Vehicle door exterior panel

Abstract

This invention provides a door exterior panel for a vehicle. [Solution] The vehicle door out panel belongs to the field of automotive parts technology and comprises an inner surface made of thermoplastic resin, an intermediate reinforcing part made of continuous fiber-reinforced thermoplastic composite material with one surface connected to the inner surface, and an outer surface made of thermoplastic resin material with the other surface connected to the intermediate reinforcing part. The beneficial effects are that this vehicle door out panel can be painted in the body color, effectively solving the difficult problem of composite material out panels being difficult to paint, significantly improving the dent resistance of the out panel and the overall performance of the door in terms of door rigidity, increasing overall strength, better solving the problem of deformation of the out panel due to temperature changes, and is recyclable because the materials used are thermoplastic resin and continuous fiber-reinforced thermoplastic composite material.

Description

Technical Field

[0001] This invention belongs to the technical field of vehicle parts and relates to the door outer panel of a vehicle.

Background Art

[0002] The door outer panel of a vehicle is an important part of the vehicle interior. The currently popular polypropylene injection-molded outer panel in the market has low rigidity, poor dent resistance, and is prone to white marks when kicked, hooked, or rubbed during user use, has poor scratch resistance, and the entire door outer panel of the vehicle is heavy. Also, when affected by high and low temperatures, the deformation becomes severe, making it difficult to control the gaps and steps in the appearance on the side of the vehicle body. In severe cases, the door cannot be opened and closed normally. On the other hand, a door outer panel using only composite materials such as carbon fiber or glass fiber generally shows the texture of carbon fiber in appearance and cannot meet the painting requirements of the vehicle body, and the selection in appearance treatment is relatively single.

[0003] As described above, there are corresponding defects in the existing vehicle door outer panels, and there is a large room for improvement.

Summary of the Invention

Problems to be Solved by the Invention

[0004] Regarding the above defects of the prior art, the technical problem that this invention attempts to solve is to provide a vehicle door outer panel.

Means for Solving the Problems

[0005] This invention aims to propose a vehicle door outer panel for the above problems existing in the prior art.

[0006] The object of this invention can be achieved by the following aspects.

[0007] An inner surface part made of a thermoplastic resin material, One side is connected to the inner surface and is an intermediate reinforcing part which is a continuous fiber-reinforced thermoplastic composite, The other side of the intermediate reinforcement portion is connected to the outer surface portion which is made of thermoplastic resin, A door exterior panel for a vehicle equipped with this feature.

[0008] In the door out panel of the above-mentioned vehicle, the outer surface portion and the intermediate reinforcing portion are injection-molded bodies formed by integral casting.

[0009] In the door out panel of the above-mentioned vehicle, the inner surface is an insert injection molded body.

[0010] In the door out panel of the above-mentioned vehicle, both the inner surface and the outer surface are made of polypropylene.

[0011] In the door-out panel of the above-mentioned vehicle, the end of the inner surface portion is bent toward the outer surface portion and connected to the outer surface portion to form a shielding portion, and the shielding portion shields the end of the intermediate reinforcing portion.

[0012] In the door out panel of the above-mentioned vehicle, the end of the outer surface extends beyond the shielding portion, forming a thin-walled portion.

[0013] In the door outer panel of the above-mentioned vehicle, the shielding portion and the thin-walled portion are located to the side or below the door outer panel of the vehicle.

[0014] In the door out panel of the above-mentioned vehicle, the thickness of the inner surface is 0.8 mm to 2.5 mm, the thickness of the intermediate reinforcement is 0.6 mm to 1.2 mm, and the thickness of the outer surface is 0.8 mm to 2.5 mm.

[0015] In the door out panel of the above-mentioned vehicle, the inner surface portion is a rib having a connecting portion and a plurality of reinforcing heads connected to the intermediate reinforcing portion via the connecting portion.

[0016] In the door out panel of the above-mentioned vehicle, the connecting portion is connected to the intermediate reinforcing portion by adhesive or welding.

