KR20010023785A - Device for vehicles and method for manufacturing the device - Google Patents

Abstract

A vehicle, in particular a lightweight vehicle device, comprises a metal frame 2 which forms a support part for a body comprising large body units 8, 9 of plastic, in particular thermoplastics. The frame 1 comprises pillars 5, 6 which project upwardly from the base structure, which pillars support the body of the vehicle and possibly also the roof / side beams. The front part of the vehicle, ie the front body part 9, is designed as a component part molded into one part and is mounted / attached in the front set of frames of the pillars 5. In the same way the rear body part 8 of the vehicle is a component part molded into one part and attached to the rear pillar 6. The part between the front and rear pillars 5, 6 together with the upper loop part is covered by plate part 10, door part and the like, all parts consisting of large plastic parts.

Description

DEVICE FOR VEHICLES AND METHOD FOR MANUFACTURING THE DEVICE}

Today, the manufacture of vehicles, in particular the manufacture of automobiles, welds plates and panels into units, structures that have the required strength and rigidity, and the structure of the body formed by assembling the body with the installation of chassis, springs, wheel suspensions, engines and other parts. Based on this, a variety is made. This construction method consists of a rigid frame and is substantially advanced over conventional vehicle structures in which panels and body parts are mounted to the frame.

The development is based on the use of steel with plates formed as panels and very reasonably and effectively welded together and automating assembly lines. Therefore, this fabrication method is very advanced in terms of control and precision by making a lot of investments involved. Therefore, this kind of fabrication method is appropriate and financially rational for the production of large fabrication volumes.

Today, further developments are miniaturization and lightweight, and above all, the production of vehicles and vehicles that can be driven with reduced energy consumption, thereby reducing the environmental burden. For this purpose, recent materials and new manufacturing methods are applied. Another feature of this development direction is the manufacture of vehicles or motor vehicles that cover special needs or sales markets, which are not intended for universal use, such as over long distances. Such "sale" vehicles, which are also regarded as means of transport or transport, do not usually meet the requirements for the production of very large production volumes, and are therefore the particular application of such vehicles that have not been widely used in automobile construction so far. Develop manufacturing methods and materials.

However, even in the case of the vehicle, a vehicle providing a user with a very high degree of safety is very important, and in this case, it is also essential to combine the required strength and deformation state of the design in order to satisfy the current safety requirements.

The use of profiles made of aluminum is shown to provide an interesting structural method for the development of future vehicles through so-called "space frames". The frame is manufactured by joining the profiles together by welding, glue bonding or by other mechanical attachment means. Such a frame, for example made of aluminum, is light in weight and can be calculated and sized to provide a very high level of safety. In order to be able to construct the final vehicle, panels and body parts must be continuously manufactured on each other on this frame. For this purpose a metal, possibly an aluminum panel or a plastic panel, mounted on the frame by a substantially known method can be used. Although this may represent a step back towards the traditional structural technology to which the frame is applied, at the same time the greater safety is achieved with the frame, the only difference is that modern materials such as aluminum and plastic are used, and this type of drying method It may be a huge benefit for the new vehicle type described above. One reason for this is that a fairly low investment is required to enable the development of vehicles on this basis. The modern method is best suited for smaller production numbers.

Support frames of this kind can be produced relatively simply in steel structures in which simple surface treatments are carried out to prevent corrosion. This treatment can be substantially simplified compared to the surface treatment of traditional automotive bodies that are subsequently popular.

"Spatial frame" is the term for this type of frame consisting of a profile with a joining point. This applies to many types and brings significant benefits. However, the main purpose is to be able to achieve a simplified and reasonable installation of body parts and panels.

The prior art uses plastics in body parts of various design variants combined with aluminum frames or steel frames. Polyester or epoxy body parts are most commonly used, but other types of plastics are also applied by vacuum forming (injection molding) and panels are made by spraying and fitting.

