Lightweight high-strength steel-aluminum mixed motor home body

Abstract

The utility model discloses a light-weight high-strength steel-aluminum mixed motor home body, and relates to the technical field of motor home manufacturing. Comprising a vehicle body frame assembly, a frame connecting piece assembly, an outer plate assembly and an inner plate assembly, the vehicle body frame assembly is connected and fixed through the frame connecting piece assembly, and the outer plate assembly, the inner plate assembly and the vehicle body frame assembly are connected through direct welding; the automobile body frame assembly and the outer plate assembly are made of aluminum alloy materials, and the inner plate assembly is made of steel materials for automobiles. The motor home body is of an all-metal vehicle body structure, the technical blank that the existing small and medium-sized motor home field is lack of a pure-metal vehicle body structure is broken through, and the motor home body has remarkable market application value and development potential. Through the steel and aluminum mixed design, the double technical advantages are achieved, the structural strength of the vehicle body is remarkably improved, and the lightweight breakthrough that the weight is reduced by 20% or above compared with a conventional metal vehicle body is achieved.

Description

Technical Field

[0001] This utility model relates to the field of RV manufacturing technology, specifically to a lightweight, high-strength steel-aluminum hybrid RV body. Background Technology

[0002] As a mobile living and travel tool, the strength and durability of the caravan's body structure directly affect its safety and user experience. Currently, the main materials used for caravan bodies are traditional wood structures and new fiberglass structures, but both have significant technical defects, becoming key issues restricting the improvement of caravan performance.

[0003] Traditional travel trailers typically use wooden structures as the mainstream option. While this structure can meet the basic needs of daily vacations, its technological limitations are becoming increasingly apparent. First, wooden structures have relatively low strength and are prone to deformation or damage under long-term use or extreme road conditions, affecting driving safety. Second, wooden materials require frequent maintenance (such as anti-corrosion and moisture-proofing treatments), increasing the user's operating costs and time, similar to the care required for wooden floors. Furthermore, the traditional design of wooden structures is considered outdated in today's market and fails to meet users' demands for lightweight and high-strength modern travel trailers.

[0004] In recent years, with the development of materials technology, fiberglass reinforced plastic (FRP) has gradually become a new choice for trailer caravan bodies. FRP is a high-strength, energy-saving sheet material made from glass fiber and resin through a UV reaction process and surface polishing. It features double-sided hollow construction and an internal support structure. Its advantages include flame retardancy, heat insulation, and lightweight properties, which improve the safety and energy efficiency of caravans to a certain extent. However, the aging problem exposed to long-term outdoor use severely restricts its application. Prolonged exposure to wind and sun can cause FRP material performance degradation and a significant decrease in strength, thus threatening the overall stability of the vehicle body structure and potentially causing safety accidents.

[0005] In conclusion, both traditional wooden structures and new fiberglass structures suffer from insufficient strength or poor durability, becoming a "Achilles' heel" in the towed caravan industry. This technological bottleneck not only limits the lifespan and applicability of caravans but also poses a potential threat to the personal safety of passengers. Utility Model Content

[0006] To address the problem of insufficient strength in existing towed caravan bodies, this invention provides a lightweight, high-strength steel-aluminum hybrid caravan body with high strength and excellent durability.

[0007] The purpose of this utility model is to provide a lightweight and high-strength steel-aluminum hybrid RV body, including a body frame assembly, a frame connector assembly, an outer panel assembly, and an inner panel assembly. The body frame assembly is connected and fixed through the frame connector assembly, and the outer panel assembly and the inner panel assembly are directly welded to the body frame assembly.

[0008] The body frame assembly and outer panel assembly are made of aluminum alloy, and the inner panel assembly is made of automotive steel.

[0009] In one embodiment, the frame connectors are generally made of hot-formed steel.

[0010] In one embodiment, the vehicle frame assembly includes a floor frame, a left side frame, a right side frame, a front side frame, a front roof beam, and a rear roof beam. The floor frame is connected at the bottom between the left side frame and the right side frame. The front side frame is connected at the front between the left side frame and the right side frame. The front roof beam and the rear roof beam are connected at the front and rear sides of the top between the left side frame and the right side frame.

