of the forming tool, and the core material assembly is connected with the component main body in an integrated structure.
[0027] In this way, the strength of the vehicle body component can be improved.
[0028] In a third aspect, the embodiments of the present application further provide a vehicle, which comprises a chassis and the vehicle body component described above, and the vehicle body component is connected with the chassis.
[0029] The vehicle provided in the embodiments of the present application has the same beneficial effects as the vehicle body component described above, and thus will not be described here again. BRIEF DESCRIPTION OF DRAWINGS
[0030] Figure 1 is a forming process flow chart of a vehicle body component disclosed in the related art;
[0031] Figure 2 is one of the schematic diagrams of the forming tool, the composite material layer and the embedded part in a cross-sectional view according to the embodiments of the present application;
[0032] Figure 3 is another schematic diagram of the forming tool, the composite material layer and the embedded part in a cross-sectional view according to the embodiments of the present application;
[0033] Figure 4 is a cross-sectional view of a mold according to the embodiments of the present application;
[0034] Figure 5 is a schematic diagram of the composite material layer laid on the cavity wall of the forming cavity of the mold in a cross-sectional view according to the embodiments of the present application;
[0035] Figure 6 is a perspective view of a core material assembly according to the embodiments of the present application;
[0036] Figure 7 is a connection relationship diagram of the first core material block and the embedded part according to the embodiments of the present application;
[0037] Figure 8is a perspective view of a second core material block disclosed by embodiments of the present application;
[0038] Figure 9 is a perspective view of a third core material block disclosed by embodiments of the present application;
[0039] Figure 10 is a process flow diagram of a forming process of a vehicle body component disclosed by embodiments of the present application;
[0040] Figure 11 is a front view of a rocker beam disclosed by embodiments of the present application;
[0041] Figure 12 is Figure 11 a sectional view of A-A direction in
[0042] Figure 13 is Figure 11 a sectional view of A-A reverse direction in
[0043] Figure 14 is Figure 11 a sectional view of B-B direction in
[0044] Figure 15 is a perspective view of a rocker beam disclosed by embodiments of the present application.
[0045] Legend of reference signs:
[0046] 100 - mold; 110 - first mold; 111 - first mold block; 112 - second mold block;
[0047] 120 - second mold; 130 - forming cavity; 131 - forming groove; 200 - composite material layer;
[0048] 210 - containing cavity; 211 - containing groove; 300 - core material assembly; 301 - auxiliary positioning hole;
[0049] 302 - inclined surface; 303 - first support surface; 304 - second support surface; 310 - core material block;
[0050] 311 - first core material block; 312 - second core material block; 313 - third core material block; 400 - insert;
[0051] 500 - vacuum bag; 600 - rocker beam; 610 - first part; 620 - second part;
[0052] 630 - third part; 601 - process hole; 700 - integrated core material; 101 - mold block. DETAILED DESCRIPTION
[0053] With reference to the drawings of the embodiments of the present application, the technical solutions in the embodiments of the present application will be clearly described. Obviously, the described embodiments are only some of the embodiments of the present application, but not all of the embodiments of the present application. Based on the embodiments of the present application, all other embodiments obtained by those of ordinary skill in the art are within the scope of the present application.
[0054] The terms "first", "second", and the like in the specification and claims of the present application are used to distinguish similar objects, and are not used to describe a specific order or sequence. It should be understood that the data used in this way can be exchanged under appropriate circumstances, so that the embodiments of the present application can be implemented in an order other than those illustrated or described herein, and the objects distinguished by "first", "second", etc. are generally a class, and are not limited to the number of objects, for example, the first object can be one or more. In addition, "and / or" in the specification and claims indicates at least one of the connected objects, and the character " / ", generally indicates that the front and rear associated objects are in an "or" relationship.
[0055] The forming tool, the vehicle body component and the vehicle provided by the embodiments of the present application will be described in detail below with reference to the drawings, through specific embodiments and application scenarios.
[0056] Reference Figures 2-10 The forming tool provided by the embodiments of the present application can include a mold 100 and a core material assembly 300.
[0057] The mold 100 can be provided with a forming cavity 130, and the cavity wall of the forming cavity 130 can be used to lay the composite material layer 200, so that the composite material layer 200 surrounds the accommodation cavity 210.