An example of such a known design can be found, for example, in DE 19500361, which discloses a body / frame structure in which the rear frame part and the outer loop beam make up the part and are in turn attached to the lower floor part. In the rear, the outer panel is attached to the outside of it in order. In EPO 584576 an external structure is applied, which forms a substantial cabin in which the front module is mounted and the parts are glued together. Similar designs based on complete cabins are also detailed in EPO 547583.

In EP patents 485457 and 697974 the method is described in detail how a metal frame can be used in combination with a large body part that can form the entire body in a simple design.

The present invention relates to a vehicular device comprising a metal frame, which frame forms a support part for a body consisting of a large body unit made of plastic, preferably thermoplastic, in particular colored thermoplastic. The frame also includes pillars that project upwardly from the base structure to support the body of the vehicle and, if necessary, to support the loop / side beams. The invention also relates to a method for manufacturing a vehicle of this kind.

1 is a complete schematic view of the device according to the invention in which the parts are completely separated from each other;

2 is a second embodiment of the present invention showing a schematic horizontal portion,

3 is a side view of one embodiment corresponding to FIG. 2 in relation to a cabriolet design, FIG.

4 is a side view of the cooper type vehicle design of FIG. 3.

It is an object of the present invention to provide a new shape of a vehicle assembly in which the vehicle body can be manufactured from a large plastic unit, preferably a new shape of a vehicle assembly that can be manufactured from a thermoplastic plastic unit, in particular a colored thermoplastic unit. To provide. The body parts are manufactured in a smaller production series and can be mounted in a simple and quick manner on a vehicle frame structure made of aluminum or the like without the use of complicated aids.

This object is achieved according to the invention with a device of the type mentioned in the introduction, which is characterized by the features of the claims. The invention also includes a method for manufacturing a vehicle of this kind, which method is specified by the features of claim 13.

The present invention differs from known designs and presents very simplified designs. A known design problem is that the process of mounting rigid cast bodies or large parts of the bodies is slow and difficult because the prefabricated frame structures are difficult to integrate and mount.

In any case, it is necessary to divide the frame structure so that a large body member can be installed. This not only results in special working operations with the frame assembly to ensure simplified mounting and safety satisfaction, but also often results in damage and cost of the frame structure. For example, a design according to DE 19500361 requires a frame structure of welded and integrated metal plates, since only body panels are given to the vehicle without the closely coupled body modules.

It is an object of the present invention to integrate a style and appearance that has a functional solution and utility by the combination of a metal frame and a plastic panel. This is achieved in such a way that the plastic body part has a more integrated function than being simpler with external and visible advantages. In addition, the construction method is applied such that the plastic body parts include functions such as the separation and sealing of the vehicle's internal and external environment, which parts include parts such as wheel arches, drip trays and the like, sealing edges and the like. It may include.

It is also a special feature of the present invention that the molding method and material can be used for the manufacture of body parts which can eliminate the need for the painting of the body parts. The painting is an undesirable operation because of environmental conditions and costs.

In a particular embodiment of the invention the front and rear vehicle body parts are designed to overlap and consequently reinforce the central part in the vehicle. This provides additional reinforcement and separation between the external and internal environments, which can be useful in particular applications.

The invention will be explained in more detail by the embodiment shown in the drawings.

As mentioned above, the drawings are complete schematic and show the main design of the device according to the invention and the method of manufacturing the device. Other features may vary and will be techniques that can be practiced by those skilled in the art without difficulty, so that only the parts included in the drawings are necessary to illustrate the inventive concept.

1 illustrates the principle of the device according to the invention in which the final assembly shape is shown by broken lines, while any body part is drawn to the side.

The basic component in the design is a metal frame, for example a frame of the "space frame" type, denoted by reference numeral 1, on which the necessary mechanical components and systems are mounted in a simple and reasonable manner. The frame opens to an easy passage. The vehicle is therefore composed of chassis systems, engines and other technical coupling members at the front and rear without any obstacle from the enclosed area in the frame.