[0011] In one embodiment, the frame connector assembly includes a left front pillar lower connector, a right front pillar lower connector, a left wheel arch front longitudinal beam connector, a right wheel arch front longitudinal beam connector, a third crossbeam left side connector, a third crossbeam right side connector, a left wheel arch rear longitudinal beam connector, a right wheel arch rear longitudinal beam connector, a rear floor left longitudinal beam connector, a rear floor right longitudinal beam connector, a left C-pillar upright beam connector, a right C-pillar upright beam connector, a left side central longitudinal beam outer connector, and a right side central longitudinal beam outer connector. The left front pillar lower connector and the right front pillar lower connector are located at the connection between the front side frame and the floor frame. The left wheel arch front longitudinal beam connector and the left wheel arch rear longitudinal beam connector... The following components are installed at the connection between the floor frame and the left wheel arch: the front longitudinal beam connector of the right wheel arch and the rear longitudinal beam connector of the right wheel arch are installed at the connection between the floor frame and the right wheel arch; the left side connector and the right side connector of the third crossbeam are used to connect the middle beam and the outer beam of the floor frame; the left longitudinal beam connector and the left C-column beam connector of the rear floor are installed at the connection between the floor frame and the left side enclosure frame; the right longitudinal beam connector and the right C-column beam connector of the rear floor are installed at the connection between the floor frame and the right side enclosure frame; the outer connectors of the left and right side enclosure longitudinal beams are installed at the connection between the front enclosure frame and the left and right enclosure frames.

[0012] In one embodiment, the frame connector assembly further includes a left lower longitudinal beam reinforcement, a right lower longitudinal beam reinforcement, a left middle longitudinal beam reinforcement, and a right middle longitudinal beam reinforcement. The left lower longitudinal beam reinforcement and the left middle longitudinal beam reinforcement are used to connect the beams of the left side frame; the right lower longitudinal beam reinforcement and the right middle longitudinal beam reinforcement are used to connect the beams of the right side frame.

[0013] In one embodiment, the outer panel assembly includes a left outer panel, a right outer panel, a left front trim mounting plate, a right front trim mounting plate, a left rear trim mounting plate, a right rear trim mounting plate, a front outer panel, and a front top outer panel. The left front trim mounting plate and the left rear trim mounting plate are respectively connected to the bottom sides of the left outer panel, and the right front trim mounting plate and the right rear trim mounting plate are respectively connected to the bottom sides of the right outer panel. The front outer panel and the front top outer panel are welded between the left outer panel and the right outer panel, and the front top outer panel is welded onto the front outer panel.

[0014] In one embodiment, the left front side trim mounting plate and the left rear side trim mounting plate are fixed to the left outer panel by bolts or rivets, and the right front side trim mounting plate and the right rear side trim mounting plate are fixed to the right outer panel by bolts or rivets.

[0015] In one embodiment, the left outer panel is welded to the left outer frame, the right outer panel is welded to the right outer frame, the front outer panel is welded to the front outer frame, and the front top outer panel is welded to the front top beam, the left outer frame, and the right outer frame.

[0016] In one embodiment, the inner panel assembly includes a front top inner panel, a lifting top frame inner panel, a left side inner panel, a right side inner panel, and a floor. The front top inner panel and the lifting top frame inner panel are welded between the left side inner panel and the right side inner panel. The front top inner panel and the lifting top frame inner panel are welded together. The floor is arranged parallel to the lifting top frame inner panel.

[0017] In one embodiment, the front top inner panel is welded to the front top crossbeam, the left side frame, and the right side frame; the lifting top frame inner panel is welded to the front top crossbeam and the rear top crossbeam; the left side inner panel is welded to the left side frame; the right side inner panel is welded to the right side frame; and the floor is welded to the floor frame.

[0018] Compared with the prior art, the above technical solutions adopted by this utility model have the following advantages: 1. The RV body of this application adopts an all-metal body structure, which breaks through the technical gap of lacking pure metal body structure in the field of existing small and medium-sized RVs, and has significant market application value and development potential.

[0019] 2. This application achieves dual technical advantages through a steel-aluminum hybrid design: it significantly improves the structural strength of the vehicle body and achieves a lightweight breakthrough by reducing the weight by more than 20% compared to conventional metal bodies.

[0020] 3. The frame connector assembly of this application is made of hot-formed steel, which further improves the overall lightweight level of the vehicle body while ensuring the load-bearing performance of key parts.