[0017] In the door out panel of the above-mentioned vehicle, the thickness of the outer surface portion is 2.0 mm to 3.0 mm, the thickness of the intermediate reinforcing portion is 0.1 mm to 1.2 mm, and the thickness of the connecting portion is 1.5 mm to 3 mm.

[0018] In the door out panel of the above-mentioned vehicle, the reinforcing head is integrally connected to the connecting portion and further comprises a protruding portion that extends from the connecting portion.

[0019] In the door-out panel of the above-mentioned vehicle, the cross-sectional area of ​​the connection point between the connecting portion and the protruding portion is smaller than the cross-sectional area of ​​the connection point between the connecting portion and the intermediate reinforcement portion, and the cross-sectional area of ​​the connecting portion extending from the intermediate reinforcement portion toward the protruding portion gradually decreases.

[0020] The door out panel of the above-mentioned vehicle further comprises an exterior portion connected to a surface on the outer surface that is away from the intermediate reinforcing portion, and the exterior portion is a painted layer.

[0021] The door out panel of the above-mentioned vehicle further comprises an exterior portion connected to a surface on the outer surface that is away from the intermediate reinforcing portion, and the exterior portion is made of polyurethane material.

[0022] The door out panel of the above-mentioned vehicle further comprises an exterior portion consisting of two layers: a polyurethane layer connected to a surface on the outer surface away from the intermediate reinforcing portion, and a paint layer located on the outer surface of the polyurethane layer. [Effects of the Invention]

[0023] Compared to conventional technology, the beneficial effects of this invention are as follows:

[0024] 1. The door outer panel of this vehicle can be painted with the vehicle body color, effectively improving the problem that it is difficult to paint the outer panel made of composite materials. At the same time, it significantly improves the dent resistance of the outer panel and the overall performance of the door in terms of rigidity, increases the overall strength, and can better solve the deformation problem caused by temperature changes of the outer panel. Since the materials used are thermoplastic resin materials and continuous fiber reinforced thermoplastic composites, they are recyclable.

[0025] 2. Taking the integrally injection - molded state of both the outer surface part and the intermediate reinforcement part as an insert, the inner surface part and the door outer panel of this vehicle are formed by insert molding. The manufacturing process is simple, and the connection of the three parts is strong.

[0026] 3. The end of the inner surface part is bent towards the outer surface part and connected to the outer surface part, forming a shielding part that shields the end of the intermediate reinforcement part. The shielding part shields the intermediate reinforcement part, preventing the intermediate reinforcement part from being exposed outside and being difficult to paint.

[0027] 4. At the edge of the door outer panel of the vehicle, the thickness within the range of about 20 mm to 30 mm from the boundary is appropriately thinned, and the end of the outer surface part extends to form a thin - walled part beyond the shielding part. This structure mainly considers the movement calibration of the door to meet the normal opening and closing function of the door.

[0028] 5. The rib structure is different from the structure of the overall reinforcement layer or reinforcement plate. Based on the results of computer fluid analysis and thermal deformation analysis, iterative optimization is carried out, corresponding to a structure that forms local depressions on the entire back surface of the intermediate reinforcement part, and it is further weight - reduced.

[0029] 6. The protrusion can play a reinforcing role in the door outer panel of this vehicle. Since the connection cross - sectional area at the connection location between the connection part and the protrusion is smaller than the connection cross - sectional area at the connection location between the connection part and the intermediate reinforcement part, the connection part can enhance the connection strength between the reinforcement head and the intermediate reinforcement part.

[0030] 7. The cross-sectional area extending from the intermediate reinforcement portion toward the protruding portion at the connecting section gradually decreases, reducing the overall thickness of the intermediate reinforcement portion and reducing local surface abrasion caused by the ribs.

