Hot air inflatable roof beam structure

Abstract

This utility model relates to the field of electric vehicle technology, specifically, to a hot-expansion top side beam structure, including a top cover side beam; the top cover side beam is a hot-expansion integrally formed beam; a rear top crossbeam is provided on one side of the top cover side beam; the rear top crossbeam is connected to a rear top connecting plate; the rear top connecting plate is connected to the top cover side beam via FDS nails; the rear top connecting plate is connected to a rear column; the top cover side beam is connected to a top-tail connecting plate; the top-tail connecting plate is connected to the rear column via FDS nails; the top cover side beam adopts hot-expansion technology, integrally formed with an annular cross section, resulting in high overall structural strength, improved torsional stiffness, and avoidance of poor dimensional accuracy in bending processes; the overlapping area of ​​the top cover side beam with the rear top crossbeam and the rear column adopts cold connection technology (FDS), using a patch plate method, eliminating the traditional welding scheme, and significantly improving dimensional accuracy and joint strength.

Description

Technical Field

[0001] This utility model relates to the field of electric vehicle technology, and more specifically, to a thermally expanded top edge beam structure. Background Technology

[0002] In the current production of all-aluminum frame body structures, the top edge beam profiles have large dimensional deviations due to bending, and the aluminum profiles also have large welding deformations. After being welded into the body frame, the dimensional deviations at local installation points are large, which is not conducive to the overall vehicle installation and matching. In addition, the joints of all-aluminum frame bodies are mostly welded, which results in serious performance degradation.

[0003] The applicant discovered through a search that Chinese patent document application number 202110752286.9, published on August 27, 2021, discloses a roof side beam, including a main roof side beam and an auxiliary side beam. The main roof side beam is an integral structure, comprising a base and a connecting part. The lower end of the base is used to connect to the side wall of the vehicle body, and the connecting part is used to connect to a first roof. The base has a conventional structure in the longitudinal direction. The lower end of the auxiliary side beam is welded and fixed to the base, and the upper end of the auxiliary side beam is used to connect to a second roof. In the longitudinal direction, a portion of the base is provided with the auxiliary side beam, and a portion of the base is provided with the connecting part. The portion where the auxiliary side beam is provided does not have the connecting part. The second roof is higher than the first roof. This device also fails to solve the aforementioned technical problem.

[0004] Therefore, in order to improve or solve at least one of the above problems, it is necessary to provide a hot gas expansion top edge beam structure that reduces thermal deformation of traditional aluminum profile body welding connections and improves dimensional accuracy and joint strength. Utility Model Content

[0005] The purpose of this utility model is to provide a thermal expansion top edge beam structure that reduces thermal deformation of traditional aluminum profile body welding connections, improves dimensional accuracy, and enhances joint strength.

[0006] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is as follows: a hot-expanding top edge beam structure, including a top cover edge beam; the top cover edge beam is a hot-expanding integrally molded beam;

[0007] A rear top crossbeam is provided on one side of the top cover side beam; the rear top crossbeam is connected to a tail rear top connecting plate; the tail rear top connecting plate is connected to the top cover side beam by FDS nails; the tail rear top connecting plate is connected to a tail column; the top cover side beam is connected to a top tail connecting plate; the top tail connecting plate is connected to the tail column by FDS nails.

[0008] The rear top connecting plate includes a first mounting plate and a second mounting plate; the FDS nail is connected to the first mounting plate; the FDS nail is connected to the end of the top cover side beam.

[0009] The rear top crossbeam includes a bottom plate and a side plate; the end of the bottom plate is welded to the first mounting plate; the bottom plate is connected to the rear top connecting plate on the side away from the top cover side beam.

[0010] The end of the tail column abuts against the top cover side beam; the second mounting plate is welded to the side of the tail column.

[0011] The top and tail connecting plate includes a third mounting plate and a fourth mounting plate; an FDS nail is connected to the fourth mounting plate; the FDS nail is connected to the tail post on the side away from the tail rear top connecting plate.

[0012] The third mounting plate is welded to the top cover side beam; the third mounting plate is connected to the side of the top cover side beam away from the rear top connecting plate.

[0013] The rear top crossbeam is an extruded aluminum beam; the tail column is an extruded aluminum column.

