CN111845292A

CN111845292A - Composite material door system and construction method thereof

Info

Publication number: CN111845292A
Application number: CN202010848272.2A
Authority: CN
Inventors: 梁卫兴; 杜春欢; 朱玉满; 茅菁; 汪文彬; 黄金华
Original assignee: Yanfeng Plastic Omnium Automotive Exterior Systems Co Ltd
Current assignee: Yanfeng Plastic Omnium Automotive Exterior Systems Co Ltd
Priority date: 2020-08-21
Filing date: 2020-08-21
Publication date: 2020-10-30

Abstract

The present invention provides a composite door system and method of construction thereof, the composite door system comprising: a door inner panel; an insert assembly; a door sash assembly; a door outer panel bracket; and a door outer panel; the inner door plate, the outer door plate bracket and the outer door plate are all made of composite materials. According to the composite material door system and the construction method thereof provided by the invention, various requirements of light weight of the whole vehicle, diversified shapes, simplified assembly, rapid maintenance development and the like can be met, and the composite material door system is more suitable for doors of new energy electric vehicles and automatic driving vehicles in the future.

Description

Composite material door system and construction method thereof

Technical Field

The present invention relates to the automotive field, and more particularly to a composite door system and method of construction thereof.

Background

At present, in the traditional whole vehicle design, no matter the inner plate and the outer plate of the vehicle door or the bearing piece still adopt a steel plate or an aluminum alloy plate to carry out stamping and a robot edge covering form to connect the inner plate and the outer plate. The steel plate is made of sheet metal materials, has the advantages of good toughness and high strength, but has heavy weight, and has certain difficulty in later disassembly and assembly. Most of the punching materials are cold-rolled steel sheets. If parts stamped out of cold-rolled steel sheets are often exposed to air, the surfaces of the parts are easily oxidized. When the parts are used, a great deal of time is spent on surface treatment, electrophoresis and paint spraying.

Now, with the development of the automobile industry, the current society has more and more paid attention to the lightweight requirements of automobiles, and in the era of the wide application of electric vehicles, in order to improve the performance requirements of the whole automobiles, improve the endurance mileage of the electric vehicles and have more and more intelligent requirements of future intelligent automobiles, the traditional vehicle door structure is difficult to adapt to the requirements.

Firstly, the traditional production process has the disadvantages of large equipment investment, complex coating process, long overall arrangement of the production line and incapability of greatly improving the production takt time. Secondly, as the personalized needs of purchasers gradually increase, the single product location has been difficult to meet the needs of customers. Due to the limitation of the automobile door process, the individual requirements of the traditional automobile model on the automobile door shape are very limited, and the customer requirements cannot be better met. Finally, in a traffic accident, once a traditional sheet metal door is damaged, the maintenance is very difficult or the whole door is directly replaced, so that the maintenance cost of a consumer is high. This is contrary to the important direction of light weight, diversified shapes, simplified assembly and rapid maintenance.

Disclosure of Invention

The invention aims to provide a composite material door system and a construction method thereof, so as to solve the problem that the automobile door in the prior art cannot simultaneously meet various requirements of light weight, diversified shapes, simplified assembly, rapid maintenance development and the like of the whole automobile.

In order to solve the technical problems, the invention adopts the following technical scheme:

according to a first aspect of the present invention there is provided a composite door system comprising: a door inner panel; an insert assembly; a door sash assembly; a door outer panel bracket; and a door outer panel; the inner door plate, the outer door plate bracket and the outer door plate are all made of composite materials.

The insert assembly is formed by assembling and welding a door sash insert, a B-pillar decorative plate insert, a door hinge area insert, a door water-cutting windowsill insert and a door sill insert.

The inner plate of the vehicle door is respectively provided with different reinforcing rib shapes in different areas where the insert of the vehicle door sash, the insert of the B-pillar decorative plate, the insert of the vehicle door hinge area, the insert of the vehicle door water-cutting windowsill and the insert of the vehicle door threshold are positioned.