[0031] 8. The exterior consists of two layers: a polyurethane layer and a painted layer, which can solve special color challenges. [Brief explanation of the drawing]

[0032] [Figure 1] This is a schematic diagram of one embodiment of the present invention. [Figure 2] This is a view from the direction of arrow P in Figure 1. [Figure 3] This is a schematic cross-sectional view of line AA in Figure 2. [Figure 4] This is an enlarged view of section D in Figure 3. [Figure 5] This is an enlarged view of section E in Figure 3. [Figure 6] Figure 2 is a schematic cross-sectional view of line BB. [Figure 7] Figure 2 is a schematic cross-sectional view of the CC line. [Figure 8] This is a schematic diagram of one embodiment of the present invention. [Figure 9] This is a diagram illustrating an explosion in one embodiment of the present invention. [Figure 10] Figure 9 is a schematic diagram of the configuration. [Figure 11] Figure 10 is a schematic cross-sectional view of the FF line. [Figure 12] This is a schematic diagram of one embodiment of the present invention. [Figure 13] This is a schematic diagram of one embodiment of the present invention. [Figure 14] This is a schematic diagram of one embodiment of the present invention. [Figure 15] This is a schematic diagram of one embodiment of the present invention. [Modes for carrying out the invention]

[0033] The following are specific embodiments of the present invention, and the aspects of the present invention will be further described with reference to the drawings, but the present invention is not limited to these embodiments.

[0034] In the embodiments of this invention, all direction indicators (e.g., up, down, left, right, front, back, etc.) are used solely to describe the relative positional relationships and motions between each component in a specific orientation (as shown in the drawings). If this specific orientation changes, the direction indicators will also change accordingly.

[0035] Furthermore, descriptions of "first," "second," "1," etc., in this invention are used solely to describe the purpose and are not intended to explicitly or implicitly indicate their relative importance or suggest the number of technical features represented. Therefore, the features defining "first" and "second" may explicitly or implicitly include at least one feature. In the description of this invention, "multiple" means at least two, for example, two, three, etc., unless otherwise clearly and specifically defined.

[0036] In this invention, unless otherwise clearly and specifically defined, terms such as "connection" and "fixation" should be understood in a broad sense. Unless otherwise clearly and specifically defined, for example, "fixation" may refer to a fixed connection, a removable connection, or a single unit, a mechanical connection, an electrical connection, a direct connection, an indirect connection via an intermediate medium, an internal connection between two elements, or an interaction relationship between two elements. Those skilled in the art will be able to understand the specific meaning of the above terms in this invention depending on the specific situation.

[0037] Furthermore, while the embodiments of each part of the present invention can be combined with one another, if a combination of embodiments results in a contradiction or is not feasible, based on what a person skilled in the art can achieve, then such a combination of embodiments should be considered nonexistent and outside the scope of protection required by the present invention.

[0038] The specific embodiments described herein are for illustrative purposes only and illustrate the spirit of the present invention. Those skilled in the art can make various modifications and additions to the described specific embodiments or substitute them with similar embodiments without departing from the spirit of the present invention or exceeding the scope defined in the claims.

[0039] As shown in Figures 1 to 7, the door out panel of a vehicle comprises an inner surface portion 100, an intermediate reinforcing portion 200, and an outer surface portion 300.

[0040] Here, the inner surface 100 is made of a thermoplastic resin material.

[0041] Specifically, the thickness of the inner surface portion 100 is 0.8 mm to 2.5 mm.

[0042] Specifically, the inner surface portion 100 is made of polypropylene.

[0043] The intermediate reinforcing portion 200 has one surface connected to the inner surface portion 100 and is a continuous fiber-reinforced thermoplastic composite material.

[0044] Specifically, the thickness of the intermediate reinforcement portion 200 is 0.6 mm to 1.2 mm.

[0045] Here, the outer surface portion 300 is connected to the other surface of the intermediate reinforcing portion 200 and is made of thermoplastic resin material.

[0046] Specifically, the thickness of the outer surface portion 300 is 0.8 mm to 2.5 mm.

[0047] Specifically, the outer surface portion 300 is made of polypropylene.