[0058] The core material assembly 300 can include at least two core material blocks 310, and at least one core material block 310 can be provided with an auxiliary positioning hole 301 for positioning the insert 400.
[0059] In the case that the composite material layer 200 is laid on the cavity wall of the forming cavity 130 and forms the containing cavity 210, the core material blocks 310 can be placed in the containing cavity 210 in sequence, so that the composite material layer 200 and the insert 400 can be formed into the vehicle body component. That is, in the process, the composite material layer 200 can be laid on the cavity wall of the forming cavity 130 first, without the need to wrap the composite material layer 200 on the core material assembly 300, thereby eliminating the deformation of the composite material layer 200 in the transfer process. In addition, since the core material assembly 300 includes at least two core material blocks 310, the core material block 310 provided with the auxiliary positioning hole 301 which is in contact with the side wall of the containing cavity 210 can be placed first, and then the core material block 310 without the auxiliary positioning hole 301 or other core material blocks 310 can be placed, thereby reducing the displacement of the insert 400 caused by the transfer and placement of the core material assembly 300, and reducing the extrusion of the composite material layer 200 in the insertion direction of the core material assembly 300 when placed, thereby reducing the deformation of the composite material layer 200 in the insertion direction of the core material assembly 300, so as to effectively reduce the defects of the formed vehicle body component.
[0060] In an optional embodiment of the present application, as shown in Figure 10 The mold 100 can include a first mold 110 and a second mold 120, the first mold 110 can be provided with a forming groove 131, and the second mold 120 is detachably connected with the first mold 110, so that the forming groove 131 and the second mold 120 form the forming cavity 130. In this way, the groove wall of the forming groove 131 can be used to lay part of the composite material layer 200, so that part of the composite material layer 200 forms the containing groove 211. In this way, the composite material layer 200 can be laid on the cavity wall of the forming cavity 130, and the core material block 310 can be placed in the containing groove 211 formed by the composite material layer 200. In addition, the second mold 120 is used to contact the remaining part of the composite material layer 200, so as to seal the composite material layer 200 in the forming cavity 130.
[0061] The core material blocks 310 can be distributed in the accommodating grooves 211 along a first direction, where the first direction is perpendicular to the direction of the second mold 120 to the first mold 110. In this way, the operator can have a more open operation space, and the operator can easily put the core material blocks 310 into the accommodating grooves 211 one by one from the groove opening of the accommodating grooves 211. The operation process is more intuitive, and the position of the core material blocks 310 can be easily observed and adjusted. In addition, compared with the mode in which the core material blocks 310 are distributed along the direction of the second mold 120 to the first mold 110, the deformation of the composite material layer 200 in the direction of the second mold 120 to the first mold 110 and the displacement of the insert 400 in the direction of the second mold 120 to the first mold 110 are less likely to occur during the placement of the core material blocks 310, thereby reducing the deformation of the composite material layer 200 and the displacement of the insert 400.
[0062] In other embodiments, the core material blocks 310 can be distributed in the accommodating grooves 211 along the direction of the second mold 120 to the first mold 110.
[0063] In this embodiment, the first mold 110 can be of an integrated structure. In this way, the mold 100 can be divided into multiple modules, thereby simplifying the structure of the mold 100 and facilitating the reduction of errors generated during the docking process of the modules of the mold 100 and the reduction of gaps between the modules, thereby facilitating the improvement of the molding effect of the mold 100 on the vehicle body component.
[0064] Of course, the first mold 110 can also include a first mold block 111 and a second mold block 112, and the first mold block 111 and the second mold block 112 can be connected to form the molding groove 131. In this way, the mold 100 can be easily demolded after the process is completed.
[0065] In an optional embodiment, the side of the core material block 310 adjacent to the first groove wall of the molding groove 131 and facing away from the first groove wall can be provided with an inclined surface 302. The first groove wall is adjacent to the groove opening of the molding groove 131, and the inclined surface 302 extends along the direction of the second mold 120 to the first mold 110 and is inclined to the direction away from the first groove wall. In this embodiment, by providing the inclined surface 302 on the core material block 310 adjacent to the first groove wall of the molding groove 131, it can be ensured that the space remaining at the groove opening after the core material block 310 adjacent to the first groove wall of the molding groove 131 is placed is large enough to facilitate the insertion of other core material blocks 310 into the accommodating grooves 211. At the same time, the inclined surface 302 can also guide the insertion of other core material blocks 310, to further facilitate the insertion of other core material blocks 310 into the accommodating grooves 211, thereby improving the operation convenience, and also reducing the tolerance between the core material blocks 310.
