A vehicle body frame and a vehicle

Abstract

The embodiment of the present application provides a vehicle body frame and a vehicle. An outer surface of the vehicle body frame comprises a first area, the first area comprises at least one curved surface or at least two intersecting planes, the vehicle body frame comprises a fiber thermoplastic composite layer and a covering layer. The covering layer at least covers at least part of the outer surface of the fiber thermoplastic composite layer, and a side surface of the covering layer away from the continuous fiber composite material layer forms at least part of the outer surface of the vehicle body frame. The melting temperature of the covering layer is higher than the viscous flow temperature of the thermoplastic matrix of the fiber thermoplastic composite layer. In the embodiment of the present application, in the process of heating and forming, the covering layer can keep solid state and play a restraining role on the fibers in the fiber thermoplastic composite layer, so that the probability of exposed fibers on the finished product outer surface of the vehicle body frame is reduced, the surface quality of the outer surface of the vehicle body frame is improved, and subsequent paint spraying and other processes are facilitated.

Description

Technical Field

[0001] This application relates to the field of vehicle technology, specifically to a vehicle body frame and a vehicle. Background Technology

[0002] Some structural components of the vehicle body frame can be made of non-metallic composite materials to simplify the manufacturing process of the body frame and facilitate its lightweighting.

[0003] In related technologies, non-metallic composite materials contain fibers, and a thin film is coated on the outer surface of the non-metallic composite material to cover the exposed fibers in the non-metallic composite material, so as to make the appearance of the vehicle frame flat.

[0004] During the body frame forming process, the blank of the body frame needs to be heated and bent. During the processing, under the action of bending stress, the fibers may pass through the film covering the outer surface of the non-metallic composite material and be exposed on the surface of the body frame, which will have an adverse effect on the surface quality of the outer surface of the body frame. Utility Model Content

[0005] In view of this, embodiments of this application aim to provide a vehicle body frame and vehicle that are beneficial to improving the surface quality of the outer surface.

[0006] To achieve this objective, the technical solution of this application embodiment is implemented as follows:

[0007] This application provides a vehicle body frame for forming a vehicle. The outer surface of the vehicle body frame includes a first region, which includes at least one curved surface or at least two intersecting planes. The vehicle body frame includes:

[0008] Fiber thermoplastic composite layer;

[0009] A covering layer that at least partially covers the outer surface of the fiber thermoplastic composite layer, wherein the side surface of the covering layer opposite to the fiber thermoplastic composite layer forms at least a portion of the outer surface of the vehicle frame;

[0010] The melting temperature of the covering layer is higher than the viscous flow temperature of the thermoplastic matrix of the fiber thermoplastic composite layer.

[0011] The vehicle frame in this embodiment of the application is advantageous because the covering layer can remain solid during the heating and forming process, thereby restraining the fibers in the fiber thermoplastic composite layer. This reduces the probability of exposed fibers on the outer surface of the finished vehicle frame, improves the surface quality of the outer surface of the vehicle frame, and facilitates subsequent processes such as painting.

[0012] In some embodiments, the covering layer covers at least a portion of the outer surface of the fiber thermoplastic composite layer facing the outside of the vehicle;

[0013] And / or, the covering layer covers at least a portion of the outer surface of the fiber thermoplastic composite layer facing the inside of the vehicle.

[0014] This improves the surface quality of the vehicle's exterior, making subsequent painting easier or even eliminating the need for painting, thus enhancing the user experience.

[0015] In some embodiments, the cover layer is a thermoplastic resin, and the viscous flow temperature of the thermoplastic matrix in the fiber thermoplastic composite layer is within the range of the glass transition temperature and viscous flow temperature of the cover layer. Thus, the cover layer is in a highly elastic state, which facilitates deformation, allowing the cover layer to be molded synchronously with the fiber thermoplastic composite layer to meet the final shape requirements of the vehicle frame; the highly elastic cover layer also possesses a certain structural strength, which helps to constrain the movement of the fibers.

[0016] In some embodiments, the thermoplastic matrix in the fiber thermoplastic composite layer is PP, and the cover layer is PC or PET. This ensures that during the heating and deformation of the vehicle frame, the cover layer remains in a highly elastic state, facilitating deformation while maintaining structural strength to constrain fiber movement.

[0017] In some embodiments, the covering layer is made of a metallic material. This gives the covering layer a certain degree of ductility, allowing it to be molded simultaneously with the fiber thermoplastic composite layer during the manufacturing process of the vehicle frame, thus meeting the final shape requirements of the vehicle frame. Furthermore, the high melting point and high structural strength of the metallic material better constrain the movement of the fibers.

[0018] In some embodiments, the thermoplastic matrix in the fiber thermoplastic composite layer is one of PP, PC, or PET, and the cover layer is an aluminum alloy. This allows the melting point of the cover layer to be higher than the viscous flow temperature of the thermoplastic matrix in the fiber thermoplastic composite layer, and the cover layer has high structural strength and low density, which is beneficial for the overall lightweighting of the vehicle frame.

