WO2024244236A1 - 一种车身结构及其制造方法和汽车 - Google Patents

一种车身结构及其制造方法和汽车 Download PDF

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Publication number
WO2024244236A1
WO2024244236A1 PCT/CN2023/121343 CN2023121343W WO2024244236A1 WO 2024244236 A1 WO2024244236 A1 WO 2024244236A1 CN 2023121343 W CN2023121343 W CN 2023121343W WO 2024244236 A1 WO2024244236 A1 WO 2024244236A1
Authority
WO
WIPO (PCT)
Prior art keywords
panel
pillar
outer panel
plate
wheel cover
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/CN2023/121343
Other languages
English (en)
French (fr)
Inventor
杨忠
杨周林
廖水平
徐治安
彭代顺
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Deepal Automobile Technology Co Ltd
Original Assignee
Deepal Automobile Technology Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Deepal Automobile Technology Co Ltd filed Critical Deepal Automobile Technology Co Ltd
Priority to EP23939210.3A priority Critical patent/EP4556352A4/en
Publication of WO2024244236A1 publication Critical patent/WO2024244236A1/zh
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/02—Side panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/02—Side panels
    • B62D25/025—Side sills thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/08—Front or rear portions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/08—Front or rear portions
    • B62D25/088—Details of structures as upper supports for springs or dampers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/20—Floors or bottom sub-units
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D65/00—Designing, manufacturing, e.g. assembling, facilitating disassembly, or structurally modifying motor vehicles or trailers, not otherwise provided for
    • B62D65/02—Joining sub-units or components to, or positioning sub-units or components with respect to, body shell or other sub-units or components
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/08—Front or rear portions
    • B62D25/082—Engine compartments
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/40—Engine management systems

Definitions

  • the present invention relates to the technical field of automobile body structures, and in particular to a body structure and a manufacturing method thereof, and an automobile.
  • the traditional automobile body is made of hundreds of parts and components that are welded through multiple processes, from single parts to sub-assemblies, and from sub-assemblies to assemblies, that is, the front cabin welding assembly, front floor welding assembly, rear floor welding assembly, side panel welding assembly, top cover welding assembly, and other major assemblies are formed, and finally assembled into the body-in-white assembly on the main line.
  • the production process it is necessary to arrange reinforcement plates on each single part, resulting in more than 500 single parts.
  • thousands of sets of molds and hundreds of sets of fixtures are required to be welded through more than 6,000 welding points.
  • Each single part has many separate molding and welding processes and high labor costs.
  • One of the purposes of the present invention is to provide a vehicle body structure to solve the problem of too many integrated parts in the vehicle body structure in the prior art; the second purpose is to provide a method for manufacturing the vehicle body structure; and the third purpose is to provide a car.
  • a vehicle body structure is provided, the key of which is to include:
  • Left and right side enclosure inner panels including a left side enclosure inner panel and a right side enclosure inner panel formed by hot stamping of a whole sheet material, wherein the left side enclosure inner panel and the right side enclosure inner panel are symmetrically arranged on both sides;
  • the left and right side outer panel reinforcement plates include a left side outer panel reinforcement plate and a right side outer panel reinforcement plate formed by hot stamping of an integral sheet material.
  • the left side outer panel reinforcement plate and the right side outer panel reinforcement plate are symmetrically arranged on both sides, the left side outer panel reinforcement plate is arranged on the outside of the left side inner panel, and the right side outer panel reinforcement plate is arranged on the outside of the right side inner panel;
  • a cabin frame is provided between the left side inner panel and the right side inner panel and is located at the front section of the left and right side inner panels, and the cabin frame includes a cabin frame left front longitudinal beam section, a cabin frame right front longitudinal beam section and a cabin frame rear section, which are formed by hot stamping of an integral sheet material;
  • Left and right front wheel covers including a left front wheel cover and a right front wheel cover formed by hot stamping of a whole sheet material, wherein the left front wheel cover and the right front wheel cover are respectively arranged on both sides of the cabin frame;
  • a front panel formed by hot stamping of a whole sheet material and arranged at the rear section of the cabin frame and between the left side panel and the right side panel;
  • a rear floor frame is formed by hot stamping of a whole sheet material, and the rear floor frame is arranged between the left side inner panel and the right side inner panel and is located at the rear section of the left and right side inner panels;
  • the left and right rear wheel covers include a left rear wheel cover and a right rear wheel cover which are integrally formed by hot stamping of a whole sheet material, and the left rear wheel cover and the right rear wheel cover are respectively arranged on both sides of the rear floor frame.