[0066] It should be noted that the first groove wall of the forming groove 131 can be the groove wall of the forming groove 131 in the first direction.
[0067] In other embodiments, the inclined surface 302 can also not be arranged on the core material block 310 adjacent to the first groove wall of the forming groove 131.
[0068] Optionally, the core material block 310 can be an elastic structure, for example, the core material block 310 can be made of foam. In this way, when the actual size of the composite material layer 200 is greater than the theoretical size, a certain acting force can be applied to each core material block 310 to cause a certain deformation of the core material block 310, thereby facilitating the placement of the core material block 310 in the accommodating cavity 210 surrounded by the composite material layer 200.
[0069] It should be noted that the actual size of the core material assembly 300 can be smaller than the theoretical size of the accommodating cavity 210 surrounded by the composite material layer 200, so as to ensure that the core material assembly 300 can be placed in the accommodating cavity 210. When the theoretical thickness of the composite material layer 200 is 10 mm, the tolerance compensation amount of the core material assembly 300 can be set to 2 mm, that is, the size of the core material assembly 300 can be 2 mm smaller than the theoretical size of the accommodating cavity 210 surrounded by the composite material layer 200. When the theoretical thickness of the composite material layer 200 is 5 mm, the tolerance compensation amount of the core material assembly 300 can be set to 1 mm, that is, the size of the core material assembly 300 can be 1 mm smaller than the theoretical size of the accommodating cavity 210 surrounded by the composite material layer 200.
[0070] In optional embodiments, as shown in Figure 2 At least two core material blocks 310 can include a first core material block 311, a second core material block 312 and a third core material block 313 which are sequentially butted in the first direction, and the sides of the first core material block 311 and the third core material block 313 which are away from each other are respectively used to be fitted with two groove walls of the accommodating groove 211 in the first direction. In this way, the core material assembly 300 can be adapted to the form of the vehicle body member which has an insert 400 arranged on only one side or has an insert 400 arranged on both sides, and for the form of the vehicle body member which has an insert 400 arranged on both sides, the core material blocks 310 on both sides (i.e. the first core material block 311 and the third core material block 313) can be placed first, and the core material block 310 in the middle (i.e. the second core material block 312) can be placed later, so as to ensure that the insert 400 can be placed in the mold 100 without being unable to be placed during the process, and at the same time, the number of core material blocks 310 can be minimized to reduce the forming error.
[0071] Of course, in other embodiments, the at least two core material blocks 310 can only include the first core material block 311 and the third core material block 313.
[0072] And, the side of the first core material block 311 close to the second core material block 312 and the side of the third core material block 313 close to the second core material block 312 are both provided with inclined surfaces 302, so that the inclined surfaces 302 can play a guiding role for the second core material block 312 when the core material blocks 310 are placed in the accommodating grooves 211, the inclined surfaces 302 can prevent hard collision and jamming between the core material blocks 310, make the three core material blocks 310 more easily butt against each other, and the operator can more easily place the core material blocks 310 in order, reduce the resistance and difficulty in the placement process. Of course, the side of the first core material block 311 close to the second core material block 312 and the side of the third core material block 313 close to the second core material block 312 can also not be provided with inclined surfaces 302.
[0073] In the direction from the second mold 120 to the first mold 110, the width of the second core material block 312 in the first direction gradually decreases. In this way, on the one hand, the second core material block 312 can adapt to the shape of the first core material block 311 and the third core material block 313, and on the other hand, it is more convenient for the second core material block 312 to be inserted into the accommodating groove 211. Of course, in the direction from the second mold 120 to the first mold 110, the width of the second core material block 312 in the first direction can also remain unchanged.
[0074] In optional embodiments, the two sides of the core material block 310 in the direction from the second mold 120 to the first mold 110 are respectively provided with a first supporting surface 303 and a second supporting surface 304, the first supporting surface 303 is used to be in surface contact with the composite material layer 200 at the slot opening of the forming groove 131, and the second supporting surface 304 is used to be in surface contact with the composite material layer 200 at the groove bottom of the forming groove 131. In this way, the cross section of the core material block 310 can be trapezoidal or similar to a trapezoidal structure, thereby improving the bending strength of the core material block 310, so that the core material block 310 is not easy to be broken under force.