According to the electric system, that is, whether the engine requiring space for arranging the electrically powered batteries as possible is installed in front or in the rear, the floor system 2 can be made flexible, and therefore, for example, Designated by the symbol 3, a space for the electric system is formed below the vehicle.

The floor 2 is therefore attached to the frame on two levels, for example to provide space and the opportunity for mounting batteries underneath the vehicle in the region. In this kind of design it is attempted to place a high floor level under the seat 4.

The pillars, denoted by A and B pillars and projecting upwards of the vehicles 5 and 6, are mounted on the frame together with the roof frame 7 for closed vehicles. The pillars projecting upwards are preferably arranged almost vertically, but may be angled or curved depending on the body design.

The body consists mainly of the rear parts 8, which comprise large body parts, including both rear parts, wheel arches and fenders, and possibly other floor parts attached to the B pillars 6 of the vehicle. If the vehicle has four doors, the component 8 can be attached to the so-called C pillar of the vehicle, and the B pillar becomes an intermediate pillar. The front part 9 of the vehicle is indicated as a cover which opens below, thereby being placed on the engine and wheels and attached to the area around the A pillars 5 of the vehicle. Inside, it is convenient to construct a separate torpedo wall from the pedals assembled on the dashboard to close and seal the inner cabin. This cover 12 may also be an extended part of the plate of the floor. A loose roof 10 may be attached to the frame on the window, and the door may be installed between the pillars on the A and B pillars 5 and 6, respectively, possibly three pillars on each side. It can be installed by using.

In figures 2 to 4 a second embodiment of the invention is shown in which the rear and front parts 8, 9 overlap each other. The front body part 9 of the vehicle extends rearward to the outside size and design of the vehicle in the area up to the A pillar 5, while the rear body part 8 extends the vehicle from the rear pillar or B pillar 6 to the area. It is designed by the external shape and external measurement required. In this embodiment, the front part of the rear body part 8 extends forward from the inside of the pillars 5, 6 to the remaining area of the inside of the cabin, the inside of the cabin being the inner compartment of the cabin and the outer technical compartment or motor compartment. A wall 11 protrudes or extends upwardly therebetween, and is limited to attachment or closure of the lower window frame 13. In the same way, the rear body part comprises the dashboard of the vehicle or the basic part of the dashboard as shown in FIG. 3.

By applying suitable plastic materials and molding techniques, the bumper cover can be molded into the front part 9 together with other detailed parts such as safety means for grills, recesses and the like.

The door is installed as a continuous part of the assembly process and is attached to the front pillar 5 and fixed in a sealed state with respect to the pillar 6. An important feature of this design is that the split line between the door and the rear body part can be adjusted in a simple manner by adjusting or changing the hinge point for the door on the pillar 5. The front part can then be adjusted towards the front door line, as a result of being completely aligned with the door split.

That is, when three pillars such as A, B and C pillars are used, the process procedure will be the same and also when mounting the rear door. 1 shows a vehicle with a roof structure. 4 may be applied to the same vehicle device design without a loop.

The present invention describes a very reasonable and effective way of constructing a vehicle. After mechanical parts, chassis, springs, engines and the like are mounted on this open frame, body parts, front and rear parts 9 and 8 are mounted. It can be made into different types of plastic by different manufacturing methods that offer the possibility of constructing three-dimensional large parts. One example of such a part is a rotationally molded part and vacuum forming and suction may also be applied for a given design criterion. Preferred materials are thermoplastics and in particular colored thermoplastics, but other plastics with similar properties may also be used.

The assembly of the plastic body part and the metal structure is not more than a body to be bonded and sealed to each other, thus providing the possibility of providing good sealing. The plastic edge can be pressed into the metal structure and fixed by clamping, for example. Despite the fact that this relatively large body part does not provide any structural strength in the structure, the body parts have an obvious functional effect that is reached in a complete vehicle.