[0019] In some embodiments, the dimensions of the cover layer along the stacking direction of the fiber thermoplastic composite layer and the cover layer range from 0.1 mm to 1 mm. This helps to ensure that the cover layer has sufficient structural strength and reduces the probability of fibers penetrating the cover layer and being exposed on the outer surface of the vehicle frame.

[0020] In some embodiments, the dimensions of the cover layer along the stacking direction of the fiber thermoplastic composite layer and the cover layer range from 0.15 mm to 0.5 mm. This helps to ensure that the cover layer has sufficient structural strength, and further helps to reduce the probability of fibers penetrating the cover layer and being exposed on the outer surface of the vehicle frame.

[0021] In some embodiments, the vehicle frame further includes an adhesive layer located between the fiber thermoplastic composite layer and the cover layer to bond the two together. The melting temperature of the adhesive layer is lower than the viscous flow temperature of the thermoplastic matrix in the fiber thermoplastic composite layer. This allows the adhesive layer to melt and flow during the heating and shaping of the vehicle frame, ensuring that it remains in contact with both the fiber thermoplastic composite layer and the cover layer after subsequent cooling.

[0022] In some embodiments, at least a portion of the first region protrudes outward from the vehicle frame, and the cover layer is located on one side of the protruding direction of the fiber thermoplastic composite layer. This allows the cover layer to shield the fibers in the protruding region, improving the surface quality of the outer surface of the vehicle frame.

[0023] In some embodiments, the fiber thermoplastic composite layer has a cavity on the side facing the inside of the vehicle. This cavity helps to improve the overall structural strength and stiffness of the fiber thermoplastic composite layer.

[0024] In some embodiments, the vehicle frame further includes a reinforcing structure, at least partially disposed within the cavity, to enhance the strength of the fiber thermoplastic composite layer. The reinforcing structure can suppress deformation of the fiber thermoplastic composite layer, thereby contributing to improved overall strength of the vehicle frame.

[0025] In some embodiments, the reinforcing structure is a fiber-reinforced thermoplastic composite material, and a portion of the covering layer covers at least a portion of the surface of the reinforcing structure on the side facing inwards towards the vehicle. The melting temperature of the covering layer material is higher than the viscous flow temperature of the thermoplastic material of the reinforcing structure. Thus, the covering layer can constrain and shield the fibers within the reinforcing structure, which helps improve the overall appearance quality of the vehicle body frame.

[0026] In some embodiments, a portion of the cover layer is located between the reinforcing structure and the fiber thermoplastic composite layer. This cover layer reduces the risk of fiber breakage due to frictional stress between the reinforcing structure and the fiber thermoplastic composite layer, thus extending the service life of the vehicle frame.

[0027] This application also provides a vehicle, which includes a chassis and a body frame as described in any of the foregoing embodiments, the body frame being disposed on the chassis.

[0028] By adopting the vehicle body frame in the aforementioned embodiments, it is beneficial to improve the surface quality of the vehicle's exterior and interior surfaces, thereby enhancing the user experience. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of an explosion of a vehicle in one embodiment of this application;

[0030] Figure 2 for Figure 1 Diagram of the section cut at position AA;

[0031] Figure 3 This is a cross-sectional view of another embodiment of this application at position AA;

[0032] Figure 4 This is a cross-sectional view of another embodiment of this application at position AA;

[0033] Figure 5 This is a schematic diagram of a vehicle in one embodiment of this application.

[0034] Explanation of reference numerals in the attached figures

[0035] 1000, Vehicle; 100, Vehicle frame; 100a, First area; 200, Controller; 300, Motor; 400, Chassis; 410, Battery unit; 10, Fiber thermoplastic composite layer; 10a, Cavity; 11, Fiber; 12, Continuous fiber composite layer; 20, Covering layer; 30, Adhesive layer; 40, Reinforcing structure. Detailed Implementation

[0036] It should be noted that, unless otherwise specified, the embodiments and technical features in the embodiments of this application can be combined with each other, and the detailed descriptions in the specific implementation should be understood as explanations of the purpose of this application and should not be regarded as undue limitations on this application.

[0037] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs; the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit this application; the terms “comprising” and “having”, and any variations thereof, in the specification and drawings of this application are intended to cover non-exclusive inclusion.

[0038] In the description of the embodiments of this application, technical terms such as "first," "second," and "third" are used only to distinguish different objects and should not be construed as indicating or implying relative importance or implicitly specifying the number, specific order, or primary and secondary relationship of the indicated technical features. In the description of the embodiments of this application, "multiple" means two or more, unless otherwise explicitly defined.

[0039] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0040] In the description of the embodiments in this application, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, and B existing alone. Additionally, the character " / " in this document generally indicates that the preceding and following related objects are in an "or" relationship.

[0041] In the description of the embodiments of this application, unless otherwise expressly specified and limited, technical terms such as "installation," "connection," "joining," and "fixing" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; 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. For those skilled in the art, the specific meaning of the terms in the embodiments of this application can be understood according to the specific circumstances.

