Outer panel of a vehicle door

Abstract

Outer panel of a vehicle door, characterized in that it comprises: an inner surface section which is a thermoplastic resin component; a middle reinforcement section, one side of which is connected to the inner surface section, wherein the middle reinforcement section is a continuously fiber-reinforced thermoplastic composite component; and an outer surface section which is connected to the other side of the middle reinforcement section, wherein the outer surface section is a thermoplastic resin component.

Description

TECHNICAL AREA The present invention belongs to the technical field of motor vehicle components and relates to an outer panel of a vehicle door. STATE OF THE ART The outer panel of a vehicle door is a crucial component of the car's interior. Currently available polypropylene injection-molded outer panels have low inherent rigidity and poor dent resistance. When used by the customer, they are susceptible to kick damage, scratches, or scuffs that leave white marks, and their scratch resistance is inadequate. Furthermore, the entire outer door panel is heavy. Under the influence of high and low temperatures, it deforms considerably, making it difficult to check gaps and surface tolerances on the side of the vehicle. In severe cases, this can prevent the door from opening or closing properly.Exterior panels made exclusively from composite materials such as carbon or glass fibers typically have a carbon fiber look and cannot meet the requirements for painted vehicle colors, resulting in a limited selection of surface treatments. In summary, the existing outer panels of vehicle doors each exhibit corresponding defects and thus offer considerable scope for improvement. CONTENT OF THE PRESENT INVENTION As a solution to the aforementioned disadvantage of the existing technology, the present invention aims to provide an outer panel for a vehicle door. Technical solution The purpose of the present invention is to propose an outer panel for a vehicle door, taking into account the aforementioned problems of the prior art. The purpose of the present invention can be achieved by the following technical solutions: an outer panel for a vehicle door comprising: an inner surface section, which is a thermoplastic resin component; a central reinforcement section, one side of which is connected to the inner surface section, wherein the central reinforcement section is a continuously fiber-reinforced thermoplastic composite component; and an outer surface section, which is connected to the other side of the central reinforcement section, wherein the outer surface section is a thermoplastic resin component. In the aforementioned outer panel of a vehicle door, the outer surface section and the middle reinforcement section are formed in one piece by compression molding and subsequent overmolding. In the aforementioned outer panel of a vehicle door, the inner surface section is formed using the insert injection molding process. In the aforementioned outer panel of a vehicle door, both the inner surface section and the outer surface section are polypropylene components. In the aforementioned outer panel of a vehicle door, the end of the inner surface section is bent towards the outer surface section, thus connecting it to the outer surface section and forming a locking section that holds back the end of the middle reinforcement section. In the aforementioned outer panel of a vehicle door, the end of the outer surface section extends and protrudes beyond the locking section, thus forming a thin-walled section. In the aforementioned outer panel of a vehicle door, the locking section and the thin-walled section are located to the side or below the outer panel. In the aforementioned outer panel of a vehicle door, the thickness of the inner surface section is 0.8 mm to 2.5 mm, the thickness of the middle reinforcement section is 0.6 mm to 1.2 mm, and the thickness of the outer surface section is 0.8 mm to 2.5 mm. In the aforementioned outer panel of a vehicle door, the inner surface section is designed as a stiffening rib, wherein the stiffening rib comprises several reinforcing heads, wherein the reinforcing heads comprise a connecting section, and wherein the reinforcing heads are connected to the central reinforcing section via the connecting section. In the aforementioned outer panel of a vehicle door, the connecting section is joined to the central reinforcement section by gluing or welding. In the aforementioned outer panel of a vehicle door, the thickness of the outer surface section is 2.0 mm to 3.0 mm, the thickness of the middle reinforcement section is 0.1 mm to 1.2 mm, and the thickness of the connecting section is 1.5 mm to 3 mm. In the aforementioned outer panel of a vehicle door, the reinforcing heads further comprise a projection, wherein the projection is integrally connected to the connecting section and