[0075] In other embodiments, one side of the core material block 310 in the direction from the second mold 120 to the first mold 110 can be provided with a supporting surface, and the other side can not be provided with a supporting surface, for example, one side of the core material block 310 in the direction from the second mold 120 to the first mold 110 is in line contact with the composite material layer 200 at the slot opening of the forming groove 131, and the other side of the core material block 310 in the direction from the second mold 120 to the first mold 110 is in surface contact with the composite material layer 200 at the groove bottom of the forming groove 131.
[0076] Optionally, the abutting surface of at least one of the two adjacent core material blocks 310 is provided with a smooth coating. The smooth coating in this embodiment can significantly reduce the surface roughness of the abutting surface, making the abutting surface of the core material block 310 smoother and more even, which means that only a small force needs to be applied when inserting the core material block 310, so that the core material block 310 can be smoothly inserted into the predetermined position, greatly reducing the difficulty of the insertion operation. Here, the smooth coating can be a polytetrafluoroethylene coating or a polyurethane coating, or other coatings.
[0077] In this embodiment, the abutting surface of each of the two adjacent core material blocks 310 can be provided with a smooth coating.
[0078] Of course, the abutting surface of each of the two adjacent core material blocks 310 can also not be provided with a smooth coating.
[0079] In an optional embodiment of the present application, the cavity wall of the forming cavity 130 can be provided with a fixing portion, which can be used to fix the insert 400. In this way, the stability of the fixing of the insert 400 can be further improved to further prevent displacement of the insert 400. Here, the fixing portion can be a protrusion on the cavity wall of the forming cavity 130.
[0080] During the process, after laying the composite material layer 200, the insert 400 can be placed in the forming groove 131, so that the insert 400 is fixed on the fixing portion, and then the core material block 310 provided with the auxiliary positioning hole 301 is placed in the receiving groove 211, and part of the insert 400 extends into the auxiliary positioning hole 301. In this way, the fixing portion and the auxiliary positioning hole 301 can double-fix the insert 400, which can further prevent displacement of the insert 400 during the forming process.
[0081] In other embodiments, the cavity wall of the forming cavity 130 can also not be provided with a fixing portion.
[0082] In an embodiment of the present application, the forming process of the vehicle body component is as follows:
[0083] As Figure 10As shown, the mold 100 is prepared, and first, a part of the composite material layer 200 is laid on the groove wall of the forming groove 131 of the first mold 110, so that the composite material layer 200 encloses the accommodating groove 211, then the insert 400 is placed, the first core material block 311 and the third core material block 313 are placed in the accommodating groove 211, and a part of the insert 400 extends into the auxiliary positioning hole 301 of the first core material block 311 and / or the third core material block 313, then the second core material block 312 is placed in the accommodating groove 211, and then the part of the composite material layer 200 outside the forming groove 131 is bent to the groove opening of the forming groove 131 and covers the core material blocks 310, then the second mold 120 is covered on the first mold 110 to realize the clamping of the mold 100; finally, the composite material layer 200 and the insert 400 are formed into a vehicle body component by means of hot pressing. In this embodiment, the part of the composite material layer 200 outside the forming groove 131 can include a first bendable part and a second bendable part, the first bendable part and the second bendable part are respectively located on both sides of the groove opening of the forming groove 131 in the first direction, and the first bendable part and the second bendable part can be bent to the groove opening of the forming groove 131, and at least part of the first bendable part and at least part of the second bendable part can overlap after being bent to ensure the sealing of the formed vehicle body component. In addition, the edge of the first bendable part and / or the edge of the second bendable part can be in contact with the first supporting surface 303 of the core material block 310, that is, after the first bendable part is bent, the edge of the first bendable part will not be bent to the joint between the first mold 110 and the second mold 120, and / or after the second bendable part is bent, the edge of the second bendable part will not be bent to the joint between the first mold 110 and the second mold 120, thereby improving the forming quality of the vehicle body component.