[0021] 4. Compared with the wood or fiberglass structures commonly used in RVs of the same class, the steel-aluminum hybrid metal body of this application has improved corrosion resistance and extended the structural aging cycle, which can effectively ensure the long-term reliability of RVs in complex environments. Attached Figure Description

[0022] Figure 1 This is a schematic diagram showing the connection between the vehicle frame assembly and the frame connector assembly.

[0023] Figure 2 This is a detailed structural diagram of the vehicle body frame assembly;

[0024] Figure 3 Detailed structural diagram of the frame connector assembly;

[0025] Figure 4 This is a detailed structural diagram of the outer panel assembly;

[0026] Figure 5 This is a detailed structural diagram of the inner panel assembly;

[0027] Among them: 1. Body frame assembly, 2. Frame connector assembly;

[0028] 11. Floor frame; 12. Left side perimeter frame; 13. Right side perimeter frame; 14. Front side perimeter frame; 15. Front top beam; 16. Rear top beam;

[0029] 21. Lower connector of left front pillar; 22. Lower connector of right front pillar; 23. Connector of front longitudinal beam of left wheel arch; 24. Connector of front longitudinal beam of right wheel arch; 25. Left side connector of third crossbeam; 26. Right side connector of third crossbeam; 27. Rear longitudinal beam connector of left wheel arch; 28. Rear longitudinal beam connector of right wheel arch; 29. ​​Left longitudinal beam connector of rear floor; 210. Right longitudinal beam connector of rear floor; 211. Connector of left C-pillar upright beam; 212. Connector of right C-pillar upright beam; 213. Outer connector of left side wall longitudinal beam; 214. Outer connector of right side wall longitudinal beam; 215. Reinforcing member of lower longitudinal beam of left side wall; 216. Reinforcing member of lower longitudinal beam of right side wall; 217. Reinforcing member of left side wall longitudinal beam; 218. Reinforcing member of right side wall longitudinal beam.

[0030] 31. Left side outer panel; 32. Right side outer panel; 33. Left front side trim mounting plate; 34. Right front side trim mounting plate; 35. Left rear side trim mounting plate; 36. Right rear side trim mounting plate; 37. Front side outer panel; 38. Front roof outer panel;

[0031] 41. Front roof inner panel; 42. Lifting roof frame inner panel; 43. Left side inner panel; 44. Right side inner panel; 45. Floor. Detailed Implementation

[0032] To make the technical problems, technical solutions, and beneficial effects to be solved by this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and are not intended to limit the scope of this application.

[0033] It should be noted that when a component is referred to as being "fixed to" or "set on" another component, it can be directly on or indirectly on that other component. When a component is referred to as being "connected to" another component, it can be directly connected to or indirectly connected to that other component.

[0034] In the description of this application, it should be understood that the terms "center", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0035] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0036] This embodiment provides a lightweight, high-strength steel-aluminum hybrid RV body, including a body frame assembly, a frame connector assembly, an outer panel assembly, and an inner panel assembly;

[0037] The vehicle frame assembly is constructed using aluminum alloy square tubing, and its connection nodes are divided into welded fixing parts and detachable connection parts. The detachable connection parts are assembled through the frame connector assembly.

[0038] The outer panel assembly and the inner panel assembly are respectively integrated with the body frame assembly by continuous welding to form an integral structure;

[0039] The body frame assembly and outer panel assembly are made of aluminum alloy to achieve lightweighting, the frame connector assembly is made of hot-formed thin-walled high-strength steel to balance strength and weight, and the inner panel assembly is made of automotive high-strength steel to improve overall torsional resistance.

[0040] In this embodiment, the vehicle frame assembly includes a floor frame, a left side frame, a right side frame, a front side frame, a front roof crossbeam, and a rear roof crossbeam. The floor frame is fixed to the bottom of the left and right side frames via thermoformed connectors, forming the basic load-bearing structure of the vehicle body; the front side frame is welded to the front ends of the left and right side frames, forming the front collision protection zone; the front and rear roof crossbeams are respectively assembled to the front and rear ends of the top of the left and right side frames, forming the longitudinal support frame of the roof.