protrudes from the connecting section. In the aforementioned outer panel of a vehicle door, a connecting cross-sectional area at a connection point between the connecting section and the projection is smaller than a connecting cross-sectional area at a connection point between the connecting section and the central reinforcing section, wherein the cross-sectional area of ​​the connecting section gradually decreases from the central reinforcing section towards the projection. In the aforementioned outer panel of a vehicle door, it further comprises an appearance section, wherein the appearance section is connected to a side of the outer surface section facing away from the central reinforcing section, and wherein the appearance section is a paint layer. In the aforementioned outer panel of a vehicle door, it further comprises an appearance section, wherein the appearance section is connected to a side of the outer surface section facing away from the central reinforcement section, wherein the appearance section is a polyurethane component. In the aforementioned outer panel of a vehicle door, it further comprises an appearance section consisting of two layers, namely a polyurethane layer and a paint layer, wherein the polyurethane layer is connected to a side of the outer surface section facing away from the central reinforcement section and the paint layer is arranged on the outer surface of the polyurethane layer. Beneficial effect Compared to the prior art, the advantageous effects of the present invention are as follows: 1. This outer panel of the vehicle door can be sprayed with body paint, effectively solving the difficulty of spraying composite outer panels. Furthermore, the door's rigidity can be significantly increased by improving the dent resistance of the outer panel and the overall performance of the door, thus increasing its overall strength. This allows for better management of the outer panel's deformation problem due to temperature fluctuations. The material used consists of thermoplastic resin components and continuously fiber-reinforced thermoplastic composite components and is recyclable. 2.The condition in which the outer surface section and the middle reinforcement section are formed together in one piece by compression molding and subsequent overmolding is used as an insert and joined to the inner surface section by the insert injection molding process to form the outer panel of a vehicle door. This allows for a simple manufacturing process and ensures a strong bond between the three components. 3. The end of the inner surface section is bent towards and joined to the outer surface section, forming a locking section that retains the end of the middle reinforcement section. The locking section can cover the middle reinforcement section to prevent it from being exposed and difficult to spray. 4. In the edge region of the outer panel of a vehicle door, the thickness should be appropriately reduced within a range of approximately 20 mm to 30 mm from the boundary.The end of the outer surface section extends and projects beyond the locking section, forming a thin-walled section. This structure primarily addresses the door's movement control to ensure its normal opening and closing functions. 5. The stiffening rib structure differs from the integral reinforcement layer or reinforcement plate structure. It was iteratively optimized based on computer fluid dynamics and thermal deformation analysis results, resulting in a locally recessed structure on the back of the entire central reinforcement section to achieve further weight reduction. 6.The projection can reinforce the outer panel of a vehicle door, with the cross-sectional area of ​​the connection at a junction between the connecting section and the projection being smaller than the cross-sectional area of ​​the connection at a junction between the connecting section and the central reinforcing section. This allows the connecting section to increase the connection strength between the reinforcing head and the central reinforcing section. 7. The cross-sectional area of ​​the connecting section extending from the central reinforcing section to the projection gradually decreases, thereby reducing the areas with an overall thicker wall thickness of the central reinforcing section. This reduces the local surface indentations caused by the reinforcing rib. 8. The appearance consists of two layers: a polyurethane layer and a paint layer, which can address specific color issues. BRIEF DESCRIPTION OF THE DRAWING Fig. 1 is a schematic structure diagram of an embodiment of the present invention. Fig. 2 shows a view of Fig. 1 in the P direction. Fig. 3 is a schematic representation of the section in the AA viewing direction of Fig. 2. Fig. 4 shows an enlarged view of section D in Fig. 3. Fig. 5 shows an enlarged view of section E in Fig. 3. Fig. 6 is a schematic representation of the