  • the left side inner panel and the right side inner panel are both formed by hot stamping of an integral plate body having two closed door rings; the left side inner panel and the right side inner panel each include:
  • An inner panel A-pillar portion comprising an inner panel A-pillar upper end portion and an inner panel A-pillar lower end portion;
  • An inner panel threshold portion is located between the lower end of the inner panel A-pillar and the lower end of the inner panel C-pillar, and the lower end of the inner panel B-pillar is connected to the middle of the inner panel threshold portion;
  • the first inner panel side beam portion is located between the upper end of the inner panel B-pillar and the upper end of the inner panel A-pillar;
  • the second inner panel side beam portion is located between the upper end of the inner panel B-pillar and the upper end of the inner panel C-pillar;
  • the inner panel A-pillar portion, the first inner panel upper side beam portion, the inner panel B-pillar portion and the inner panel threshold portion form a first inner closed door ring
  • the inner panel C-pillar portion, the second inner panel upper side beam portion, the inner panel B-pillar portion and the inner panel threshold portion form a second inner closed door ring.
  • an inner panel B-pillar patch plate is provided on the upper portion of the inner panel B-pillar portion, and the inner panel B-pillar patch plate is hot stamped together with the integrated plate body.
  • the left side outer panel reinforcement plate and the right side outer panel reinforcement plate are both formed by hot stamping of an integrated plate body having two closed door rings; the left side outer panel reinforcement plate and the right side outer panel reinforcement plate both include:
  • the A-pillar part of the outer panel includes the upper end of the A-pillar of the outer panel and the lower end of the A-pillar of the outer panel;
  • An outer panel B-pillar portion including an outer panel B-pillar upper end portion and an outer panel B-pillar lower end portion;
  • An outer panel C-pillar portion including an outer panel C-pillar upper end portion and an outer panel C-pillar lower end portion;
  • An outer panel threshold portion is located between the lower end of the outer panel A-pillar and the lower end of the outer panel C-pillar, and the lower end of the outer panel B-pillar is connected to the middle of the outer panel threshold portion;
  • the first outer panel side beam portion is located between the upper end of the outer panel B-pillar and the upper end of the outer panel A-pillar;
  • the second outer panel side beam portion is located between the upper end of the outer panel B-pillar and the upper end of the outer panel C-pillar;
  • the outer panel A-pillar portion, the first outer panel upper side beam portion, the outer panel B-pillar portion and the outer panel sill portion form a first outer closed door ring
  • the outer panel C-pillar portion, the second outer panel upper side beam portion, the outer panel B-pillar portion and the outer panel sill portion form a second outer closed door ring.
  • the left side outer panel reinforcement plate and the right side outer panel reinforcement plate also include an outer panel A-pillar upper patch plate and an outer panel A-pillar lower patch plate;
  • the outer panel A-pillar upper patch plate starts at the upper end of the outer panel A-pillar and extends along the first outer panel upper beam portion to the upper end of the outer panel B-pillar, and the outer panel A-pillar upper patch plate is hot stamped together with the integrated plate body;
  • the outer panel A-pillar lower patch plate is arranged on the outer panel A-pillar portion and is located between the upper end of the outer panel A-pillar and the lower end of the outer panel A-pillar, and the outer panel A-pillar lower patch plate is hot stamped together with the integrated plate body.
  • the outer edges of the left side outer panel reinforcement plate, the right side outer panel reinforcement plate, and the inner edges of the first outer closed door ring and the second outer closed door ring are all provided with flange connection surfaces
  • the outer edges of the left side inner panel, the right side inner panel, and the inner edges of the first inner closed door ring and the second inner closed door ring are all provided with flange connection surfaces
  • the left side outer panel reinforcement plate and the left side inner panel, and the right side outer panel reinforcement plate and the side inner panel are respectively connected through the flange connection surfaces.