[0014] Both the tail-rear top connecting plate and the top-tail connecting plate are made of aluminum plates.

[0015] The beneficial effects of this utility model are as follows:

[0016] The top cover side beam of this utility model adopts hot air expansion technology and is formed into an integral ring cross section, resulting in high overall structural strength and improved torsional stiffness. At the same time, it avoids the poor dimensional accuracy of the bending process. The overlapping area of ​​the top cover side beam with the rear top cross beam and the tail column adopts cold connection technology (FDS) and uses a patch plate method to eliminate the traditional welding solution, which greatly improves dimensional accuracy and joint strength. Attached Figure Description

[0017] The specific embodiments of this utility model will be further described in detail below with reference to the accompanying drawings, wherein:

[0018] Figure 1 This is a schematic diagram of the structure of this utility model.

[0019] Figure 2 This is a schematic diagram of the structure of the rear top connecting plate of this utility model.

[0020] The markings in the above figures are all:

[0021] The diagram is marked as follows:

[0022] 1. Top cover edge beam,

[0023] 2. Rear top crossbeam, 201. Base plate, 202. Side plate.

[0024] 3. Rear top connecting plate, 301. First mounting plate, 302. Second mounting plate.

[0025] 4. FDS nails

[0026] 5. Tail column,

[0027] 6. Top and tail connecting plate, 601. Third mounting plate, 602. Fourth mounting plate. Detailed Implementation

[0028] The specific embodiments of this utility model will be further described in detail below with reference to the accompanying drawings, in order to help those skilled in the art to have a more complete, accurate and in-depth understanding of the inventive concept and technical solution of this utility model, and to facilitate its implementation.

[0029] Figure 1-2 The hot-expansion top edge beam structure shown includes a top edge beam 1; the top edge beam 1 is a hot-expansion integrally molded beam.

[0030] A rear top crossbeam 2 is provided on one side of the top cover side beam 1; the rear top crossbeam 2 is connected to the rear top connecting plate 3; the rear top connecting plate 3 is connected to the top cover side beam 1 through FDS nail 4; the rear top connecting plate 3 is connected to the rear column 5; the top cover side beam 1 is connected to the top and tail connecting plate 6; the top and tail connecting plate 6 is connected to the tail column 5 through FDS nail 4.

[0031] Hot gas expansion technology is an advanced process that involves heating a metal tube blank to the austenitic region, injecting high-pressure inert gas, and causing it to expand and fit into the cavity within a sealed mold, forming it in one step and simultaneously quenching it. It can produce weld-free, high-strength, lightweight closed-section beams.

[0032] Flow-Drill Screw (FDS) is a mechanical fastening process that is free from pre-drilling and heat-affected zones. A specially designed screw that rotates at high speed generates heat through friction under axial pressure, instantly softening the connected parts and self-drilling into them. It is then squeezed to form a threaded engagement, achieving a one-time firm connection of multiple dissimilar materials (such as aluminum-steel or composite-metal), and has the advantages of high torsional resistance, sealing, and disassembly.

[0033] The top cover side beam 1 adopts hot air expansion technology and is formed into an integral ring section, resulting in high overall structural strength and improved torsional stiffness. It also avoids the poor dimensional accuracy of the bending process. The overlapping area of ​​the top cover side beam 1 with the rear top crossbeam 2 and the tail column 5 adopts cold connection technology (FDS) and uses a patch plate method to eliminate the traditional welding solution, which greatly improves dimensional accuracy and joint strength.

[0034] The rear top connecting plate 3 includes a first mounting plate 301 and a second mounting plate 302; an FDS nail 4 is connected to the first mounting plate 301; the FDS nail 4 is connected to the end of the top cover side beam 1.

[0035] The first mounting plate 301 and the second mounting plate 302 are an integral structure; the rear top connecting plate 3 has a V-shaped cross section; two FDS nails 4 are connected on the rear top connecting plate 3; the first mounting plate 301 uses the two FDS nails 4 to directly screw into the side of the end of the roof side beam 1 without pre-drilling, the rotational friction generates heat to soften the material and extrudes it to form a high-strength thread engagement, realizing the cold connection of aluminum-steel dissimilar materials; replacing traditional welding, eliminating thermal deformation and weld defects, significantly improving the torsional stiffness of the body, assembly accuracy and joint fatigue life, while maintaining disassembly and maintainability.