section in the BB viewing direction of Fig. 2. Fig. 7 is a schematic representation of the section in the CC viewing direction of Fig. 2. Fig. 8 is a schematic structure diagram of an embodiment of the present invention. Fig. 9 is an exploded view of an embodiment of the present invention. Fig. 10 is a schematic representation of the structure of Fig. 9. Fig. 11 is a schematic representation of the section in the FF viewing direction of Fig. 10. Fig. 12 is a schematic structure diagram of an embodiment of the present invention.Figure 13 is a schematic structure diagram of an embodiment of the present invention. Figure 14 is a schematic structure diagram of an embodiment of the present invention. Figure 15 is a schematic structure diagram of an embodiment of the present invention. In the figure: 100, inner surface section; 110, barrier section; 120, stiffening rib; 121, connecting section; 122, projection; 200, central reinforcement section; 300, outer surface section; 310, thin-walled section; 400, appearance section; polyurethane layer 401; paint layer 402. DETAILED DESCRIPTION Specific embodiments of the present invention are described below with reference to the accompanying drawings in order to further explain the technical solution of the present invention. However, the present invention is not limited to these embodiments. It should be noted that all directional terms in the embodiments of this utility model application (such as above, below, left, right, front, back, etc.) serve only to explain the relative positions and movements between the individual components in a specific orientation (as shown in the drawings). If this specific orientation is changed, the directional terms change accordingly. Furthermore, in the present invention, descriptions such as "first," "second," or "one" serve purely descriptive purposes and must not be understood as indicating or suggesting their relative importance or as implicitly specifying the number of the designated technical features. Therefore, features designated as "first," "second," etc., may expressly or implicitly include at least one such feature. In the description of the present invention, "several" means at least two, for example, two, three, etc., unless expressly and specifically defined otherwise. In the present invention, unless expressly specified and defined otherwise, the terms "connect" and "fasten," etc., are to be understood broadly. For example, "fasten" may mean a permanent connection, a detachable connection, or an integral design; it may be a mechanical connection or an electrical connection; the connection may be direct or indirect via an intermediate medium; it may denote the internal continuity between two components or the interaction between two components, unless expressly defined otherwise. For a person skilled in the art, the specific meaning of the above terms within the scope of this invention may be understood depending on the specific circumstances. Furthermore, the technical solutions of the various embodiments of the present invention can be combined with one another. However, this requires that a person skilled in the relevant field is able to implement the combination. If the combination of the technical solutions results in contradictions or is not feasible, it must be assumed that such a combination of technical solutions does not exist and is not within the scope of protection of the present invention. The specific embodiments described in this text serve only as examples to illustrate the spirit of the present invention. Those skilled in the art in the field to which this invention belongs may make various modifications or additions to the described specific embodiments or apply similar methods of substitution without, however, departing from the spirit of this invention or exceeding the scope defined by the appended claims. As shown in Fig. 1, Fig. 2, Fig. 3, Fig. 4, Fig. 5, Fig. 6 to Fig. 7, an outer panel of a vehicle door comprises an inner surface section 100, a middle reinforcement section 200 and an outer surface section 300. The inner surface section 100 is a thermoplastic resin component. Specifically, the thickness of inner surface section 100 is 0.8 mm - 2.5 mm. Specifically, inner surface section 100 is a polypropylene component. In this case, one side of the middle reinforcement section 200 is connected to the inner surface section 100; the middle reinforcement section 200 is a continuously fiber-reinforced thermoplastic composite component. Specifically, the thickness of the central reinforcement section 200 is 0.6 mm - 1.2 mm. The outer surface section 300 is connected to the other side of the central reinforcement section 200, and the outer surface section 300 is a thermoplastic resin component. Specifically, the thickness of outer surface section 300 is 0.8 mm - 2.5 mm. Specifically, outer surface section 300 is a polypropylene component. In