  • the cross-sections of the left front longitudinal beam section and the right front longitudinal beam section of the cabin frame are both " ⁇ "-shaped force transmission structures with the opening facing upward.
  • a front longitudinal beam sealing plate is provided at the upward openings of the left front longitudinal beam section and the right front longitudinal beam section of the cabin frame.
  • the cabin frame further includes a first cabin patch plate and a second cabin patch plate, which are arranged at the rear section of the cabin frame and are stamped integrally with the overall sheet material.
  • the front panel includes an upper front panel portion, a lower front panel portion, and a reinforcing beam portion located between the upper front panel portion and the lower front panel portion, and a cavity with a triangular cross-section is formed between the footrest position of the lower front panel portion and the rear section of the cabin frame.
  • the front panel further includes a first front panel patch plate and a second front panel patch plate
  • the first front panel patch plate is arranged at the left portion of the upper plate portion of the front panel and overlaps the reinforcing beam portion downward
  • the second front panel patch plate is arranged at the middle portion of the lower plate portion of the front panel and overlaps the reinforcing beam portion upward
  • the first front panel patch plate and the second front panel patch plate are integrally hot stamped with the overall sheet material of the front panel.
  • the rear floor frame includes a left beam portion, a right beam portion, and a front cross beam portion, a middle cross beam portion, and a rear cross beam portion located between the left beam portion and the right beam portion, wherein the front cross beam portion is closed and connected to the front ends of the left beam portion and the right beam portion, the rear cross beam portion is close to the rear ends of the left beam portion and the right beam portion, and the middle cross beam portion is located between the front cross beam portion and the right beam portion. between the part and the rear crossbeam.
  • the left rear wheel cover and the right rear wheel cover both include a rear wheel cover outer panel and a rear wheel cover inner panel
  • the front portion of the rear wheel cover inner panel is provided with a first overlapping edge and a second overlapping edge connected to the left and right side panel inner panels
  • the upper portion of the rear wheel cover inner panel is provided with a third overlapping edge overlapping the D-pillar
  • the rear portion of the rear wheel cover inner panel is provided with a fourth overlapping edge overlapping the rear wheel cover outer panel
  • the lower portion of the rear wheel cover inner panel is provided with a fifth overlapping edge overlapping the rear floor frame.
  • the outer C-pillar portions of the left and right side panel outer panel reinforcement plates and the inner C-pillar portions of the left and right side panel inner panels are correspondingly provided with flanges, the flanges of the inner C-pillar portions overlap with the first overlapping edge of the rear wheel house inner panel and the outer panel of the rear wheel house, the flanges of the outer C-pillar portions overlap with the plate surface of the rear wheel house outer panel, and a cavity structure with a closed cross-section is formed between the outer C-pillar portion and the inner C-pillar portion.
  • the left front wheel cover and the right front wheel cover both include a shock absorber mounting portion, a wheel cover portion, a wheel cover rear reinforcement portion, a wheel cover front reinforcement portion, a first front wheel cover patch plate and a second front wheel cover patch plate, wherein the first front wheel cover patch plate is attached to the shock absorber mounting portion and the inner side of the wheel cover portion, and the second front wheel cover patch plate is attached to the inner side of the wheel cover portion.
  • a method for manufacturing a vehicle body structure comprises the following steps:
  • Hot stamping is performed on the sheets after the patch plates are installed to form an integrated left side inner panel, a right side inner panel, a left side outer panel reinforcement plate, a right side outer panel reinforcement plate, a cabin frame, a left front wheel cover, a right front wheel cover, a front panel, a rear floor frame, a left rear wheel cover, and a right rear wheel cover;
  • the left side inner panel and the left side outer panel reinforcement plate are connected to form the left side panel assembly
  • the right side inner panel and the right side outer panel reinforcement plate are connected to form the right side panel assembly
  • the cabin frame is connected to the left front wheel, the right front wheel and the front panel to form the cabin assembly
  • the rear floor frame is connected to the left rear wheel cover and the right rear wheel cover to form the rear floor assembly
  • the front cabin assembly is connected to the left side panel assembly, the right side panel assembly and the rear floor assembly to form the body structure.