And the insert assembly and the vehicle door inner plate integrated mold are subjected to insert injection molding to form the vehicle door inner plate assembly.

The door sash assembly comprises: the door frame sealing plate, the B column decorative plate and the door inner plate are adhered, and the glass front guide rail and the glass rear guide rail are in threaded connection or riveted with the door inner plate.

The composite door system further comprises a door anti-collision beam in threaded connection or riveting with the door inner plate assembly.

The outer vehicle door plate support is connected with the inner vehicle door plate through mushroom nails and anti-theft screws.

The edges of the outer vehicle door plate and the inner vehicle door plate are sealed by sealing collodion.

The appearance surface of the outer door panel is provided with a false seam to realize color separation and/or piece separation.

Composites suitable for use in the present invention include: PP + EPDM-TD30, PP-GF30, PP-GF40, SMC and ASA.

According to a second aspect of the present invention there is provided a method of constructing a composite door system as described above, comprising the steps of: 1) the door sash insert, the B-pillar trim plate insert, the door hinge area insert, the door water-cutting windowsill insert and the door sill insert are spliced and welded into an insert assembly; 2) providing a vehicle door inner plate, and integrally insert-molding the insert assembly and the vehicle door inner plate to form the vehicle door inner plate assembly; 3) providing a vehicle door and window frame assembly comprising: the door sash assembly is connected with the door inner plate assembly; 4) providing a vehicle door anti-collision beam, and screwing or riveting the vehicle door anti-collision beam with the vehicle door inner plate assembly; 5) providing a door outer plate bracket and a door outer plate, and bonding the door outer plate bracket to the inner side of the door outer plate; 6) providing a car door outer horizontal cutting windowsill beam integrated with an outer door handle metal reinforcing plate, and bonding the windowsill beam to the inner side of the upper end of the car door outer plate to form a car door outer plate assembly; and 7) connecting the outer door plate assembly with the inner door plate assembly through a fastener, wherein the edges of the outer door plate and the inner door plate are sealed by sealing collodion.

According to the invention, the vehicle door which is more suitable for new energy electric vehicles and automatic driving vehicles in the future can be provided, the light weight requirement of the vehicle can be met, the endurance mileage of the electric vehicle can be increased, and various important directions such as modeling diversification, assembly simplification, maintenance rapid development and the like can be met.

According to the invention, the insert injection molding process is firstly applied to the automobile side door, the unicity that the automobile door is made of sheet metal materials for centuries is broken through, more possibilities are provided for meeting the light weight of the automobile, and the defects brought by the traditional metal door are changed, such as: easy rusting, visible welding lines, welding marks and welding seams, unattractive gray areas, easy bulging, cracking and falling of paint at the welding seams, numerous parts, heavy vehicle doors, high cost and the like.

According to the composite material vehicle door inner plate provided by the invention, the main body structure at the lower side of the vehicle door inner plate and the window frame area of the vehicle door inner plate are integrated into a whole independent part, and one of the advantages is that the appearance surface of the inner plate exposed at one side of the composite material vehicle door inner plate is not limited to the color of the whole vehicle like a sheet metal vehicle door or an aluminum alloy vehicle door. The composite material vehicle door inner plate can completely be independent of a whole vehicle paint spraying process, and the color and the appearance surface treatment of the inner plate exposed on one side of the composite material vehicle door inner plate can be customized, for example, the customized spraying of high-grade color or dermatoglyph paint different from the color of a vehicle body and the dermatoglyph surface treatment are performed. One of the other advantages is that the welding seam and welding spot printing appearance of the inner plate of the vehicle door in the window frame and the body area of the inner plate of the vehicle door can be abandoned, and the corrosion prevention problem of the inner plate of the vehicle door caused by tailor welding or paint cracking is also greatly improved.

