CN212473052U - Composite material car door system - Google Patents

Abstract

The utility model provides a combined material car door system, this combined material car door system includes: 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 utility model provides a pair of combined material door system and construction method thereof can satisfy multiple demands such as whole car lightweight, molding diversification, equipment simplification, maintenance rapid development simultaneously, the door that is more applicable to new forms of energy electric motor car and autopilot in future.

Description

Composite material car door system

Technical Field

The utility model relates to the field of automobiles, more specifically relates to a combined material door system.

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.

SUMMERY OF THE UTILITY MODEL

The utility model aims at providing a combined material door system to solve among the prior art automobile door and can't satisfy the problem of multiple demands such as whole car lightweight, molding diversification, equipment simplification, maintenance rapid development simultaneously.

In order to solve the technical problem, the utility model discloses a following technical scheme:

according to the utility model discloses, a combined material door system is provided, include: 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.

Composite material suitable for the utility model discloses a include: PP + EPDM-TD30, PP-GF30, PP-GF40, SMC and ASA.

According to 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 utility model discloses, a can satisfy the door that future more is applicable to new forms of energy electric motor car and automatic driving car, satisfy car lightweight demand, promote electric automobile's continuation of the journey mileage, satisfy multiple important directions such as molding diversification, equipment simplification, maintenance rapid development simultaneously.

According to the utility model discloses, propose for the first time to be applied to car side door with inserts injection molding process, break through for a century car door and for the unicity of panel beating material, for satisfying the car lightweight and provide more probably, changed the not enough that traditional metal door brought, if: 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 utility model provides a pair of combined material door inner panel, at the independent part of door inner panel downside major structure and the regional formula as an organic whole of door inner panel window frame, one of its advantages is the exposed inner panel outward appearance in combined material door inner panel one side, no longer like panel beating door or aluminum alloy door, can only confine to whole car colour. The utility model discloses a combined material door inner panel can be independent of the technology that whole car sprayed paint completely, can customize combined material door inner panel appearance face colour and outward appearance surface treatment that exposed in one side, for example, high-grade colour or dermatoglyph lacquer and dermatoglyph surface treatment that customization spraying and automobile body colour are different. 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 utility model provides an inserts assembly, the profile of every independent inserts all matches completely with the profile of door inner panel, and is regional at the sealed face of door, all designs the unsmooth or the sectional panel beating inserts of bending that have certain intensity. 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 different regional performance requirements of door, the utility model discloses still design the strengthening rib connection scheme of combined material door inner panel for different strengthening rib forms, arrange stronger strengthening rib and push down metal insert, make that 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.

According to the composite material door outer plate in the composite material door outer plate assembly provided by the utility model, the appearance surface of the lower side of the composite material door outer plate has a false seam characteristic on the shape, wherein after the automobile door outer plate is designed by the composite material outer plate, the plasticity of the shape is improved, different colors and patterns of the door outer plate can be customized, and the split 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 a word, according to the utility model provides a pair of combined material door system can satisfy simultaneously that whole car lightweight, molding are diversified, the equipment is simplified, multiple demands such as the quick development of maintenance, the door that is more applicable to new forms of energy electric motor car and autopilot in 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 the composite material inner panel of the vehicle door and the sheet metal insert of the present invention formed as an independent integral part after being integrally injection molded;

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

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

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

FIGS. 7A and 7B are an enlarged view and a sectional view of the reinforcing rib in the window frame region of the composite door inner panel according to the present invention;

FIG. 8A and FIG. 8B are an enlarged view and a cross-sectional view of a detailed structure of a reinforcing rib in the area of a B-pillar trim panel of a composite door inner panel according to the present invention;

FIGS. 9A and 9B are an enlarged view and a cross-sectional view of a structure of a reinforcing rib in a water-cut windowsill region in a composite material door inner panel according to the present invention;

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

FIGS. 11A and 11B are an enlarged view and a sectional view of the hinge region of the composite door inner panel according to the present invention;

fig. 12 is a schematic view of the installation positions of the window frame closing plate, the B-pillar trim plate, the front and rear glass auxiliary guide rails made of the composite material, and the anti-collision 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 material vehicle door showing the completion of the installation of the window frame sealing plate and the B-pillar trim plate on the side of the a-pillar;

figure 14 is a sectional view of the structure of the window frame sealing plate on one side of the a pillar of the composite vehicle door of the present invention.

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

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

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

fig. 18A and 18B are simplified schematic illustrations of other possible derivative shapes of 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 embodiments. It should be understood that the following examples are illustrative of the present invention 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 structure and the main components in the door cavity except for the glass and the glass lifter can be clearly seen through the transparent outer plate. The following detailed description is provided for various details of the composite door system 100:

as shown in fig. 2, which is an exploded view of the composite door system assembly 100 of the present invention, as shown in the figure, 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 of the present invention are only the best case of this embodiment, but not limited to this form, and can include various grids, such as hexagon, triangle, circle, square, rhomboid, etc. 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 material inner door panel 10 of the present invention is completely enclosed in the area of the window regulator assembly, and the enclosed 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 inserts appearance shape, the change of the material of inserts, for example the panel beating inserts replacement is the inserts of materials such as carbon fiber, all belongs to the utility model discloses within the scope of protection.

According to a preferred embodiment of the present invention, the assembly process of the embodiment of the present 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.

What has been described above is only the preferred embodiment of the present invention, not for limiting the scope of the present invention, but various changes can be made to the above-mentioned embodiment of the present invention. All the simple and equivalent changes and modifications made according to the claims and the content of the specification of the present invention fall within the scope of the claims of the present invention. The present invention is not described in detail in the conventional technical content.

Claims (9)

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.

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