[0048] In this embodiment, the door outer panel of this vehicle can be painted in the body color, effectively improving the difficulty of painting composite material outer panels, significantly improving the dent resistance of the outer panel and the overall performance of the door in terms of door rigidity, increasing overall strength, and better resolving the deformation problem of the outer panel due to temperature changes. Furthermore, since the materials used are thermoplastic resin and continuous fiber-reinforced thermoplastic composite, they are recyclable.

[0049] As shown in Figures 1 to 7, in addition to the embodiments described above, the outer surface portion 300 and the intermediate reinforcing portion 200 are integrally molded injection-molded bodies.

[0050] In this embodiment, both the outer surface portion 300 and the intermediate reinforcing portion 200 are integrally injection-molded, resulting in a simple manufacturing process and a strong connection between the two.

[0051] As shown in Figures 1 to 7, in addition to the above embodiment, the inner surface portion 100 is an insert injection molded body.

[0052] In this embodiment, the outer surface portion 300 and the intermediate reinforcing portion 200 are integrally injection-molded as an insert, and the inner surface portion 100 and the door out panel of the vehicle are formed by insert injection, resulting in a simple manufacturing process and a strong connection between the three components.

[0053] As shown in Figures 1 to 7, in addition to the embodiments described above, the end of the inner surface portion 100 is bent toward the outer surface portion 300 and connected to the outer surface portion 300 to form a shielding portion 110, and the shielding portion 110 shields the end of the intermediate reinforcing portion 200.

[0054] In this embodiment, the thickness of the edge of the vehicle's door out panel is appropriately thinned within a range of approximately 20 mm to 30 mm from the boundary, and the end of the outer surface portion 300 extends beyond the shielding portion 110 to form a thin-walled portion 310. This structure is designed primarily to accommodate the normal opening and closing function of the door, taking into consideration the motion calibration of the door.

[0055] As shown in Figures 1 to 7, in addition to the embodiments described above, the end of the outer surface portion 300 extends beyond the shielding portion 110 to form a thin-walled portion 310.

[0056] In this embodiment, the thickness of the edge of the vehicle's door out panel is appropriately reduced within a range of approximately 20 mm to 30 mm from the boundary, and the end of the outer surface portion 300 extends beyond the shielding portion 110 to form a thin-walled portion 310. This structure is designed primarily to ensure that the normal opening and closing function of the door is maintained, and the motion calibration of the door is taken into consideration.

[0057] Furthermore, the shielding portion 110 and the thin-walled portion 310 are located to the side or below the vehicle's door out panel, and specifically, they can be used in front of, behind, and below the vehicle's door out panel to ensure the normal opening and closing function of the door.

[0058] As shown in Figure 8, in addition to the above embodiment, the vehicle further comprises an exterior portion 400 connected to a surface of the exterior portion 300 that is away from the intermediate reinforcing portion 200, and the exterior portion 400 can be divided into the following two types. The first is that the exterior portion 400 is a painted layer, that is, the exterior surface of the exterior portion 300 is directly painted with the body color, and the thickness of the painted layer is 50 to 75 μm, preferably 60 μm. The second is that the exterior portion 400 is made of polyurethane material, that is, a polyurethane material of the body color is connected to the exterior surface of the exterior portion 300, also called a PUR layer, and the thickness when the exterior portion 400 is made of polyurethane material is 0.25 to 0.7 mm, preferably 0.5 mm.

[0059] As shown in Figures 9 to 11, the door out panel of a vehicle comprises an inner surface portion 100, an intermediate reinforcing portion 200, and an outer surface portion 300.

[0060] Here, the inner surface 100 is made of a thermoplastic resin material.

[0061] Specifically, the inner surface portion 100 is a rib 120 having a connecting portion 121 and a plurality of reinforcing heads connected to the intermediate reinforcing portion 200 via the connecting portion 121.

[0062] Specifically, the rib 120 is made of polypropylene.