According to the insert assembly provided by the invention, the molded surface of each independent insert is completely matched with the molded surface of the inner plate of the vehicle door, and the sheet metal inserts with certain strength and concave-convex or bent sections are designed in the region of the sealing surface of the vehicle door. Compared with the integral design, the segmented insert design can save cost and reduce the generation of sheet metal waste; in addition, the insert design of the sub-area is more flexible, metal inserts with different labels can be adopted in different areas, and different insert material thicknesses can be designed according to the key performance of necessary areas.

According to the performance requirements of different areas of the vehicle door, the reinforcing rib connection scheme of the composite material vehicle door inner plate is designed into different reinforcing rib forms, and stronger reinforcing ribs are arranged to press the metal insert, so that the metal insert can be better integrated with the composite material vehicle door inner plate and cannot be separated under any working condition. If different connection forms of the latticed reinforcing ribs are designed, the metal sheet metal insert assembly can be better pressed against areas with high rigidity requirements, such as a car door window frame, a car door inner windowsill and the like, so that the metal sheet metal insert assembly and the composite material inner plate are combined into a car door inner plate whole body with high strength, high rigidity and binding force meeting requirements, and the key attention position of a customer is met.

According to the composite material outer door plate in the composite material outer door plate assembly, the appearance surface of the lower side of the composite material outer door plate has a false seam characteristic on a model, wherein after the outer door plate of the automobile is designed by the composite material outer door plate, the plasticity of the model is improved, and not only can different colors and patterns of the outer door plate be customized, but also the block design can be carried out; the vehicle door system also provides more possibilities and contribution values for intelligent man-machine interaction carriers of the vehicle door, intelligent vehicle door exterior lighting and vehicle body aerodynamics.

In short, according to the composite material door system and the construction method thereof provided by the invention, various requirements such as light weight of the whole vehicle, diversified shapes, simplified assembly, rapid maintenance development and the like can be met, and the composite material door system is more suitable for doors of new energy electric vehicles and automatic driving vehicles in the future.

Drawings

FIG. 1 is a schematic structural view of a composite door assembly of the present invention;

FIG. 2 is an exploded view of the composite door assembly of the present invention;

FIG. 3 is a schematic view of an independent integral part formed by the composite material vehicle door inner plate and the sheet metal insert after being integrally injection molded;

FIG. 4 is a schematic view of a metal sheet insert assembly resembling a Chinese character 'ri' in a composite vehicle door of the present invention;

FIG. 5 is a schematic structural view of a door hinge region in a composite vehicle door of the present invention;

FIG. 6 is a reinforcing rib connection scheme of the metal sheet insert assembly in the composite material vehicle door and the integrated inner plate mold insert injection molding of the composite material inner plate;

FIGS. 7A and 7B are an enlarged view and a cross-sectional view of a reinforcement in the area of the sash of the composite door inner panel of the present invention;

FIGS. 8A and 8B are an enlarged detail view and a cross-sectional view, respectively, of a reinforcement in the area of a B-pillar trim panel of a composite door inner panel of the present invention;

FIGS. 9A and 9B are an enlarged detail view and a cross-sectional view, respectively, of a reinforcement in the water-cut sill area of the composite door inner panel of the present invention;

FIGS. 10A and 10B are an enlarged view and a sectional view of a detail of a reinforcing rib in a threshold region of a composite door inner panel according to the present invention;

FIGS. 11A and 11B are an enlarged view and a cross-sectional view of the hinge region of the composite door inner panel of the present invention showing the detail of the reinforcing ribs;

FIG. 12 is a schematic view of the mounting positions of the frame sealing plate, the B-pillar trim plate, the front and rear glass auxiliary rails made of composite material, and the impact beam on the side of the A-pillar of the composite material vehicle door according to the present invention;

FIG. 13 is a schematic view of the composite vehicle door showing the completion of the installation and matching of the window frame sealing plate and the B-pillar trim plate on the side of the A-pillar;

figure 14 is a cross-sectional view of a detail of the construction of the window frame closure panel on the a-pillar side of the composite vehicle door of the present invention.