[0042] In the description of the embodiments of this application, unless otherwise expressly specified and limited, the technical term "contact" should be interpreted broadly, and can be direct contact, contact through an intermediate medium layer, contact between two contacting parties with substantially no interaction force, or contact between two contacting parties with interaction force.

[0043] The embodiments of this application will now be described in detail.

[0044] Vehicle frames made of fiber composite materials require the extrusion molding of fiber composite sheets into structural components of the desired shape using a die of a specific shape. During the extrusion process, due to factors such as differences in the flowability between the fibers and the matrix material, the strength of their adhesion, and the incomplete coverage of the fibers by the matrix material, some fibers bend and slip under the extrusion force of the die. This causes these fibers to protrude from other fibers and be exposed on the surface of the fiber composite material, resulting in a rough surface of the formed structural component and negatively impacting the user's aesthetics.

[0045] In related technologies, a thin film made of resin material is coated on the outer surface of a fiber thermoplastic composite layer formed by fiber composite materials in the vehicle frame. The film forms the outer surface of the vehicle frame and constrains and blocks the exposed fibers.

[0046] However, the blank of the car body frame needs to be heated and then extruded by a mold to form a preset shape. During the extrusion process, due to the shaping requirements, at least part of the blank of the car body frame will bend and deform, causing some fibers in the fiber thermoplastic composite layer to move towards the film. At the same time, the film made of resin material may form a fluid after being heated, which will not be able to stop the movement of the fibers. As a result, after the car body frame is formed, some fibers will pass through the film and be exposed to the car body frame.

[0047] To address the aforementioned issues, this application provides a vehicle body frame comprising a fiber thermoplastic composite layer and a covering layer. The covering layer covers at least a portion of the outer surface of the fiber thermoplastic composite layer, and the melting temperature of the covering layer material is higher than the viscous flow temperature of the thermoplastic material in the fiber thermoplastic composite layer. Thus, during the heating and shaping of the vehicle body frame blank, the covering layer is better able to remain in a solid state, thereby blocking the fibers in the fiber thermoplastic composite layer and reducing the probability of fibers passing through the covering layer.

[0048] Specifically, see Figure 1 and Figure 2 This application provides a vehicle body frame 100 for forming a vehicle 1000. The outer surface of the vehicle body frame 100 includes a first region 100a, which includes at least one curved surface or at least two intersecting planes. The vehicle body frame 100 includes a fiber thermoplastic composite layer 10 and a cover layer 20.

[0049] The cover layer 20 covers at least a portion of the outer surface of the fiber thermoplastic composite layer 10, and the side surface of the cover layer 20 opposite to the fiber thermoplastic composite layer 10 forms at least a portion of the outer surface of the vehicle frame 100.

[0050] The melting temperature of the cover layer 20 is higher than the viscous flow temperature of the thermoplastic matrix of the fiber thermoplastic composite layer 10.

[0051] The first region 100a includes at least one curved surface or at least two intersecting planes, meaning that the outer surface of the vehicle frame 100 is not a complete plane.

[0052] The first region 100a can be a complete curved surface, multiple interconnected curved surfaces, two or more intersecting and connected planes, or a combination of curved surfaces and planes.

[0053] The fiber thermoplastic composite layer 10 refers to a structure formed by heating, molding and other methods using a thermoplastic fiber composite material.

[0054] The fiber-thermoplastic composite layer 10 includes fibers 11 and a thermoplastic matrix, with the fibers 11 embedded within the thermoplastic matrix. Embedding the fibers 11 helps to improve the overall structural strength of the fiber-thermoplastic composite layer 10.

[0055] Fiber 11 and the thermoplastic matrix together form a fiber composite material.

[0056] The vehicle frame 100 is made of fiber composite material, which is conducive to the one-time molding of the overall structure. Compared with the manufacturing method of splicing multiple metal sheet parts in the existing technology, it is beneficial to reduce the number of parts of the vehicle frame 100. This type of material has a lower density than metal materials, which is beneficial to the overall lightweight of the vehicle frame 100. Compared with metal materials, fiber composite materials are more resistant to oxidation and corrosion, which is beneficial to omitting surface treatment processes during manufacturing.

[0057] The cover layer 20 covers the side of the continuous fiber composite layer that is directly exposed to the outside, so that the surface of the cover layer 20, rather than the fiber thermoplastic composite layer 10, can be directly observed from the outside.

[0058] Understandably, the cover layer 20 does not contain fiber 11.

[0059] The melting temperature of the material of the cover layer 20 refers to the temperature at which the material of the cover layer 20 transforms into a liquid state after being heated.

[0060] The viscous flow temperature of the thermoplastic resin material in the fiber thermoplastic composite layer 10 refers to the temperature at which the thermoplastic resin material is heated to the point where it transforms into a viscous flow state.