[0041] In this embodiment, the frame connector assembly includes the following functional units:

[0042] Column connection unit: The lower connector of the left front column and the lower connector of the right front column are symmetrically installed at the joint between the front frame and the floor frame to enhance the vertical load-bearing capacity.

[0043] Wheel arch connection unit: The front / rear longitudinal beam connectors of the left wheel arch and the front / rear longitudinal beam connectors of the right wheel arch are respectively set at the joint between the floor frame and the left / right wheel arch, optimizing the wheel well space layout;

[0044] Crossbeam bridging unit: The left / right connectors of the third crossbeam connect the middle beam and the outer beam of the floor frame to achieve uniform transfer of lateral load;

[0045] Rear reinforcement unit: The left / right longitudinal beam connectors of the rear floor and the left / right C-column upright beam connectors are integrated into the rear of the floor frame and side frame to improve bending resistance;

[0046] Stress diffusion unit: The outer connectors of the left and right longitudinal beams are set at the intersection of the front frame and the left and right frames to achieve stress gradient distribution.

[0047] The frame connector assembly is further reinforced with a left lower longitudinal beam reinforcement, a right lower longitudinal beam reinforcement, a left middle longitudinal beam reinforcement, and a right middle longitudinal beam reinforcement. These reinforcements are spaced apart along the longitudinal axis of the side frame, forming localized stiffness-enhancing zones.

[0048] In this embodiment, the outer panel assembly includes a left side outer panel, a right side outer panel, and a front styling component:

[0049] The left front / rear side panel mounting plate and the right front / rear side panel mounting plate are fixed to the bottom of the corresponding side panel outer plate by riveting or bolting, forming a quick-release interface for the decorative parts.

[0050] The front side panel and the front roof panel are welded together to form an integrated streamlined front shape. The front roof panel is also welded and fixed to the front roof crossbeam and the top of the left and right side panel frames to ensure the aerodynamic performance and waterproof sealing of the roof structure.

[0051] The assembly relationship between the outer panel assembly and the body frame assembly is as follows: the left side outer panel and the right side outer panel are fixed to the outer surface of the corresponding side frame by full welding; the weld between the front side outer panel and the front roof outer panel is ground smooth to achieve surface flatness control.

[0052] In this embodiment, the inner panel assembly includes:

[0053] Roof reinforcement unit: The inner front roof panel and the inner frame panel of the lifting roof are connected by welding;

[0054] Side enclosure protection unit: The left inner panel and the right inner panel are fixed to the inner wall of the corresponding side enclosure frame by welding, and the surface is stamped with reinforcing ribs;

[0055] Floor load-bearing unit: The floor is fixed to the upper surface of the floor frame by welding, and forms a parallel load-bearing surface with the inner panel of the lifting top frame;

[0056] The welding and positioning method of the inner panel assembly is as follows: the front top inner panel is welded and fixed to the front top crossbeam and the top of the left and right side frame; the lifting top frame inner panel is welded between the front top crossbeam and the rear top crossbeam; the left / right side frame inner panels are welded in sections along the inner wall contour of the side frame; the floor and floor frame adopt a symmetrical welding sequence to prevent thermal deformation.

[0057] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application.

Claims

1. A lightweight, high-strength steel-aluminum hybrid RV body, characterized in that, It includes a body frame assembly, a frame connector assembly, an outer panel assembly, and an inner panel assembly. The body frame assembly is connected and fixed through the frame connector assembly, and the outer panel assembly and the inner panel assembly are directly welded to the body frame assembly. The body frame assembly and outer panel assembly are made of aluminum alloy, and the inner panel assembly is made of automotive steel.

2. The lightweight, high-strength steel-aluminum hybrid RV body according to claim 1, characterized in that, The frame connectors are all made of hot-formed steel.

3. The lightweight, high-strength steel-aluminum hybrid RV body according to claim 1, characterized in that, The vehicle frame assembly includes a floor frame, a left side frame, a right side frame, a front side frame, a front roof crossbeam, and a rear roof crossbeam. The floor frame is connected at the bottom between the left side frame and the right side frame. The front side frame is connected at the front between the left side frame and the right side frame. The front roof crossbeam and the rear roof crossbeam are connected at the front and rear sides of the top between the left side frame and the right side frame.