this embodiment, the outer panel of the vehicle door can be sprayed with body paint, effectively overcoming the difficulties associated with spraying composite outer panels. Furthermore, the door's rigidity can be significantly improved by increasing the dent resistance of the outer panel and the overall performance of the door, thus enhancing its overall strength. This helps to better manage the deformation problem of the outer panel due to temperature fluctuations. The material used consists of thermoplastic resin components and fiber-reinforced thermoplastic composites and is recyclable. As shown in Fig. 1, Fig. 2, Fig. 3, Fig. 4, Fig. 5, Fig. 6 to Fig. 7, based on the above-mentioned embodiment, the outer surface section 300 and the central reinforcement section 200 are formed in one piece by compression molding and subsequent overmolding. In this embodiment, the outer surface section 300 and the central reinforcement section 200 are formed together in one piece by compression molding and subsequent overmolding, which enables a simple manufacturing process and ensures a firm connection between the two. As shown in Fig. 1, Fig. 2, Fig. 3, Fig. 4, Fig. 5, Fig. 6 to Fig. 7, the inner surface section 100 is formed in an insert injection molding process based on the above-mentioned embodiment. In this embodiment, the condition in which the outer surface section 300 and the central reinforcing section 200 are formed together in one piece by compression molding and subsequent overmolding is used as an insert and joined to the inner surface section 100 by the insert injection molding process to form the outer panel of a vehicle door. This enables a simple manufacturing process and ensures a strong connection between the three components. As shown in Figures 1, 2, 3, 4, 5, 6 to 7, based on the embodiment described above, the end of the inner surface section 100 is bent towards the outer surface section 300 and connected to it, thereby forming a locking section 110 that retains the end of the central reinforcing section 200. In this embodiment, the thickness of the outer panel of a vehicle door should be appropriately reduced in the edge region, within a range of approximately 20 mm to 30 mm from the boundary. The end of the outer surface section 300 extends and projects beyond the locking section 110, thereby forming a thin-walled section 310. This structure primarily serves to control the door's movement in order to ensure its normal opening and closing functions. As shown in Fig. 1, Fig. 2, Fig. 3, Fig. 4, Fig. 5, Fig. 6 to Fig. 7, based on the embodiment mentioned above, the end of the outer surface section 300 extends and projects beyond the barrier section 110, thereby forming a thin-walled section 310. In this embodiment, the thickness of the outer sheet metal of a vehicle door should be appropriately reduced in the edge region, within a range of approximately 20 mm to 30 mm from the boundary. The end of the outer surface section 300 extends and projects beyond the locking section 110, thereby forming a thin-walled section 310. This structure primarily addresses the movement control of the door to ensure its normal opening and closing functions. It is worth noting that the locking section 110 and the thin-walled section 310 are located laterally or below the outer panel of the vehicle door, specifically for the front, rear, and lower regions of the outer panel to ensure the door's normal opening and closing function. As shown in Fig. 8, based on the embodiment described above, it further comprises an appearance section 400, wherein the appearance section 400 is connected to a side of the outer surface section 300 facing away from the central reinforcement section 200. The appearance section 400 can be divided into two forms. The first form consists in which the appearance section 400 is a paint layer, i.e., a direct paint finish in body color on the outer surface 300; the thickness of the paint layer can be 50–75 µm, with 60 µm being optimal. The second form consists in which the appearance section 400 is a polyurethane component, i.e., a polyurethane component finished in body color, which is attached to the outer surface 300 and can also be referred to as a PUR layer. If the appearance section 400 is a polyurethane component, the thickness is 0.25–0.7 mm, with 0.5 mm being optimal. As shown in Figs. 9, 10 to 11, an outer panel of a vehicle door comprises an inner surface section 100, a middle reinforcement section 200 and an outer surface section 300. The inner surface section 100 is a thermoplastic resin component. Specifically, the inner surface section 100 is designed as a stiffening rib 120, wherein the stiffening rib 120 comprises several reinforcing heads, the reinforcing heads comprising a connecting section 121, and wherein the reinforcing heads are connected to the central reinforcing section 200 via the connecting section 