[0061] It is understandable that during the processing of the blank of the body frame 100, in order to enable the outer surface of the final formed body frame 100 to include at least one curved surface or at least two intersecting planes to meet the shaping requirements of the body frame 100, the fiber thermoplastic composite layer 10 needs to be heated so that the temperature of the thermoplastic matrix of the fiber thermoplastic composite layer 10 exceeds its viscous flow temperature, so that the fiber thermoplastic composite layer 10 can deform under the extrusion of the mold without breaking, thereby enabling the fiber thermoplastic composite layer 10 to finally form the expected shape.

[0062] Understandably, because the melting temperature of the cover layer 20 is higher than the viscous flow temperature of the thermoplastic matrix of the fiber thermoplastic composite layer 10, the cover layer 20 remains solid even when the thermoplastic matrix of the fiber thermoplastic composite layer 10 is in a viscous flow state, thus possessing good structural strength. During the thermoforming process, even if the fibers 11 that have undergone bending deformation in the fiber thermoplastic composite layer 10 are displaced to the surface of the fiber thermoplastic composite layer 10 near the cover layer 20, the cover layer 20 can still act as a barrier to the fibers 11, making it difficult for the fibers 11 to pass through the cover layer 20 and be exposed on the outer surface of the vehicle frame 100.

[0063] The vehicle frame 100 in this embodiment of the application is advantageous because the covering layer 20 can remain solid during the heating and forming process, thereby restraining the fibers 11 in the fiber thermoplastic composite layer 10. This reduces the probability of exposed fibers 11 on the outer surface of the finished vehicle frame 100, which is beneficial to improving the surface quality of the outer surface of the vehicle frame 100 and facilitating subsequent processes such as painting.

[0064] The specific method for determining the viscous flow temperature of the thermoplastic matrix of the fiber thermoplastic composite layer 10 is not limited. For example, a portion of the test sample can be cut from the thermoplastic matrix of the fiber thermoplastic composite layer 10, and the test sample can be placed in a differential scanning calorimeter. The test sample can be heated and the DCS (Differential Scanning Calorimetry) curve of the test sample can be obtained. The viscous flow temperature of the thermoplastic matrix of the fiber thermoplastic composite layer 10 can be obtained through the DCS curve.

[0065] In some embodiments, see Figure 1 and Figure 2 The cover layer 20 covers at least a portion of the outer surface of the fiber thermoplastic composite layer 10 facing outwards from the vehicle 1000.

[0066] In other words, the body frame 100 is used to form part of the shell of the vehicle 1000, the outer side of the vehicle 1000 refers to the side of the vehicle 1000 that directly faces the external space, and at least a portion of the surface of the cover layer 20 opposite to the side of the fiber thermoplastic composite layer 10 forms the exterior surface of the vehicle 1000.

[0067] This improves the surface quality of the vehicle's exterior, making subsequent painting easier or even eliminating the need for painting, thus enhancing the user experience.

[0068] In some embodiments, see Figure 3 The covering layer 20 covers at least a portion of the outer surface of the fiber thermoplastic composite layer 10 facing the inside of the vehicle 1000.

[0069] In other words, the body frame 100 is used to form part of the interior trim of the vehicle 1000, the interior side of the vehicle 1000 refers to the side of the vehicle 1000 that directly faces the interior space of the vehicle 1000, and at least a portion of the surface of the cover layer opposite to the side of the fiber thermoplastic composite layer 10 forms the interior surface of the vehicle 1000.

[0070] The interior surfaces of vehicle 1000 can be the inner walls of the passenger compartment or the inner walls of the storage compartment.

[0071] This will help improve the surface quality of the vehicle's interior surfaces and enhance the user experience.

[0072] The specific material type of the covering layer 20 is not limited.

[0073] In some embodiments, the cover layer 20 is a thermoplastic resin, and the viscous flow temperature of the thermoplastic matrix in the fiber thermoplastic composite layer 10 is within the range of the glass transition temperature and viscous flow temperature of the cover layer 20.

[0074] In other words, during the process of heating and forming the blank of the body frame 100, the body frame 100 can be heated to a preset temperature. The preset temperature is higher than the viscous flow temperature of the thermoplastic matrix in the fiber thermoplastic composite layer 10 and lower than the viscous flow temperature of the cover layer 20, so that the thermoplastic matrix in the fiber thermoplastic composite layer 10 is in a viscous flow state, while the cover layer 20 is in a highly elastic state.

[0075] Thus, the high elasticity of the cover layer 20 facilitates deformation, allowing the cover layer 20 to be molded synchronously with the fiber thermoplastic composite layer 10 to meet the finished shape requirements of the vehicle frame 100; the high elasticity of the cover layer 20 has a certain structural strength, which helps to constrain the movement of the fiber 11.

[0076] In some embodiments, the thermoplastic matrix in the fiber thermoplastic composite layer 10 is PP, and the cover layer 20 is PC or PET.

[0077] PP (Polypropylene) is a thermoplastic. It has high impact resistance, strong mechanical properties, and can resist corrosion from various organic solvents and acids and alkalis. The viscous flow temperature range of PP is 164℃ to 170℃.