[0036] The rear top crossbeam 2 includes a bottom plate 201 and a side plate 202; the end of the bottom plate 201 is welded to the first mounting plate 301; the bottom plate 201 is connected to the rear top connecting plate 3 on the side away from the top cover side beam 1.

[0037] The base plate 201 and the side plate 202 are an integral structure; the rear top beam 2 has an L-shaped cross section; the end of the base plate 201 is welded to the first mounting plate 301 MIG.

[0038] The end of the base plate 201 and the first mounting plate 301 are connected by MIG welding (metal inert gas welding): the wire feeder continuously feeds welding wire as an electrode, and the argon-carbon dioxide mixed gas forms a stable protective shield around the arc, isolating air and preventing welding slag. The concentrated heat of the arc causes the two plates to fuse instantly, and then they are rapidly cooled to form a dense weld. This process utilizes the advantages of continuous wire feeding, high penetration depth, and low heat input to achieve a reliable connection between thick and thin plates without the need for pre-drilling. The weld is aesthetically pleasing, has high strength, small deformation, and is easy to automate. The rear top beam 2 and the tail rear top connecting plate 3 are rigidly fixed by the MIG weld, which can efficiently transfer the vertical and longitudinal loads borne by the rear top beam 2 to the top cover side beam 1.

[0039] The end of the tail column 5 abuts against the top cover side beam 1; the second mounting plate 302 is welded to the side of the tail column 5.

[0040] The second mounting plate 302 is welded to the tail column 5MIG;

[0041] The top surface of the rear pillar 5 is precisely pressed against the corresponding end face of the roof side beam 1 to form an axial compression fit, which directly introduces the load from the vehicle body into the closed section beam and suppresses local deformation by relying on the high torsional stiffness of the roof side beam 1; the second mounting plate 302 is attached and fixedly connected to the side of the rear pillar 5 by MIG welding.

[0042] The top and tail connecting plate 6 includes a third mounting plate 601 and a fourth mounting plate 602; the fourth mounting plate 602 is connected to an FDS nail 4; the FDS nail 4 is connected to the tail post 5 on the side away from the tail rear top connecting plate 3.

[0043] The third mounting plate 601 and the fourth mounting plate 602 are an integral structure; the top and tail connecting plate 6 has a V-shaped cross section; the top and tail connecting plate 6 forms a self-stabilizing triangular force transmission path when under stress; the fourth mounting plate 602 is directly drilled into the side of the tail column 5 without pre-drilling through four FDS nails 4 under high-speed rotation and axial pressure, and after the friction heat softens the wall plate, it is squeezed into a high-strength thread engagement to complete the cold connection; this avoids the deformation of traditional welding and improves the torsional stiffness, fatigue life and assembly accuracy of the rear of the vehicle.

[0044] The third mounting plate 601 is welded to the top cover side beam 1; the third mounting plate 601 is connected to the side of the top cover side beam 1 away from the rear top connecting plate 3.

[0045] The third mounting plate 601 is MIG welded to the side of the top cover side beam 1;

[0046] The third mounting plate 601 is fixedly connected to the side of the roof side beam 1 away from the rear top connecting plate 3 by MIG welding; the top and rear connecting plate 6 and the roof side beam 1 are rigidly connected by weld, which significantly improves the rear torsional stiffness and collision energy transfer efficiency, while avoiding additional brackets and realizing a lightweight, high-strength and maintainable body connection.

[0047] The rear top crossbeam 2 is an extruded aluminum beam; the tail column 5 is an extruded aluminum column.

[0048] Both the rear top crossbeam 2 and the rear pillar 5 are made of extruded aluminum profiles. By taking advantage of the one-time forming closed cavity and the designable wall thickness, the weight is greatly reduced while maintaining the strength of equivalent steel parts. Aluminum has a low elastic modulus but good energy absorption. During a collision, it can quickly dissipate energy through plastic deformation, which can reduce the intrusion of the passenger compartment. The extrusion process has high dimensional accuracy, taking into account the torsional stiffness of the whole vehicle, collision safety and platform expansion needs.