4. The lightweight, high-strength steel-aluminum hybrid RV body according to claim 1, characterized in that, The frame connector assembly includes a lower connector for the left front pillar, a lower connector for the right front pillar, a connector for the front longitudinal beam of the left wheel arch, a connector for the front longitudinal beam of the right wheel arch, a connector for the left side of the third crossbeam, a connector for the right side of the third crossbeam, a connector for the rear longitudinal beam of the left wheel arch, a connector for the rear longitudinal beam of the right wheel arch, a connector for the left longitudinal beam of the rear floor, a connector for the right longitudinal beam of the rear floor, a connector for the left C-pillar upright beam, a connector for the right C-pillar upright beam, an outer connector for the left side of the central longitudinal beam, and an outer connector for the right side of the central longitudinal beam. The lower connectors for the left and right front pillars are located at the connection between the front side frame and the floor frame; the connectors for the front longitudinal beam of the left wheel arch and the rear longitudinal beam of the left wheel arch are located on the floor. The connection between the frame and the left wheel arch; the front longitudinal beam connector and the rear longitudinal beam connector of the right wheel arch are located at the connection between the floor frame and the right wheel arch; the left side connector and the right side connector of the third crossbeam are used to connect the middle beam and the outer beam of the floor frame; the left longitudinal beam connector and the left C-column beam connector of the rear floor are located at the connection between the floor frame and the tail of the left side enclosure frame; the right longitudinal beam connector and the right C-column beam connector of the rear floor are located at the connection between the floor frame and the tail of the right side enclosure frame; the outer connectors of the left and right side middle longitudinal beams are located at the connection between the front enclosure frame and the left and right enclosure frames.

5. The lightweight, high-strength steel-aluminum hybrid RV body according to claim 4, characterized in that, The frame connector assembly further includes a left lower longitudinal beam reinforcement, a right lower longitudinal beam reinforcement, a left middle longitudinal beam reinforcement, and a right middle longitudinal beam reinforcement. The left lower longitudinal beam reinforcement and the left middle longitudinal beam reinforcement are used to connect the beams of the left side frame; the right lower longitudinal beam reinforcement and the right middle longitudinal beam reinforcement are used to connect the beams of the right side frame.

6. The lightweight, high-strength steel-aluminum hybrid RV body according to claim 1, characterized in that, The outer panel assembly includes a left outer panel, a right outer panel, a left front trim mounting plate, a right front trim mounting plate, a left rear trim mounting plate, a right rear trim mounting plate, a front outer panel, and a front top outer panel. The left front trim mounting plate and the left rear trim mounting plate are respectively connected to the bottom sides of the left outer panel, and the right front trim mounting plate and the right rear trim mounting plate are respectively connected to the bottom sides of the right outer panel. The front outer panel and the front top outer panel are welded between the left outer panel and the right outer panel, and the front top outer panel is welded onto the front outer panel.

7. The lightweight, high-strength steel-aluminum hybrid RV body according to claim 6, characterized in that, The left front side enclosure mounting plate and the left rear side enclosure mounting plate are fixed to the left outer enclosure plate by bolts or rivets, and the right front side enclosure mounting plate and the right rear side enclosure mounting plate are fixed to the right outer enclosure plate by bolts or rivets.

8. The lightweight, high-strength steel-aluminum hybrid RV body according to claim 6, characterized in that, The left outer panel is welded to the left outer frame, the right outer panel is welded to the right outer frame, the front outer panel is welded to the front outer frame, and the front top outer panel is welded to the front top crossbeam, the left outer frame, and the right outer frame.

9. The lightweight, high-strength steel-aluminum hybrid RV body according to claim 1, characterized in that, The inner panel assembly includes a front top inner panel, a lifting top frame inner panel, a left side inner panel, a right side inner panel, and a floor. The front top inner panel and the lifting top frame inner panel are welded between the left side inner panel and the right side inner panel. The front top inner panel and the lifting top frame inner panel are welded together. The floor is arranged parallel to the lifting top frame inner panel.

10. The lightweight, high-strength steel-aluminum hybrid RV body according to claim 9, characterized in that, The front roof inner panel is welded to the front roof crossbeam, the left side frame, and the right side frame; the lifting roof frame inner panel is welded to the front roof crossbeam and the rear roof crossbeam; the left side inner panel is welded to the left side frame; the right side inner panel is welded to the right side frame; and the floor is welded to the floor frame.

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