[0078] PC (Polycarbonate) has good heat resistance and impact resistance. The glass transition temperature of PC ranges from 145°C to 150°C, and the viscous flow temperature ranges from 220°C to 230°C.

[0079] PET (Polyethylene terephthalate) has a smooth and glossy surface, good creep resistance, fatigue resistance, and abrasion resistance, and good toughness. The glass transition temperature range of PET is 70℃ to 80℃, and the viscous flow temperature range is 265℃ to 280℃.

[0080] In this way, during the heating and deformation of the vehicle frame 100, the cover layer 20 is in a highly elastic state, which is conducive to deformation and maintains a certain structural strength to constrain the movement of the fibers 11.

[0081] In some embodiments, the cover layer 20 is made of a metallic material.

[0082] This gives the cover layer 20 a certain degree of extensibility, which makes it easy for the cover layer 20 and the fiber thermoplastic composite layer 10 to be molded simultaneously during the manufacturing process of the body frame 100, so as to meet the finished shape requirements of the body frame 100; the metal material has a high melting point and high structural strength, which can better constrain the movement of the fiber 11.

[0083] In some embodiments, the thermoplastic matrix in the fiber thermoplastic composite layer 10 is one of PP, PC or PET, and the cover layer 20 is aluminum alloy.

[0084] This allows the melting point of the cover layer 20 to be higher than the viscous flow temperature of the thermoplastic matrix in the fiber thermoplastic composite layer 10, and the cover layer 20 has high structural strength and low density, which is beneficial to the overall lightweighting of the vehicle frame 100.

[0085] Understandably, the cover layer 20 can cover at least a portion of the outer surface of the fiber thermoplastic composite layer 10 in the form of aluminum foil.

[0086] In some embodiments, see Figure 2 The dimensions of the cover layer 20 along the stacking direction of the fiber thermoplastic composite layer 10 and the cover layer 20 range from 0.1 mm (millimeters) to 1 mm. That is, the dimension of the cover layer 20 along the stacking direction of the fiber thermoplastic composite layer 10 and the cover layer 20 is L1, where 0.1 mm ≤ L1 ≤ 1 mm.

[0087] This helps to ensure that the covering layer 20 has sufficient structural strength, reducing the probability that the fibers 11 will pass through the covering layer 20 and be exposed on the outer surface of the vehicle frame 100.

[0088] In some embodiments, see Figure 2 The dimensions of the cover layer 20 along the stacking direction of the fiber thermoplastic composite layer 10 and the cover layer 20 range from 0.15 mm to 0.5 mm. That is, 0.15 mm ≤ L1 ≤ 0.5 mm.

[0089] This helps to ensure that the covering layer 20 has sufficient structural strength, and further helps to reduce the probability that the fibers 11 pass through the covering layer 20 and are exposed on the outer surface of the vehicle frame 100.

[0090] The specific dimensions of the cover layer 20 along the stacking direction of the fiber thermoplastic composite layer 10 and the cover layer 20 can be 0.1mm, 0.15mm, 0.2mm, 0.25mm, 0.3mm, 0.35mm, 0.4mm, 0.45mm, 0.5mm, 0.6mm, 0.7mm, 0.8mm, 0.9mm, 1mm, etc.

[0091] In some embodiments, see Figure 3 The vehicle frame 100 also includes an adhesive layer 30, which is located between the fiber thermoplastic composite layer 10 and the cover layer 20 to bond the two together.

[0092] Thus, using adhesive bonding helps to keep the relative position between the fiber thermoplastic composite layer 10 and the covering layer 20 fixed, reducing the risk of fiber 11 being exposed due to displacement of the two.

[0093] In some embodiments, the melting temperature of the adhesive layer 30 is lower than the viscous flow temperature of the thermoplastic matrix in the fiber thermoplastic composite layer 10.

[0094] This allows the adhesive layer 30 to melt and flow during the heating and shaping of the body frame 100, so that after subsequent cooling, the adhesive layer 30 can maintain contact with the fiber thermoplastic composite layer 10 and the cover layer 20.

[0095] In some embodiments, see Figure 3 The dimension of the adhesive layer 30 along the stacking direction of the fiber thermoplastic composite layer 10 and the cover layer 20 ranges from 0.05 mm to 0.1 mm, that is, the dimension of the adhesive layer 30 along the stacking direction of the fiber thermoplastic composite layer 10 and the cover layer 20 is L2, 0.05 mm ≤ L2 ≤ 0.1 mm. This ensures that the adhesive layer 30 has sufficient adhesive force to fix the fiber thermoplastic composite layer 10 and the cover layer 20 relatively.

[0096] The specific dimensions of the adhesive layer 30 along the stacking direction of the fiber thermoplastic composite layer 10 and the cover layer 20 can be 0.05mm, 0.06mm, 0.07mm, 0.08mm, 0.09mm, 0.1mm, etc.

[0097] The specific material of the adhesive layer 30 is not limited. For example, in some embodiments where the thermoplastic matrix in the fiber thermoplastic composite layer 10 is PP, the adhesive layer 30 is a PP hot melt agent.