FIG. 15 is a detail section view of the B-pillar trim panel position structure of the composite vehicle door of the present invention;

FIG. 16 is a schematic view of a composite door outer panel assembly construction of the present invention;

FIGS. 17A and 17B are, respectively, a schematic view and a detail cross-sectional view of an outer door panel in the composite outer door panel assembly of the present invention;

FIGS. 18A and 18B are simplified schematic illustrations of other possible derivative shapes for the composite door inner panel insert of the present invention.

Detailed Description

The present invention will be further described with reference to the following specific examples. It should be understood that the following examples are illustrative only and are not intended to limit the scope of the present invention.

Referring to fig. 1, which is a schematic overall view of a composite door system 100 according to a preferred embodiment of the present invention, the arrangement of the major components and structures within the door cavity, except for the glass and glass lifters, can be clearly seen through the transparent outer panel. The following detailed description is provided for various details of the composite door system 100:

referring to figure 2, which is an exploded view of a composite door system assembly 100 of the present invention, the composite door system 100 includes: a composite door inner panel 10; a metal panel insert assembly 20; a door sash assembly 30; a composite door outer panel bracket 40; a composite door outer panel 50. The splitting step and the hierarchical structure of the main body structure of the car door system except accessories such as a motor, a steel wire rope, a pulley, a reel and the like in the glass and glass lifter assembly can be visually shown; the structure split can be a composite material vehicle door outer plate assembly, a composite material vehicle door inner plate assembly and a safety-related bearing structural member vehicle door anti-collision beam.

Fig. 3 shows that after the metal sheet insert assembly 20 similar to the shape of the Chinese character "ri" shown in fig. 4 and the composite material door inner panel 10 are molded by insert injection in the mold, a composite material door inner panel with a metal insert attached therein is formed, namely, the composite material door inner panel assembly 101. Through the composite material insert injection molding process, the vehicle door inner plate made of the traditional metal material is completely replaced by the vehicle door inner plate made of the composite material. And through the metal inserts in necessary areas and the structural design of the optimized inner plate, the integral rigidity and strength of the vehicle door are enhanced, and the bearing performance requirements of the vehicle door in the whole vehicle door life cycle such as the self weight of a vehicle door assembly system and the vehicle door droop are improved. The innovation points are as follows: a. the insert injection molding process is innovated in the side door of the automobile; b. breaking through the unicity that automobile doors are made of sheet metal materials for centuries; c. more possibilities are provided for meeting the light weight of the automobile; d. the defects brought by the traditional metal vehicle door are changed, such as: the welding seam, welding marks and welding seams are visible, a gray area is not attractive, paint at the welding seam is easy to bulge, crack and fall off, a plurality of parts are provided, the vehicle door is heavy, and the cost is high. The difficulty of overcoming is as follows: a. the standard requirement of mandatory safety regulations of the side door of the automobile is broken through; b. various performance indexes of the automobile side door subsystem are met; c. the pain point that the metal plate is difficult to further reduce weight is solved; d. has more competitive advantages over the weight and cost of aluminum alloy doors, and also breaks through the prejudice that plastic side doors are certainly unsafe, which has long been recognized in the customer.