121. Specifically, the stiffening rib 120 is a polypropylene component. Specifically, the thickness of the connecting section 121 is 1.5 mm - 3 mm. In practical application, it is optimal to optimize the connection section 301 to 2.5 mm. In this case, one side of the middle reinforcement section 200 is connected to the inner surface section 100; the middle reinforcement section 200 is a continuously fiber-reinforced thermoplastic composite component. Specifically, the thickness of the middle reinforcement section is 200 0.1 mm - 1.2 mm. In practical application, it is optimal to optimize the middle reinforcement section 200 to 0.2 mm. The outer surface section 300 is connected to the other side of the middle reinforcement section 200, wherein the outer surface section 300 is a thermoplastic resin component. Specifically, the thickness of the outer surface section 300 is 2.0 mm - 3.0 mm. In practical application, it is optimal to optimize the outer surface section 300 to 2.2 mm. Specifically, the outer surface section 300 is a polypropylene component. It should be noted that the structure of the stiffening rib 120 in this embodiment differs from the reinforcing layer or reinforcing plate structure in the embodiments shown in Figs. 1, 2, 3, 4, 5, 6 to 7. The reinforcing layer or reinforcing plate is an integral structure, whereas the stiffening rib 120 was iteratively optimized primarily based on the results of computational fluid dynamics (CFD) and thermal deformation (TDD) analysis. This corresponds to a locally recessed structure on the back side of the entire central reinforcing section 200, resulting in a further weight reduction. As shown in Fig. 12, the reinforcing heads based on the above embodiment further comprise a projection 122, wherein the projection 122 is integrally connected to the connecting section 121 and protrudes from the connecting section 121. In this embodiment, the projection 122 can reinforce the outer panel of a vehicle door, wherein a connecting cross-sectional area at a connection point between the connecting section 121 and the projection 122 is smaller than a connecting cross-sectional area at a connection point between the connecting section 121 and the central reinforcing section 200, so that the connecting section 121 can increase the connection strength between the reinforcing head and the central reinforcing section 200. As shown in Fig. 13, based on the above embodiment, a connection cross-sectional area at a connection point between the connection section 121 and the projection 122 is smaller than a connection cross-sectional area at a connection point between the connection section 121 and the central reinforcement section 200, wherein a cross-sectional area of ​​the connection section 121 gradually decreases from the central reinforcement section 200 towards the projection 122. In this embodiment, the cross-sectional area of ​​the connecting section 121, which extends from the central reinforcing section 200 to the projection 122, gradually decreases. This reduces the areas with an overall thicker wall thickness of the central reinforcing section 200 and thus reduces the local surface indentations caused by the stiffening rib 120. As shown in Fig. 14, based on the embodiment described above, it further comprises an appearance section 400, wherein the appearance section 400 is connected to a side of the outer surface section 300 facing away from the central reinforcement section 200. The appearance section 400 can be divided into two forms. The first form consists of the appearance section 400 being a paint layer, i.e., a direct paint finish in body color on the outer surface 300, wherein the thickness of the paint layer is 50–75 µm, specifically optimized to 60 µm. The second form consists of the appearance section 400 being a polyurethane component optimized in body color, i.e., a polyurethane component designed in body color and attached to the outer surface 300. If the appearance section 400 is a polyurethane component, the thickness is 0.3 mm–0.7 mm, specifically optimized to 0.5 mm. As shown in Fig. 15, to better achieve color matching of the body, an appearance section is also included. This appearance section consists of two layers: a polyurethane layer 401 and a paint layer 402. The use of a single polyurethane layer is not possible with certain colors; therefore, after injection molding the polyurethane layer 401 in the mold, the paint layer 402 is additionally applied to its outer surface. The polyurethane layer is the polyurethane component. The polyurethane layer is bonded to the side of the outer surface section 300 that faces away from the central reinforcement section. The paint layer 402 is located on the outer surface of the polyurethane layer 401. The thickness of the polyurethane layer 401 is 0.3 mm to 0.7 mm, ideally 0.5 mm. The thickness of the paint layer 402 is 50 to 75 µm, ideally 60 µm.