The invention has been described in purely schematic terms, and it is described that three pillars may be used on each side instead of two pillars. The apparatus can be varied in many ways within the scope of the claims by maintaining the components in a three-dimensional shape that gives the main features: large component parts as the front part and large component parts as the rear part, giving great strength and rigidity. Can and thereby provide a safety body. It is possible to change the actual design and shape.

Claims (13)

A vehicle comprising a metal frame (1) forming a support part for a plastic body (8, 9), wherein the metal frame (1) comprises a base structure and a plastic body (8, 9), possibly loop / In a vehicle comprising two or more sets of support pillars 5, 6 protruding upward of the side beams, The front part 9 of the vehicle, such as the front part of the plastic body, which is a component part molded into one part, is mounted / attached to the area of the front set of the metal frame of the pillar 5, In the same way the rear part of the plastic body is a component part molded into one part, attached to the rear set of pillars 6, With the upper loop part, the part between the front and rear sets of pillars 5, 6 is covered with plate parts 10, such as door parts, all of which are molded as plastic parts of a large body. vehicle. 2. The vehicle according to claim 1, wherein an additional pillar is provided between the pillars (5,6) for installation of two door parts on each side of the vehicle. 2. The vehicle according to claim 1, wherein the rear body part (8) is designed with one piece of side wall, wheel arch, rear part and floor. 2. Vehicle according to claim 1, characterized in that the front body part (9) comprises a bumper, a side, a wheel arch and a bonnet, preferably with a hole downwards for the engine for maintenance purposes. The floor according to claim 1, wherein a floor is mounted on the metal frame structure (1), preferably a metal floor is welded on the metal frame structure, the floor from the rear end of the vehicle on the back wheel toward the toffee wall of the vehicle. An extension, forming two levels, such that the drive system, battery, tank, etc. can be mounted below the highest floor level of the vehicle. 2. The edge of the rear body part and possibly the floor part according to claim 1 in which the profile on the metal frame structure 1 forms an attachment and seal between the frame 1 and the plastic body parts 8, 9. A vehicle which is guided / fixed against the vehicle. 2. The front body component (9) according to claim 1, characterized in that the front body component (9) is attached to the front with respect to the bumper component and at the front set of the lower and upper portions of the pillars (5) to form an opening in which the door can swing. Vehicle made. 2. Vehicle according to claim 1, characterized in that at least one said plastic body part (8,9) is designed from translucent plastic material. 2. The rear body part (8) according to claim 1, wherein the rear body part (8) extends behind the pillar (5) and preferably past the front set of pillars (5) by means of the extension (5). The front set of (6) is characterized in that the front wall protruding upwards, the opening necessary for the door cut from the body part, and the like are terminated. 10. A component according to claim 9, wherein the component facing upwards of the rear component (8) of the vehicle on the interior of the pillars (5) and (6) comprises an upper component forming a seal and attachment to the lower frame component of the windscreen. Characterized in that the vehicle. 10. The device according to claim 9, wherein the upwardly facing part or the front part of the rear part 8 of the vehicle comprises an upper part which forms, in whole or in part, the dashboard of the vehicle or the basic part of the dashboard. Featured vehicle. 10. The vehicle according to claim 9, wherein the rear body part (8) is formed / formed as a part together with the roof (10) of the vehicle. Plastic frame of metal frame structure 1, a set of pillars 5, 6 protruding upwards in the lateral region of the vehicle, preferably of large component parts 8, 9 made of thermoplastic and in particular colored thermoplastics In the manufacturing method of the vehicle provided with, Mounting a plastic component part 8 as a part on the metal frame 1 from the rear end region of the vehicle on the frame, attaching it to the rear set of pillars 6 and to the actual frame 1, Preferably attached by a clamp, Being attached to the front pillar and the front set of pillars by means of a rear body part 8 having an extended lateral portion, The front plastic body part 9 then engages in a similar manner from the front side of the vehicle, Doors, windows, etc. are coupled between the pillars, and The method of manufacturing a vehicle, characterized in that the optional open loop region consists of a step covered by a plate part (10) of plastic.