The metal sheet metal insert assembly 20 similar to the shape of the Chinese character 'ri' shown in fig. 4 is formed by combining five sections, and is formed by splicing and welding five sectional metal sheet inserts, namely a vehicle door hinge region metal sheet insert 21, a window frame metal sheet insert 22, a door lock B-column side metal sheet insert 23, a vehicle door internal water cutting windowsill metal sheet insert 24 and a vehicle door threshold metal sheet insert 25, like the structure of the Chinese character 'ri'. The molded surface of each independent sheet metal insert is completely matched with the molded surface of the inner plate of the vehicle door, and the sheet metal inserts with certain strength, concave and convex shapes or bent sections are designed in the region of the sealed surface of the vehicle door. Compared with the integral design, the segmented sheet metal insert design can save cost and reduce sheet metal waste; in addition, the sheet metal insert design in the sub-regions is more flexible, metal inserts with different labels can be adopted in different regions, and different sheet metal insert material thicknesses can be designed according to the key performance of necessary regions, for example, a door hinge region as illustrated in fig. 5 is a key performance region, wherein the thickness of the sheet metal insert substrate 211 in the door hinge region is 0.7mm as that of the basic materials of five sheet metal inserts in other segments, and the hinge region is formed by overlapping the hinge insert substrate 211 with the hinge reinforcing plate 212 and the stopper reinforcing plate 213, wherein the thickness of the basic materials of the hinge reinforcing plate 212 and the stopper reinforcing plate 213 is 2.0mm, so that the integral bearing requirement of the vehicle door can be further improved. The innovation points are as follows: compared with the integral design, the segmented sheet metal insert design can save cost and reduce sheet metal waste; the design of the sheet metal insert with the regions is more flexible.

The reinforcing rib connection scheme that the similar chinese character "day" font of door inner panel beating metal panel insert assembly 20 and the integrative mould interior embedding of combined material door inner panel 10 were moulded plastics is shown in figure 6, according to the performance requirement in the different regions of door, with the reinforcing rib connection scheme of combined material door inner panel 10, design for different reinforcing rib forms, arrange stronger reinforcing rib and push down metal insert, make it can be better combine together with combined material door inner panel, under any operating mode condition, all do not break away from. If different connection forms of the latticed reinforcing ribs are designed, the metal sheet metal insert assembly can be better pressed against areas with high rigidity requirements, such as a car door window frame, a car door inner windowsill and the like, so that the metal sheet metal insert assembly and the composite material inner plate are combined into a car door inner plate whole body with high strength, high rigidity and binding force meeting requirements, and the key attention position of a customer is met. Fig. 6 shows the area of five key reinforcing ribs, and fig. 7A to 11B show an enlarged detail view and a sectional view of the structure of each reinforcing rib. The grid-shaped reinforcing ribs designed in the invention are only the best case of the embodiment, but not limited to the form, and can comprise various grids, such as hexagons, triangles, circles, squares, rhombuses and the like. The innovation points are as follows: different positions, different operating modes and the different performance requirements in each region of door to the door, the design different integrated intramode inserts of combined material inner panel are moulded plastics the strengthening rib and are satisfied the door inner panel body and more have with the integration of metal panel beating inserts, still more conveniently adjust the design simultaneously.

Fig. 6 shows another inventive point of the present invention, that is, the composite door inner panel 10 of the present invention is completely closed in the area of the window regulator assembly, and the closed area integrates the front guide rail, the rear guide rail, the seat plate of the motor pulley and the mounting point structures of the four pulleys in the window regulator assembly. The integrated technical scheme of the glass lifting area is supplemented with the composite material vehicle door inner plate 10 and is integrally injection-molded with the composite material vehicle door inner plate. The technical scheme of the invention is different from the scheme of a sheet metal vehicle door, the glass lifter is arranged on the inner plate of the metal vehicle door, and a mounting, debugging and maintenance process hole is required to be formed on the inner plate of the sheet metal vehicle door; and the glass lifter assembly is integrated on the split plastic mounting plate, which is different from the scheme of the vehicle door inner plate door module in recent years. The structural design scheme reduces the number of parts in the vehicle door assembly, and simultaneously has great contribution and advantages to light weight of the whole vehicle and cost reduction. The innovation and improvement points are as follows: a. the important direction of the assembly simplification and the rapid maintenance development of the vehicle door in the future is met; b. the sound quality of the automobile door is improved; c. the part quantity reduces, and door single-piece cost descends a lot, and the mould examines utensil also reduces correspondingly.