[0063] Specifically, the thickness of the connecting portion 121 is 1.5 mm to 3 mm.

[0064] In practical terms, the connecting portion 301 is preferably 2.5 mm in diameter.

[0065] Here, the intermediate reinforcing portion 200 has one surface connected to the inner surface portion 100 and is a continuous fiber-reinforced thermoplastic composite material.

[0066] Specifically, the thickness of the intermediate reinforcement portion 200 is 0.1 mm to 1.2 mm.

[0067] In practical terms, the intermediate reinforcement portion 200 is preferably 0.2 mm thick.

[0068] Here, the outer surface portion 300 is connected to the other surface of the intermediate reinforcing portion 200 and is made of thermoplastic resin material.

[0069] Specifically, the thickness of the outer surface portion 300 is 2.0 mm to 3.0 mm.

[0070] For practical purposes, the outer surface portion 300 is preferably 2.2 mm in thickness.

[0071] Specifically, the outer surface portion 300 is made of polypropylene.

[0072] Furthermore, the structure of the rib 120 in this embodiment differs from the structure of the reinforcing layer or reinforcing plate in the embodiments shown in Figures 1 to 7. While the reinforcing layer or reinforcing plate is the overall structure, the rib 120 is designed to undergo iterative optimization mainly based on the results of computer fluid analysis and thermal deformation analysis. It corresponds to a structure that forms localized cutouts across the entire back surface of the intermediate reinforcing portion 200, and is further reduced in weight.

[0073] As shown in Figure 12, in addition to the above embodiment, the reinforcing head further includes a protruding portion 122 that is integrally connected to the connecting portion 121 and protrudes from the connecting portion 121.

[0074] In this embodiment, the protruding portion 122 can provide reinforcement to the door out panel of the vehicle, and since the cross-sectional area of ​​the connection point between the connecting portion 121 and the protruding portion 122 is smaller than the cross-sectional area of ​​the connection point between the connecting portion 121 and the intermediate reinforcement portion 200, the connecting portion 121 can increase the connection strength between the reinforcement head and the intermediate reinforcement portion 200.

[0075] As shown in Figure 13, in addition to the above embodiment, the cross-sectional area of ​​the connection point between the connecting portion 121 and the protruding portion 122 is smaller than the cross-sectional area of ​​the connection point between the connecting portion 121 and the intermediate reinforcement portion 200, and the cross-sectional area of ​​the connecting portion 121 extending from the intermediate reinforcement portion 200 toward the protruding portion 122 gradually decreases.

[0076] In this embodiment, the cross-sectional area extending from the intermediate reinforcing portion 200 toward the protruding portion 122 in the connecting portion 121 gradually decreases, reducing the overall thickness of the intermediate reinforcing portion 200, and reducing local surface abrasion caused by the rib 120.

[0077] As shown in Figure 14, in addition to the above-described embodiment, the exterior portion 400 is provided which is connected to a surface of the exterior portion 300 that is away from the intermediate reinforcing portion 200. The exterior portion 400 can be divided into the following two types: firstly, the exterior portion 400 is a painted layer, that is, the exterior surface of the exterior portion 300 is directly painted with the body color, and the exterior portion 400 has a painted layer thickness of 50 to 75 μm, specifically preferably 60 μm; secondly, the exterior portion 400 is made of polyurethane material, and the polyurethane material is preferably the body color, that is, a polyurethane material of the body color is connected to the exterior surface of the exterior portion 300, and the exterior portion 400 has a polyurethane material thickness of 0.25 to 0.7 mm, preferably 0.5 mm.