[0084] Here, the clamped mold 100 as a whole can be placed in a hot pressing tank, and the composite material layer 200 and the insert 400 are formed into a vehicle body component in the high-temperature and high-pressure environment of the hot pressing tank. Of course, the clamped mold 100 can also be placed on a hydraulic forming table, and after a certain time of high temperature and high pressure, the composite material layer 200 and the insert 400 in the mold 100 are co-cured to form a vehicle body component.
[0085] Optionally, in the case of molding the composite material layers 200 and the insert 400 by means of a heat pressing tank, the molding tooling can further include a vacuum bag 500, which can be laid on the groove wall of the accommodating groove 211 to wrap the composite material layers 200. During the process, the air in the vacuum bag 500 can be pumped out by a vacuum pump. After the vacuum bag 500 is vacuumized, a uniform pressure is formed on the surface of the composite material layers 200, which assists the pressure in the heat pressing tank to make the composite material layers 200 more closely adhere to each other, facilitates the resin to better infiltrate the composite material layers 200, improves the bonding force between the composite material layers 200, makes the structure of the molded vehicle body component more compact, and makes the mechanical properties more optimal.
[0086] Before the first core material block 311 and the third core material block 313 are placed in the accommodating groove 211, the molding process implementation solution of the vehicle body component can further include laying the vacuum bag 500 on the groove wall of the accommodating groove 211 to wrap the composite material layers 200.
[0087] It should be noted that the composite material layers 200 can include carbon fiber layers impregnated with resin, and the composite material layers 200 can be adhered to the groove wall of the molding groove 131 by means of resin, so that the composite material layers 200 are less likely to be deformed by the action of their own gravity and are less likely to be deformed by the subsequent processes. Optionally, in order to further prevent the composite material layers 200 from being deformed, the composite material layers 200 can be adhered to the groove wall of the molding groove 131 by means of an adhesive.
[0088] Further optionally, in order to facilitate the demolding of the molded vehicle body component, the cavity wall of the molding cavity 130 can be coated with a demolding agent.
[0089] In the optional embodiment, before the composite material layers 200 are laid on the groove wall of the molding groove 131 of the first mold 110, an insert mounting hole corresponding to the insert 400 can be cut on the composite material layers 200, so as to facilitate the composite material layers 200 and the insert 400 to be co-cured as one body.
[0090] In an optional embodiment, the composite material layer 200 can include multiple layers of carbon fiber layers, wherein the laying directions of some of the carbon fiber layers can intersect, which can make the composite material layer 200 have good strength and stiffness in multiple directions. For example, the carbon fiber layers laid in 0° and 90° directions can respectively provide greater load-carrying capacity in the longitudinal and transverse directions, so that the formed body member can effectively resist deformation and damage under complex stress conditions (such as simultaneously subjected to tensile, compressive and shear forces). In addition, the intersecting laying of multiple layers of carbon fiber layers can disperse and transfer the fatigue stress between the carbon fiber layers in different directions, which can prevent stress concentration on the carbon fiber layers in a single direction, thereby improving the structural reliability and safety of the body member. At the same time, during the forming of the composite material layer 200, the intersecting laying of the carbon fiber layers is beneficial to the uniform infiltration of the resin, and the pores and channels formed between the carbon fiber layers in different directions provide more paths for the flow of the resin, so that the resin can more fully fill the gaps between the carbon fiber layers, improve the bonding quality of the carbon fiber layers and the resin, reduce the generation of pores and defects, and thus be beneficial to improving the overall performance of the composite material layer 200.
[0091] Here, when the number of layers of the carbon fiber layers is large, some of the carbon fiber layers can be first pre-formed into a first composite material layer, and then multiple first composite material layers are sequentially laid on the cavity wall of the forming cavity 130.
[0092] In the embodiments of the present application, the composite material layer 200 is laid up with the groove wall of the forming groove 131 of the mold 100 as a reference, which can effectively reduce the deformation of the composite material layer 200 in the transfer process and the clamping process. The core assembly 300 is divided into three core blocks 310 (first core block 311, second core block 312 and third core block 313), and the core blocks 310 are provided with auxiliary positioning holes 301 for positioning the inserts 400. When the core assembly 300 is placed, the first core block 311 and the third core block 313 on both sides are placed first, so that the first core block 311 and the third core block 313 are respectively left with a gap for accommodating the inserts 400 between the groove wall of the accommodating groove 211, so as to facilitate the relative positioning of the inserts 400 and the auxiliary positioning holes 301. Then, the first core block 311 and the third core block 313 are respectively moved to both sides, so that part of the inserts 400 extends into the auxiliary positioning holes 301. The second core block 312 is then placed. When the second core block 312 is placed, the first core block 311 and the third core block 313 will only move to both sides and will not move to the insertion direction of the core block 310 due to the limiting action of the groove bottom of the accommodating groove 211 and the guiding action of the inclined surface 302 on the first core block 311 and the third core block 313. Therefore, the first core block 311 and the third core block 313 will only move the inserts 400 to both sides and are not easy to move the inserts 400 to the insertion direction of the core block 310. In this way, the displacement of the inserts 400 can be effectively reduced during the forming process, thereby improving the forming precision.