As shown in fig. 2 and 12, there is also shown a door sash assembly 30 comprising: a door sash closing plate 31, a B-pillar garnish 32, a glass front rail 33, and a glass rear rail 34. Also shown is a door impact beam 35 that is bolted or riveted to the door inner panel assembly. Fig. 12 also shows the installation sequence of the door sash closing plate 31 in the a-pillar region and the B-pillar trim plate 32 in the B-pillar region of the composite door inner panel 10, wherein the door sash closing plate 31 and the B-pillar trim plate 32 are both adhered to the composite door inner panel assembly 101 shown in fig. 3 by the process of adhering with the glue 36. As shown in fig. 13 to 15, the door sash after bonding forms a closed cavity in each of the a-pillar region and the B-pillar region. The rigidity of the window frame area is improved by the structure and the installation scheme of the parts, and the strength of the window frame area meets the performance requirement of the vehicle door under all working conditions of the vehicle door assembly. The innovation and improvement points are as follows: a. a brand-new design scheme of the sheet metal insert in the window frame area of the composite side door is provided; b. the problem of insufficient rigidity of the window frame caused by replacing the traditional metal material for the composite material is solved; c. the technical difficulty of matching the window frame sealing strips in the area is solved innovatively.

In addition, fig. 12 shows that the mounting points of the front and rear auxiliary composite material guide rails of the window glass are further integrated at the corresponding positions of the inner panel of the composite material door through screws, so as to meet the requirements of mounting the front and rear

glass guide rails

33 and 34 and improve the lifting stability of the glass and the sound quality of the door of the lifted door glass; the door anticollision roof beam 35 passes through the screw spiro union or rivet riveting on combined material door inner panel assembly corresponds the position to satisfy the combined material door and provide the safety guarantee when quiet extrusion and side impact, provide the protection for the member in the car. The innovation and improvement points are as follows: the part quantity reduces, and door single-piece cost descends a lot, and the mould examines utensil also reduces correspondingly.

FIG. 16 shows a composite door outer panel assembly comprising a composite door outer panel 50, a composite door outer panel bracket 40, and a door outer sill rail 60 incorporating an outer door pull metal reinforcement plate 61. Establish the connection structure of ten connection combined material door inner panels 10 at combined material door planking support 40, this connection structure includes 8 self-adaptation detachable mushroom nail mounting points in order to joint combined material door inner panel 10, still is equipped with two cross locating pins, and there is guide structure on the top, makes things convenient for the location and the normal direction assembly of combined material door planking support 40 and assembly. The connecting structure further comprises 2 anti-drop and anti-theft screw points which are screwed on the composite material inner vehicle door panel 10.

Further, the composite door outer panel bracket 40 is bonded to the inside of the composite door outer panel 50 by a composite adhesive. The door outside water cut sill beam 60, which is integrated with the outer door handle metal reinforcement plate 61, is also bonded to the inside of the upper end of the composite material door outer panel 50 by a composite adhesive. 2 anti-drop and anti-theft screw points are respectively arranged at two ends of the outer water cut windowsill beam 60 of the outer door plate and connected to the composite material inner door plate 10, so that the internal and external rigidity of the outer water cut windowsill beam of the door can be better improved; the metal reinforcing plate 61 of the outer door handle and the outer water-cut windowsill beam 60 are molded by insert injection in an integral mould, and a composite material outer water-cut windowsill beam 60 with a metal insert is formed. The metal reinforcing plate 61 may also be bonded to the composite outer water-cut sill beam 60 by a composite adhesive. When the door lock is installed, the outer door handle metal reinforcing plate 61 is locked on the composite material inner door panel 10 through 3 screw points in the door lock area. The outer door handle metal reinforcing plate 61 also has the functions of improving the rigidity and safety of the door handle area of the vehicle door, and is used for ensuring that the door handle is kept at the correct position when and after the vehicle door is in accidental collision, so that the outer door handle area of the vehicle door is not damaged, the door lock is not opened, and the safety of passengers in the vehicle is protected. The innovation and improvement points are as follows: a. the invention creates the strategy of connecting, fastening and assembling the composite material vehicle door outer plate assembly and the composite material vehicle door inner plate assembly; b. the connecting scheme of the composite material vehicle door outer plate and the composite material vehicle door inner plate in different areas is innovatively solved; c. the anti-theft and anti-drop technical points of the composite material vehicle door outer plate are innovatively designed.