[0049] Both the rear top connecting plate 3 and the top-tail connecting plate 6 are made of aluminum plates.

[0050] Both the rear top connecting plate 3 and the top-to-rear connecting plate 6 are made of aluminum sheet and are integrally stamped, which significantly reduces the total weight of the rear upper body. The excellent thermal conductivity and low elastic modulus of aluminum allow the heat input of FDS self-tapping and MIG welding to dissipate rapidly, with minimal thermal deformation, ensuring assembly accuracy. The rear top connecting plate 3 and the top-to-rear connecting plate 6 form a homogeneous electrochemical system with the rear top crossbeam 2 and the rear pillar 5, avoiding corrosion due to the potential difference between dissimilar materials. At the same time, the oxide film on the surface of the aluminum sheet enhances the corrosion resistance life. Aluminum has high recyclability, meeting the requirements of green manufacturing, and the overall system achieves comprehensive benefits of lightweighting, high dimensional stability, long service life and sustainability.

[0051] The specific workflow of this utility model is as follows:

[0052] The top cover side beam 1 adopts hot air expansion technology and is formed into an integral ring section, resulting in high overall structural strength and improved torsional stiffness. It also avoids the poor dimensional accuracy of the bending process. The overlapping area of ​​the top cover side beam 1 with the rear top crossbeam 2 and the tail column 5 adopts cold connection technology (FDS) and uses a patch plate method to eliminate the traditional welding solution, which greatly improves dimensional accuracy and joint strength.

[0053] The present invention has been described above by way of example with reference to the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any non-substantial improvements made using the inventive concept and technical solution of the present invention; or the direct application of the inventive concept and technical solution to other situations without modification, are all within the protection scope of the present invention.

Claims

1. A hot gas inflatable crown beam structure, characterized by: Includes a top cover side beam (1); the top cover side beam (1) is a thermally expanded integrally formed beam; A rear top crossbeam (2) is provided on one side of the top cover side beam (1); the rear top crossbeam (2) is connected to a tail rear top connecting plate (3); the tail rear top connecting plate (3) is connected to the top cover side beam (1) by an FDS nail (4); the tail rear top connecting plate (3) is connected to a tail column (5); the top cover side beam (1) is connected to a top tail connecting plate (6); the top tail connecting plate (6) is connected to the tail column (5) by an FDS nail (4).

2. A hot gas inflatable crown beam structure as defined in claim 1, wherein: The rear top connecting plate (3) includes a first mounting plate (301) and a second mounting plate (302); the first mounting plate (301) is connected to the FDS nail (4); the FDS nail (4) is connected to the end of the top cover side beam (1).

3. A hot gas inflatable crown beam structure as defined in claim 2, wherein: The rear top crossbeam (2) includes a bottom plate (201) and a side plate (202); the end of the bottom plate (201) is welded to the first mounting plate (301); the bottom plate (201) is connected to the rear top connecting plate (3) on the side away from the top cover side beam (1).

4. A hot gas inflatable crown beam structure according to any one of claims 2-3, characterized in that: The end of the tail column (5) abuts against the top cover side beam (1); the second mounting plate (302) is welded to the side of the tail column (5).

5. A hot gas inflatable crown beam structure as defined in claim 4, wherein: The top and tail connecting plate (6) includes a third mounting plate (601) and a fourth mounting plate (602); an FDS nail (4) is connected to the fourth mounting plate (602); the FDS nail (4) is connected to the tail post (5) on the side away from the tail rear top connecting plate (3).

6. A hot gas inflatable crown beam structure as claimed in claim 5, wherein: The third mounting plate (601) is welded to the top cover side beam (1); the third mounting plate (601) is connected to the side of the top cover side beam (1) away from the rear top connecting plate (3).

7. A hot gas inflatable crown beam structure according to any one of claims 5-6, characterized in that: The rear top beam (2) is an extruded aluminum beam; the tail column (5) is an extruded aluminum column.

8. A hot gas inflatable crown beam structure as defined in claim 7, wherein: Both the tail-rear top connecting plate (3) and the top-tail connecting plate (6) are aluminum plates.

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