[0098] In some embodiments, see Figure 2 , Figure 3and Figure 4 At least a portion of the first region 100a protrudes outward toward the outer side of the vehicle frame 100, and the cover layer 20 is located on one side of the protruding direction of the fiber thermoplastic composite layer 10.

[0099] Understandably, the fibers 11 in the fiber thermoplastic composite layer 10 of the protruding part of the body frame 100 are more likely to be exposed to the surface of the fiber thermoplastic composite layer 10.

[0100] This helps the covering layer 20 to shield the fibers 11 in the protruding area, thereby improving the surface quality of the outer surface of the vehicle frame 100.

[0101] In some embodiments, the fiber thermoplastic composite layer 10 is a continuous fiber composite material.

[0102] Continuous fiber composites are composite materials made by embedding continuous fibers within a matrix material. The continuous fibers provide high strength and high stiffness, while the matrix material helps to transfer loads and distribute stress between the fibers.

[0103] The types of continuous fibers in continuous fiber composites can be carbon fiber, glass fiber, aramid fiber, basalt fiber, and ceramic fiber, etc.

[0104] In some embodiments, the fiber thermoplastic composite layer 10 includes multiple layers of continuous fiber composite material, each layer of continuous fiber composite material including continuous fibers and a thermoplastic matrix, with the continuous fibers embedded in the thermoplastic matrix.

[0105] It is understandable that the layers of multilayer continuous fiber composite materials are stacked together.

[0106] In some embodiments, the thickness of the single-layer continuous fiber composite layer is 0.2 mm to 0.3 mm.

[0107] In this way, on the one hand, the risk of insufficient structural strength and stiffness of the single-layer continuous fiber composite material due to excessively low thickness of the single-layer continuous fiber composite material layer is reduced; on the other hand, the problem of excessive thickness of the fiber thermoplastic composite layer 10 during the laying of multi-layer continuous fiber composite layers is reduced.

[0108] The specific values ​​for the thickness of a single-layer continuous fiber composite material layer can be 0.2mm, 0.22mm, 0.24mm, 0.25mm, 0.26mm, 0.28mm, 0.3mm, etc.

[0109] In some embodiments, the continuous fibers of each continuous fiber composite layer are laid in a unidirectional direction, and the laying angle of the continuous fibers of adjacent continuous fiber composite layers is different.

[0110] This is beneficial for improving the stress distribution of the fiber thermoplastic composite layer 10, and for ensuring that the mechanical properties of the fiber thermoplastic composite layer 10 are approximately the same in different directions, thereby reducing the risk of reduced service life due to differences in the mechanical properties of the fiber thermoplastic composite layer 10 in a certain direction.

[0111] The laying angle of the continuous fibers between the layers of a multilayer continuous fiber composite material can be 0°, 45°, 90°, -45°, etc.

[0112] The specific method of manufacturing the vehicle body frame 100 is not limited. In an embodiment where the thermoplastic matrix in the fiber thermoplastic composite layer 10 is PP and the cover layer 20 is one of PC, PET, and aluminum alloy, the blank of the vehicle body frame 100 formed by stacking the fiber thermoplastic composite layer 10, the adhesive layer 30, and the cover layer 20 is heated to 180°C to 210°C to melt the thermoplastic matrix in the fiber thermoplastic composite layer 10 and transform it into a viscous flow state. Then, the blank of the vehicle body frame 100 is extruded through a mold to form the desired shape and cooled to form the finished vehicle body frame 100.

[0113] In some embodiments, see Figure 2 and Figure 3 A cavity 10a is provided on the side of the fiber thermoplastic composite layer 10 facing the inside of the vehicle 1000.

[0114] Thus, by forming the cavity 10a, it is beneficial to improve the overall structural strength and stiffness of the fiber thermoplastic composite layer 10.

[0115] In some embodiments, the cavity 10a is open toward the inside of the vehicle 1000.

[0116] In some embodiments where the cavity 10a is open toward the inside of the vehicle 1000, see [reference]. Figure 3 A portion of the covering layer 20 covers at least a portion of the inner wall of the cavity 10a.

[0117] In other words, at least a portion of the inner wall of the cavity 10a can form the interior surface of the vehicle 1000.

[0118] Thus, the surface quality of the interior surfaces of the vehicle 1000 can be improved through the covering layer 20.

[0119] In some embodiments, see Figure 4 The vehicle frame 100 also includes a reinforcing structure 40, at least a portion of which is disposed within the cavity 10a to enhance the strength of the fiber thermoplastic composite layer 10.

[0120] At least part of the reinforcing structure 40 is located within the cavity 10a, which facilitates the use of the space in the cavity 10a, improves the space utilization rate of the vehicle frame 100, and reduces the probability of installation interference between the reinforcing structure 40 and other structures inside the vehicle 1000.

[0121] The reinforcing structure 40 can suppress the deformation of the fiber thermoplastic composite layer 10, thereby helping to improve the overall strength of the vehicle frame 100.