The edge of the composite material outer door plate 50 is provided with sealing collodion 51 adhered to the edge of the outer door plate, when the composite material outer door plate 50 is assembled on the composite material inner door plate 10, the sealing collodion 51 adhered to the outer plate is cured to form elastic semicircular sealing foam, and simultaneously, along with the application of assembly force of screwing and clamping on the inner plate, the semicircular sealing collodion 51 is compressed into an oblong shape so as to achieve the sealing effect. The innovation and improvement points are as follows: the sealing problem of the composite material vehicle door assembly is solved.

FIGS. 17A and 17B show the appearance of the underside of a composite door outer panel 50 in a composite door outer panel assembly having a contoured false seam feature 52 characterizing the separation or color of the parts of the door outer panel in this region. The core of the method is different from the design concept of the traditional vehicle door, and other parts do not need to be independently split on the outer plate of the vehicle door, and only different colors or surface treatment processes need to be defined in the upper area and the lower area of the false seam characteristic. On the basis of meeting the requirement of the shape of the whole vehicle, the design can reduce the number of parts and the weight of the vehicle door assembly, and also can reduce the cost of the whole vehicle to have a certain effect. FIG. 17A shows only a simple feature of the composite door outer panel 50 of the present embodiment, wherein the plasticity of the molding is improved after the automobile door outer panel 50 is designed from the composite material outer panel, so that not only can different colors and patterns of the door outer panel be customized, but also the design of the split block can be performed; the vehicle door system also provides more possibilities and contribution values for intelligent man-machine interaction carriers of the vehicle door, intelligent vehicle door exterior lighting and vehicle body aerodynamics. The innovation and improvement points are as follows: the invention innovatively provides a composite material vehicle door, and provides various solutions such as more integration, private customization, intelligent carriers and the like for a vehicle door outer plate and a future intelligent vehicle.

For example, as shown in the schematic illustrations of fig. 18A and 18B, the "japanese" -shaped sheet metal insert assembly 20 of the present invention may be derived to resemble a "bolt" -shaped insert assembly 20, a "Jiong" -shaped "" -shaped insert assembly 20, or a "square" -shaped insert assembly 20 in the case of a composite frameless vehicle door; except the change of the appearance shape of the insert, the change of the material of the insert, such as the replacement of the sheet metal insert with the insert made of the material such as carbon fiber and the like, all belong to the protection scope of the invention.

According to a preferred embodiment of the invention, the assembly process of the embodiment of the invention is as follows:

firstly, welding and assembling a metal sheet metal insert assembly 20 similar to a Chinese character 'ri' in the composite material vehicle door, and forming the metal sheet metal insert assembly and the composite material vehicle door inner plate 10 into a composite material vehicle door inner plate assembly 101 after the metal sheet metal insert assembly and the composite material vehicle door inner plate 10 are integrally insert molded;

then, placing the composite material door inner plate 10 with the inserts into a tire mold, and bonding a door sash seal plate 31 and a door B pillar trim plate 32 of a door A pillar;

then, the composite material car window glass front guide rail 33, the glass rear guide rail 34 and the car door anti-collision beam 35 which are screwed with the car window glass are installed on the composite material car door inner plate 10 from the outer side of the composite material car door inner plate 10, in addition, car door hinges, a limiter, a motor, pulleys, a lifting sliding support block, reel accessories, glass sealing strips, glass, a door lock and other parts in a glass lifter are installed on the composite material car door inner plate;