Claims

Outer panel of a vehicle door, characterized in that it comprises: an inner surface section which is a thermoplastic resin component; a middle reinforcement section, one side of which is connected to the inner surface section, wherein the middle reinforcement section is a continuously fiber-reinforced thermoplastic composite component; and an outer surface section which is connected to the other side of the middle reinforcement section, wherein the outer surface section is a thermoplastic resin component. Outer panel of a vehicle door according to claim 1, characterized in that the outer surface section and the central reinforcement section are formed in one piece by compression molding and subsequent overmolding. Outer panel of a vehicle door according to claim 2, characterized in that the inner surface section is formed in the insert injection molding process. Outer panel of a vehicle door according to one of claims 1 to 3, characterized in that the inner surface section and the outer surface section are both polypropylene components. Outer panel of a vehicle door according to one of claims 1 to 3, characterized in that the end of the inner surface section is bent towards the outer surface section, thereby connecting it to the outer surface section and forming a locking section which retains the end of the middle reinforcement section. Outer panel of a vehicle door according to claim 5, characterized in that the end of the outer surface section extends and projects beyond the locking section, thereby forming a thin-walled section. Outer panel of a vehicle door according to claim 6, characterized in that the locking section and the thin-walled section are located laterally or below the outer panel of the vehicle door. Outer panel of a vehicle door according to one of claims 1 to 3, characterized in that the thickness of the inner surface section is 0.8 mm to 2.5 mm, the thickness of the middle reinforcement section is 0.6 mm to 1.2 mm, and the thickness of the outer surface section is 0.8 mm to 2.5 mm. Outer panel of a vehicle door according to claim 1 or 2, characterized in that the inner surface section is designed as a stiffening rib, wherein the stiffening rib comprises several reinforcing heads, wherein the reinforcing heads comprise a connecting section, and wherein the reinforcing heads are connected to the central reinforcing section via the connecting section. Outer panel of a vehicle door according to claim 9, characterized in that the connecting section is connected to the central reinforcement section by gluing or welding. Outer panel of a vehicle door according to claim 9, characterized in that the thickness of the outer surface section is 2.0 mm to 3.0 mm, the thickness of the middle reinforcement section is 0.1 mm to 1.2 mm, and the thickness of the connecting section is 1.5 mm to 3 mm. Outer panel of a vehicle door according to claim 9, characterized in that the reinforcing heads further comprise a projection, wherein the projection is integrally connected to the connecting section and protrudes from the connecting section. Outer panel of a vehicle door according to claim 12, characterized in that a connecting cross-sectional area at a connection point between the connecting section and the projection is smaller than a connecting cross-sectional area at a connection point between the connecting section and the central reinforcement section, wherein a cross-sectional area of ​​the connecting section gradually decreases from the central reinforcement section towards the projection. Outer panel of a vehicle door according to claim 1, characterized in that it further comprises an appearance section, wherein the appearance section is connected to a side of the outer surface section facing away from the central reinforcement section, wherein the appearance section is a paint layer. Outer panel of a vehicle door according to claim 1, characterized in that it further comprises an appearance section, wherein the appearance section is connected to a side of the outer surface section facing away from the central reinforcement section, wherein the appearance section is a polyurethane component. Outer panel of a vehicle door according to claim 1, characterized in that it further comprises an appearance section, wherein the appearance section consists of two layers, namely a polyurethane layer and a paint layer, wherein the polyurethane layer is connected to a side of the outer surface section facing away from the central reinforcement section and the paint layer is arranged on the outer surface of the polyurethane layer.

Images