  • a car in a third aspect, is provided, the key of which is that it includes the car body structure described in any embodiment of the first aspect.
  • the beneficial effects of the present invention are as follows:
  • the present invention integrates the individual pieces of the vehicle body structure into an integrated sheet material, which is then hot stamped into an integrated part, and then the parts are welded to form a highly integrated vehicle body structure; the traditional welding of multiple parts, multiple processes and multiple welding points is changed to a simple welding of several integrated hot-formed parts, thereby avoiding matching quality problems caused by part size errors; avoiding collision performance differences caused by differences in the consistency of the states of multiple parts; reducing the number of welding points, thereby reducing the probability of welding point failure, thereby improving collision stability and improving the safety of the entire vehicle.
  • FIG1 is a schematic diagram of the parts layout of a vehicle body structure shown in an exemplary embodiment of the present invention.
  • FIG2 is a perspective view of a vehicle body structure shown in an exemplary embodiment of the present invention.
  • FIG3 is a schematic structural diagram of a cabin frame
  • Fig. 4 is a cross-sectional view taken along line F-F in Fig. 3;
  • FIG5 is a schematic diagram of the structure of the left and right front wheel covers
  • FIG6 is a rear view of FIG5
  • FIG7 is a schematic diagram of the structure of the front panel
  • Fig. 9 is a cross-sectional view of H-H in Fig. 8.
  • FIG10 is a schematic diagram of the structure of the left and right side inner panels
  • Fig. 11 is a cross-sectional view taken along line G-G of Fig. 10;
  • FIG12 is a schematic diagram of the structure of the left and right side outer panel reinforcement plates
  • FIG13 is a rear view of FIG12
  • FIG14 is a perspective view of the left and right side outer panel reinforcement plates
  • Fig. 15 is a cross-sectional view taken along line A-A in Fig. 13;
  • Fig. 16 is a cross-sectional view taken along line B-B in Fig. 13;
  • Fig. 17 is a cross-sectional view taken along line C-C in Fig. 13;
  • Figure 18 is a schematic diagram of the structure of the penetrating ribs
  • Fig. 19 is a cross-sectional view taken along line D-D in Fig. 13;
  • Fig. 20 is a cross-sectional view taken along line E-E in Fig. 13;
  • FIG21 is a schematic diagram of the left and right side panel outer panel reinforcement plates and the front finger beam, rear wheel cover, and door anti-collision beam;
  • Fig. 22 is a cross-sectional view taken along line I-I in Fig. 21;
  • FIG23 is a schematic diagram of the structure of the rear floor frame
  • FIG24 is a schematic diagram of the structure of the rear wheel housing inner plate
  • FIG25 is a partial enlarged view of the upper portion of FIG24;
  • FIG26 is a process flow chart of a method for preparing a vehicle body structure according to an exemplary embodiment of the present invention.
  • FIG27 is a schematic diagram of the force release of the vehicle body structure of the present invention.
  • FIG. 1 is a schematic structural diagram of a vehicle body structure shown in an exemplary embodiment of the present invention
  • FIG. 2 is a stereoscopic diagram of a vehicle body structure shown in an exemplary embodiment of the present invention.
  • This exemplary embodiment proposes a vehicle body structure, including left and right side inner panels, left and right side outer panel reinforcement panels, a cabin frame 1000, left and right front wheel housings, a front panel 3000, a rear floor frame 6000 and left and right rear wheel housings.
  • the left and right side panel inner plates include a left side panel inner plate formed by hot stamping of a whole sheet material.
  • the left side panel inner plate 4000L and the right side panel inner plate 4000R are symmetrically arranged on both sides.
  • the left and right side panel outer plate reinforcement plates include a left side panel outer plate reinforcement plate 5000L and a right side panel outer plate reinforcement plate 5000R formed by hot stamping of an integral sheet material, and the left side panel outer plate reinforcement plate 5000L and the right side panel outer plate reinforcement plate 5000R are symmetrically arranged on both sides, the left side panel outer plate reinforcement plate 5000L is arranged on the outside of the left side panel inner plate 4000L, and the right side panel outer plate reinforcement plate 5000R is arranged on the outside of the right side panel inner plate 4000R.