then, bonding the composite material outer door panel bracket 40 to the inner side of the composite material outer door panel 50, and bonding the outer door trim sill 60 integrated with the outer door handle metal reinforcing plate 61 to the inner side of the upper end of the composite material outer door panel 50 through a composite adhesive to form a composite material outer door panel assembly 102;

finally, the composite material outer door plate assembly 102 is clamped on the composite material inner door plate 10 through a self-adaptive detachable mushroom nail fastener, meanwhile, 4 anti-falling and anti-theft screws are in threaded connection with the composite material inner door plate 10, and the edge matching area of the composite material outer door plate 50 and the composite material inner door plate 10 is matched through the sealing collodion 51, so that the overall sealing performance of the composite material door system is realized.

The above embodiments are merely preferred embodiments of the present invention, which are not intended to limit the scope of the present invention, and various changes may be made in the above embodiments of the present invention. All simple and equivalent changes and modifications made according to the claims and the content of the specification of the present application fall within the scope of the claims of the present patent application. The invention has not been described in detail in order to avoid obscuring the invention.

Claims

1. A composite door system, comprising:

a door inner panel;

an insert assembly;

a door sash assembly;

a door outer panel bracket; and

an outer panel of the vehicle door;

the inner door plate, the outer door plate bracket and the outer door plate are all made of composite materials.

2. The composite door system of claim 1, wherein the insert assembly is assembled and welded from a door sash insert, a B-pillar trim panel insert, a door hinge region insert, a door sill trim insert, and a door sill insert.

3. The composite door system of claim 2, wherein the door inner panel has a different bead shape in different regions of the door sash insert, the B-pillar trim insert, the door hinge region insert, the door sill trim insert, and the door sill insert, respectively.

4. The composite door system of claim 3, wherein the insert assembly is insert molded in-mold with the door inner panel to form the door inner panel assembly.

5. The composite door system of claim 1, wherein the door sash assembly comprises: the door frame sealing plate, the B column decorative plate and the door inner plate are adhered, and the glass front guide rail and the glass rear guide rail are in threaded connection or riveted with the door inner plate.

6. The composite door system of claim 4, further comprising a door impact beam bolted or riveted to the door inner panel assembly.

7. The composite door system of claim 1, wherein the outer door panel bracket is connected to the inner door panel by mushroom nails and anti-theft screws.

8. The composite door system of claim 1, wherein edges of the outer door panel and the inner door panel are sealed with a sealant.

9. The composite door system of claim 1, wherein the exterior door panel has a false seam on an exterior facing surface to effect color and/or piece separation.

10. A method of constructing a composite door system as claimed in any one of claims 1 to 9, comprising the steps of:

1) the door sash insert, the B-pillar trim plate insert, the door hinge area insert, the door water-cutting windowsill insert and the door sill insert are spliced and welded into an insert assembly;

2) providing a vehicle door inner plate, and integrally insert-molding the insert assembly and the vehicle door inner plate to form the vehicle door inner plate assembly;

3) providing a vehicle door and window frame assembly comprising: the door sash assembly is connected with the door inner plate assembly;

4) providing a vehicle door anti-collision beam, and screwing or riveting the vehicle door anti-collision beam with the vehicle door inner plate assembly;

5) providing a door outer plate bracket and a door outer plate, and bonding the door outer plate bracket to the inner side of the door outer plate;

6) providing a car door outer horizontal cutting windowsill beam integrated with an outer door handle metal reinforcing plate, and bonding the windowsill beam to the inner side of the upper end of the car door outer plate to form a car door outer plate assembly; and

7) the outer door plate assembly and the inner door plate assembly are connected through fasteners, and the edges of the outer door plate and the inner door plate are sealed by sealing collodion.