[0078] As shown in Figure 15, in order to improve the color scheme of the vehicle body, the exterior is further provided with two layers: a polyurethane layer 401 and a paint layer 402. In the case of special colors, if a single polyurethane layer is used, it is not possible to process the color. Therefore, after in-mold injection molding of the polyurethane layer 401, the paint layer 402 is further added to its outer surface. The polyurethane layer is made of polyurethane material, the polyurethane layer is connected to the surface of the outer surface portion 300 that is away from the intermediate reinforcement portion, 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, preferably 0.5 mm, and the thickness of the paint layer 402 is 50 to 75 μm, preferably 60 μm. [Explanation of Symbols]

[0079] 100: Inner part 110: Shielding part 120: Rib 121:Connection part 122:Protrusion 200: Intermediate reinforcement section 300: External part 310: Thin-walled section 400: Exterior 401: Polyurethane layer 402: Paint layer

Claims

1. The inner surface is made of thermoplastic resin, One side is connected to the inner surface and is an intermediate reinforcing part which is a continuous fiber-reinforced thermoplastic composite, The other side of the intermediate reinforcement portion is connected to the outer surface portion which is made of thermoplastic resin material. A vehicle door out panel characterized by having the following features.

2. The door out panel for a vehicle according to claim 1, characterized in that the outer surface portion and the intermediate reinforcing portion are integrally molded injection-molded bodies.

3. The door out panel for a vehicle according to claim 2, characterized in that the inner surface portion is an insert injection molded body.

4. The door out panel for a vehicle according to any one of claims 1 to 3, characterized in that both the inner surface and the outer surface are made of polypropylene.

5. The door out panel for a vehicle according to any one of claims 1 to 3, characterized in that the end of the inner surface portion is bent toward the outer surface portion and connected to the outer surface portion to form a shielding portion, and the shielding portion shields the end of the intermediate reinforcing portion.

6. The door out panel for a vehicle according to claim 5, characterized in that the end of the outer surface extends beyond the shielding portion and forms a thin-walled portion.

7. The door outer panel for a vehicle according to claim 6, characterized in that the shielding portion and the thin-walled portion are located to the side or below the door outer panel of the vehicle.

8. The door out panel for a vehicle according to any one of claims 1 to 3, characterized in that the thickness of the inner surface is 0.8 mm to 2.5 mm, the thickness of the intermediate reinforcing portion is 0.6 mm to 1.2 mm, and the thickness of the outer surface is 0.8 mm to 2.5 mm.

9. The door out panel of a vehicle according to claim 1 or 2, characterized in that the inner surface portion is a rib having a connecting portion and a plurality of reinforcing heads connected to the intermediate reinforcing portion via the connecting portion.

10. The door out panel of a vehicle according to claim 9, characterized in that the connecting portion is connected to the intermediate reinforcing portion by adhesive or welding.

11. The door out panel for a vehicle according to claim 9, characterized in that the thickness of the outer surface portion is 2.0 mm to 3.0 mm, the thickness of the intermediate reinforcing portion is 0.1 mm to 1.2 mm, and the thickness of the connecting portion is 1.5 mm to 3 mm.

12. The reinforcing head is integrally connected to the connecting portion and further comprises a protruding portion that protrudes from the connecting portion, characterized in that it is a door out panel for a vehicle according to claim 9.

13. The door out panel of a vehicle according to claim 12, characterized in that the cross-sectional area of ​​the connection point between the connecting portion and the protruding portion is smaller than the cross-sectional area of ​​the connection point between the connecting portion and the intermediate reinforcing portion, and the cross-sectional area of ​​the connecting portion extending from the intermediate reinforcing portion toward the protruding portion gradually decreases.

14. The door out panel of a vehicle according to claim 1, further comprising an exterior portion connected to a surface of the outer surface portion that is away from the intermediate reinforcing portion, wherein the exterior portion is a painted layer.

15. The door out panel of a vehicle according to claim 1, further comprising an exterior portion connected to a surface of the outer surface portion that is away from the intermediate reinforcing portion, wherein the exterior portion is made of polyurethane material.

16. The door out panel of a vehicle according to claim 1, further comprising an exterior portion consisting of two layers: a polyurethane layer connected to a surface of the exterior portion that is away from the intermediate reinforcing portion, and a paint layer located on the outer surface of the polyurethane layer.

Images