[0093] In the related art, for example, Figure 1As shown, the vacuum bag 500 needs to be wrapped on the integrated core material 700 first, then the insert 400 is fixed on the integrated core material 700, then the composite material layer 200 is wound (i.e. laid up) on the integrated core material 700 wrapped with the vacuum bag 500, then the integrated core material 700 wound with the composite material layer 200 is placed in the mold 100, and the mold 100 is closed. However, due to the large size of the vehicle body component (the size of the vehicle body component can be 2000mm*500mm*1200mm), the laying operation of the composite material layer 200 is poor in the process, and the insert 400 is not easy to position, and the mold 100 is divided into more blocks due to the structure of the vehicle body component. The integrated core material 700 is a collapsible foam structure to support the composite material layer 200, but during the transfer of the core material wound with the composite material layer 200, the composite material layer 200 is easily deformed and the insert 400 is displaced, and during the process of placing the integrated core material 700 wound with the composite material layer 200 into the mold 100, the actual size of the composite material layer 200 is easily affected, which causes the mold to be difficult to close, and the mold is completely closed by relying on external force to complete the closing, which further causes the composite material layer 200 to be deformed or the insert 400 to be displaced, thereby causing the vehicle body component to be formed to have defects and affecting the performance of the vehicle body component.
[0094] In the embodiment of the present application, the mold 100 can only include two parts, i.e. the first mold 110 and the second mold 120, and the mold 100 does not need to be provided as a plurality of mold blocks 101, which on the one hand is conducive to reducing the cost of the mold 100, and on the other hand is conducive to improving the sealing performance of the mold 100 in the forming process.
[0095] In the related art, the mold 100 must include at least three parts to ensure that the integrated core material 700 wound with the composite material layer 200 can be placed in the forming cavity 130 of the mold 100.
[0096] Based on the forming tool provided in the embodiment of the present application, as shown, Figures 11-15 As shown, the vehicle body component provided in the embodiment of the present application comprises a component body, and the component body is formed by the composite material layer 200 and the insert 400 through the forming tool of any one of the above embodiments.
[0097] The beneficial effects achieved by the vehicle body component provided in the embodiment of the present application are consistent with the beneficial effects achieved by the forming tool provided in the embodiment of the present application, which will not be repeated here.
[0098] In an optional embodiment of the present application, the vehicle body component further comprises a reinforcing member inside the component body, the reinforcing member comprising a core assembly 300 of the forming tool, the core assembly 300 being connected to the component body in an integral structure. The reinforcing member in this embodiment can improve the strength of the vehicle body component.
[0099] In other embodiments, the core assembly 300 can also not be connected to the component body, for example, the core assembly 300 can only be a part of the forming tool, and during the process, the core assembly 300 can shrink under the action of high temperature, and its volume can be reduced, and after the process is completed, the core assembly 300 can be pulled out from the component body through the process hole 601 on the component body.
[0100] It should be noted that a plurality of process holes 601 can be provided on the component body.
[0101] Optionally, the vehicle body component can be a rocker beam 600, and the rocker beam 600 can be a closed cavity structure. Of course, the vehicle body component can be a spoiler or a frame, or other structures.
[0102] The rocker beam 600 can be divided into three parts, namely a first part 610, a second part 620 and a third part 630 connected in sequence, the first part 610 is used to connect with the front longitudinal beam of the vehicle, the third part 630 is used to connect with the rear longitudinal beam of the vehicle, the process hole 601 can be provided on the first part 610, the second part 620 and the third part 630, and the core assembly 300 can be divided into three sections and placed in the accommodating cavity 210 of the composite material layer 200, wherein each section of the core assembly 300 comprises a first core block 311, a second core block 312 and a third core block 313. In this way, the core assembly 300 can be easily pulled out after forming.