[0122] It is understandable that the reinforcing structure 40 and the fiber thermoplastic composite layer 10 can form a force transmission path between them through direct contact or by connection through other components, so that the force load borne by the fiber thermoplastic composite layer 10 can be transferred to the reinforcing structure 40.

[0123] In some embodiments, see Figure 4 The reinforcing structure 40 is a fiber 11 thermoplastic composite material, and a portion of the cover layer 20 covers at least a portion of the surface of the reinforcing structure 40 on the side facing the inside of the vehicle 1000. The melting temperature of the material of the cover layer 20 is higher than the viscous flow temperature of the thermoplastic material of the reinforcing structure 40.

[0124] The reinforcing structure 40 forms at least a portion of the interior surface of the vehicle 1000 on one side facing the inside of the vehicle 1000.

[0125] Thus, the covering layer 20 can constrain and shield the fibers 11 within the reinforcing structure 40, which helps to improve the overall appearance quality of the vehicle body frame 100.

[0126] It is understandable that the blank of the reinforced structure 40 is heated and then molded to form the desired shape.

[0127] It is understandable that the type of fiber 11 thermoplastic composite material used in the reinforcing structure 40 and the type of fiber thermoplastic composite material used in the fiber thermoplastic composite layer 10 may be the same or different.

[0128] In some embodiments, the cover layer 20 is a thermoplastic resin, and the viscous flow temperature of the thermoplastic matrix in the reinforcing structure 40 is within the range of the glass transition temperature and viscous flow temperature of the cover layer 20.

[0129] In this way, during the heating and forming process of the blank of the reinforcing structure 40, the covering layer 20 maintains a certain structural strength to constrain the position of the fiber 11 and helps to reduce the probability of the fiber 11 passing through the covering layer 20.

[0130] In some embodiments, the thermoplastic matrix in the reinforcing structure 40 is PP, and the cover layer 20 is PC or PET.

[0131] In some embodiments, the thermoplastic matrix in the reinforcing structure 40 is one of PP, PC or PET, and the cover layer 20 is an aluminum alloy.

[0132] In some embodiments, see Figure 4 A portion of the cover layer 20 is located between the reinforcing structure 40 and the fiber thermoplastic composite layer 10.

[0133] Thus, the covering layer 20 can reduce the risk of fiber 11 breakage due to friction between the reinforcing structure 40 and the fiber thermoplastic composite layer 10, which is beneficial to extending the service life of the vehicle frame 100.

[0134] A specific embodiment of the vehicle frame 100 in this application is as follows:

[0135] A vehicle body frame 100 is provided for forming a vehicle 1000. The outer surface of the vehicle body frame 100 includes at least one curved surface or at least two intersecting planes. The vehicle body frame 100 includes a fiber thermoplastic composite layer 10, an adhesive layer 30, and a cover layer 20. The cover layer 20 at least covers at least a portion of the outer surface of the fiber thermoplastic composite layer 10, and the side surface of the cover layer 20 opposite to the continuous fiber composite layer forms at least a portion of the outer surface of the vehicle body frame 100. The melting temperature of the cover layer 20 is higher than the viscous flow temperature of the thermoplastic matrix of the fiber thermoplastic composite layer 10. The thermoplastic matrix in the fiber thermoplastic composite layer 10 is PP, and the cover layer 20 is one of PC, PET, and aluminum alloy. The dimension of the cover layer 20 along the stacking direction of the fiber thermoplastic composite layer 10 and the cover layer 20 ranges from 0.1 mm to 1 mm. An adhesive layer 30 is located between the fiber thermoplastic composite layer 10 and the cover layer 20 to bond the two together. The melting temperature of the adhesive layer 30 is lower than the viscous flow temperature of the thermoplastic matrix in the fiber thermoplastic composite layer 10. At least a portion of the outer surface of the vehicle frame 100 protrudes outward toward the outside of the vehicle frame 100, and the cover layer 20 is located on one side of the fiber thermoplastic composite layer 10 in the protruding direction. A cavity 10a is provided on the side of the fiber thermoplastic composite layer 10 facing inward toward the vehicle 1000. At least a portion of the reinforcing structure 40 is provided within the cavity 10a to enhance the strength of the fiber thermoplastic composite layer 10. The reinforcing structure 40 is a fiber thermoplastic composite material, and a portion of the cover layer 20 covers at least a portion of the surface of the reinforcing structure 40 facing inward toward the vehicle 1000. The melting temperature of the material of the cover layer 20 is higher than the viscous flow temperature of the thermoplastic material of the reinforcing structure 40. A portion of the cover layer 20 is located between the reinforcing structure 40 and the fiber thermoplastic composite layer 10.

[0136] This application embodiment also provides a vehicle 1000, which includes a chassis 400 and a body frame 100 as described in any of the foregoing embodiments, with the body frame 100 disposed on the chassis 400.

[0137] By adopting the vehicle body frame 100 in the aforementioned embodiments, it is beneficial to improve the surface quality of the exterior and interior surfaces of the vehicle 1000, thereby enhancing the user experience.