[0103] Based on the vehicle body component provided in the embodiments of the present application, the embodiments of the present application further provide a vehicle, which comprises a chassis and the vehicle body component according to any one of the above embodiments, and the vehicle body component is connected to the chassis.
[0104] The vehicle provided in the embodiments of the present application achieves the same beneficial effects as the vehicle body component provided in the embodiments of the present application, and thus will not be described here.
[0105] The embodiments of the present application are described above in combination with the drawings, but the present application is not limited to the above specific embodiments, and the above specific embodiments are only illustrative but not restrictive, and those skilled in the art can make many forms under the inspiration of the present application without departing from the scope of the present application and the scope protected by the claims.
Claims
1. A forming tool, characterized by The application relates to a mold (100) provided with a forming cavity (130), a cavity wall of the forming cavity (130) is used for laying a composite material layer (200) so that the composite material layer (200) encloses a containing cavity (210); a core material assembly (300) comprises at least two core material blocks (310), and at least one of the core material blocks (310) is provided with an auxiliary positioning hole (301) used for positioning an insert (400); wherein, when the composite material layer (200) is laid on the cavity wall of the forming cavity (130) and encloses the containing cavity (210), each of the core material blocks (310) can be sequentially placed in the containing cavity (210) so that the composite material layer (200) and the insert (400) can be formed into a vehicle body component. The mold (100) comprises a first mold (110) provided with a forming groove (131) and a second mold (120) detachably connected with the first mold (110) so that the forming groove (131) and the second mold (120) form the forming cavity (130); a groove wall of the forming groove (131) is used for laying part of the composite material layer (200) so that the part of the composite material layer (200) encloses a containing groove (211); each of the core material blocks (310) can be distributed in the containing groove (211) along a first direction, and the second mold (120) is used for contacting the remaining part of the composite material layer (200), the first direction is perpendicular to the direction of the second mold (120) to the first mold (110). The side, away from the first groove wall, of the core material block (310) adjacent to the first groove wall of the forming groove (131) is provided with an inclined surface (302), the first groove wall is adjacent to a groove opening of the forming groove (131), the inclined surface (302) extends along the direction of the second mold (120) to the first mold (110) and is obliquely arranged away from the first groove wall. The at least two core material blocks (310) comprise a first core material block (311), a second core material block (312) and a third core material block (313) sequentially butted along the first direction, the side, away from each other, of the first core material block (311) and the third core material block (313) is used for abutting with two groove walls of the containing groove (211) in the first direction, and the side, close to the second core material block (312), of the first core material block (311) and the side, close to the second core material block (312), of the third core material block (313) are both provided with the inclined surface (302), and the width of the second core material block (312) in the first direction gradually decreases along the direction of the second mold (120) to the first mold (110).
2. The forming tool of claim 1, wherein 3. The forming tool of claim 2, wherein 4. The forming tool of claim 3, wherein 5. The forming tool of claim 2, wherein The core material block (310) is provided with a first supporting surface (303) and a second supporting surface (304) on both sides in the direction from the second mold (120) to the first mold (110), the first supporting surface (303) is used for surface contact with the composite material layer (200) located at the slot opening of the forming groove (131), and the second supporting surface (304) is used for surface contact with the composite material layer (200) located at the slot bottom of the forming groove (131).
6. The forming tool of claim 1 wherein, The abutting surface of at least one of the two adjacent core material blocks (310) is provided with a smooth coating.
7. The forming tool of claim 1 wherein, A fixing part is arranged on the cavity wall of the forming cavity (130), and the fixing part is used for fixing the insert (400).
8. A vehicle body member characterized by The vehicle body component comprises a component main body, and the component main body is formed by the composite material layer (200) and the insert (400) through the forming tooling according to any one of claims 1-7.
9. The vehicle body component of Claim 8, wherein, The vehicle body component further comprises a reinforcing part located inside the component main body, and the reinforcing part comprises the core material assembly (300) of the forming tooling, and the core material assembly (300) is connected with the component main body as an integral structure.
10. A vehicle characterized by comprising: The vehicle comprises a chassis and the vehicle body component according to claim 8 or 9, and the vehicle body component is connected with the chassis.