[0138] In some embodiments, the vehicle frame 100 and the chassis 400 are welded together.

[0139] In other embodiments, the vehicle frame 100 can be detachably connected to the chassis 400, in which case the chassis 400 is a skateboard chassis 400 integrating the three-electric system. This chassis 400 configuration achieves separation and decoupling between the vehicle frame 100 and the chassis 400, allowing the vehicle frame 100 to be replaced as needed, shortening the development cycle and reducing costs. In other words, it also increases the integration of the chassis 400, making it adaptable to various vehicle models.

[0140] For example, the body frame 100 and the chassis 400 are detachably connected by fasteners.

[0141] In some embodiments, the fastener may include at least one of bolts, studs, and screws.

[0142] See Figure 1 and Figure 5 A battery device 410 is installed inside the chassis 400. The battery device 410 can be located in the middle, front, or rear of the chassis 400. The battery device 410 can be used to power the vehicle 1000; for example, the battery device 410 can serve as the operating power source or power source for the vehicle 1000. The vehicle 1000 may also include a controller 200 and a motor 300. The controller 200 is used to control the battery device 410 to supply power to the motor 300, for example, to meet the power needs of the vehicle 1000 during starting, navigation, and driving.

[0143] The various embodiments / implementations provided in this application can be combined with each other without creating contradictions.

[0144] The above are merely preferred embodiments of this application and are not intended to limit the embodiments in this application. For those skilled in the art, the embodiments of this application can have various modifications and variations. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the embodiments of this application should be included within the protection scope of the embodiments of this application.

Claims

1. A vehicle body frame for forming a vehicle, characterized in that, The outer surface of the vehicle frame includes a first region, the first region including at least one curved surface or at least two intersecting planes, the vehicle frame comprising: Fiber thermoplastic composite layer; A covering layer that at least partially covers the outer surface of the fiber thermoplastic composite layer, wherein the side surface of the covering layer opposite to the fiber thermoplastic composite layer forms at least a portion of the first region of the vehicle frame; The melting temperature of the covering layer is higher than the viscous flow temperature of the thermoplastic matrix of the fiber thermoplastic composite layer.

2. The vehicle frame according to claim 1, characterized in that, The covering layer covers at least a portion of the outer surface of the fiber thermoplastic composite layer facing the outside of the vehicle; And / or, the covering layer covers at least a portion of the outer surface of the fiber thermoplastic composite layer facing the inside of the vehicle.

3. The vehicle frame according to claim 1, characterized in that, The covering layer is a thermoplastic resin, and the viscous flow temperature of the thermoplastic matrix in the fiber thermoplastic composite layer is within the range of the glass transition temperature and viscous flow temperature of the covering layer.

4. The vehicle frame according to claim 1, characterized in that, The thermoplastic matrix in the fiber thermoplastic composite layer is PP, and the cover layer is PC or PET.

5. The vehicle frame according to claim 1, characterized in that, The covering layer is made of metallic material.

6. The vehicle frame according to claim 1, characterized in that, The thermoplastic matrix in the fiber thermoplastic composite layer is one of PP, PC or PET, and the covering layer is aluminum alloy.

7. The vehicle frame according to claim 1, characterized in that, The dimensions of the cover layer along the stacking direction of the fiber thermoplastic composite layer and the cover layer range from 0.1 mm to 1 mm.

8. The vehicle frame according to claim 1, characterized in that, The dimensions of the cover layer along the stacking direction of the fiber thermoplastic composite layer and the cover layer range from 0.15 mm to 0.5 mm.

9. The vehicle frame according to claim 1, characterized in that, The vehicle frame also includes an adhesive layer located between the fiber thermoplastic composite layer and the cover layer to bond the two together, wherein the melting temperature of the adhesive layer is lower than the viscous flow temperature of the thermoplastic matrix in the fiber thermoplastic composite layer.

10. The vehicle frame according to claim 1, characterized in that, At least a portion of the first region protrudes outward toward the outer side of the vehicle frame, and the covering layer is located on one side of the protruding direction of the fiber thermoplastic composite layer.

11. The vehicle frame according to any one of claims 1-10, characterized in that, The fiber thermoplastic composite layer has a cavity on the side facing the inside of the vehicle.

12. The vehicle frame according to claim 11, characterized in that, The vehicle frame also includes a reinforcing structure, at least part of which is disposed within the cavity to enhance the strength of the fiber thermoplastic composite layer.

13. The vehicle frame according to claim 12, characterized in that, The reinforcing structure is a fiber thermoplastic composite material, and a portion of the covering layer covers at least a portion of the surface of the reinforcing structure on the side facing the inside of the vehicle. The melting temperature of the material of the covering layer is higher than the viscous flow temperature of the thermoplastic material of the reinforcing structure.

14. The vehicle frame according to claim 12, characterized in that, A portion of the cover layer is located between the reinforcing structure and the fiber thermoplastic composite layer.

15. A vehicle, characterized in that, The vehicle includes a chassis and a body frame as described in any one of claims 1-14, the body frame being mounted on the chassis.

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