  • the cabin frame 1000 is arranged between the left side inner panel 4000L and the right side inner panel 4000R and is located at the front section of the left and right side inner panels.
  • the cabin frame 1000 includes a cabin frame left front longitudinal beam section 1002, a cabin frame right front longitudinal beam section 1003 and a cabin frame rear section 1001, which are formed by hot stamping of an integral sheet material.
  • the left and right front wheel covers include a left front wheel cover 2000L and a right front wheel cover 2000R, which are formed by hot stamping of an integral sheet material.
  • the left front wheel cover 2000L and the right front wheel cover 2000R are arranged on both sides of the cabin frame 1000.
  • the front panel 3000 is formed by hot stamping of an integral sheet material and is arranged at the rear section 1001 of the cabin frame and is located between the left side inner panel 4000L and the right side inner panel 4000R.
  • the rear floor frame 6000 is formed by hot stamping of a whole sheet material, and is disposed between the left side inner panel 4000L and the right side inner panel 4000R and is located at the rear section of the left and right side inner panels.
  • the left and right rear wheel covers include a left rear wheel cover 7000L and a right rear wheel cover 7000R formed by hot stamping of a whole sheet material, and the left rear wheel cover 7000L and the right rear wheel cover 7000R are disposed on both sides of the rear floor frame 6000.
  • the left side inner panel 4000L and the right side inner panel 4000R are both formed by hot stamping of an integral plate body with two closed door rings; the left side inner panel 4000L and the right side inner panel 4000R both include: an inner panel A-pillar portion 4200, an inner panel B-pillar portion 4300, an inner panel C-pillar portion 4500, an inner panel sill portion 4600, a first inner panel upper side beam portion 4100 and a second inner panel upper side beam portion 4400.
  • the inner panel A-pillar portion 4200 includes an upper end portion of the inner panel A-pillar and a lower end portion of the inner panel A-pillar;
  • the inner panel B-pillar portion 4300 includes an upper end portion of the inner panel B-pillar and a lower end portion of the inner panel B-pillar;
  • the inner panel C-pillar portion 4500 includes an upper end portion of the inner panel C-pillar and a lower end portion of the inner panel C-pillar;
  • the inner panel sill portion 4600 is located between the lower end portion of the inner panel A-pillar and the lower end portion of the inner panel C-pillar, and the lower end portion of the inner panel B-pillar is connected to the middle portion of the inner panel sill portion 4600;
  • the first inner panel upper side beam portion 4100 is located between the upper end portion of the inner panel B-pillar and the upper end portion of the inner panel A-pillar;
  • the second inner panel upper side beam portion 4400 is located between the upper end portion of the inner panel B-pillar and the upper end portion of the inner panel C-pillar.
  • the inner panel A-pillar portion 4200, the first inner panel upper side beam portion 4100, the inner panel B-pillar portion 4300 and the inner panel threshold portion 4600 form a first inner closed door ring
  • the inner panel C-pillar portion 4500, the second inner panel upper side beam portion 4400, the inner panel B-pillar portion 4300 and the inner panel threshold portion 4600 form a second inner closed door ring.
  • the side panel inner panel integrates the inner panel A-pillar portion 4200 traditionally integrated into the cabin assembly into the side panel inner panel, and at the same time integrates the inner panel threshold portion 4600 traditionally integrated into the rear floor assembly into the side panel inner panel, so that the side panel inner panel forms a closed and stable " ⁇ " shaped structure.
  • the side panel inner panel parts are highly integrated into a hot stamping forming part, thereby greatly reducing the number of parts developed and the number of molds, inspection tools and fixtures. Further reducing the production process can effectively improve the accuracy of the side panel welding assembly and reduce production costs, meet the demand for lightweighting, and improve the rigidity of the vehicle body as well as the front and side collision performance, which can fully protect the car from being injured after a passive impact.
  • a first inner plate reinforcing rib 4210 is provided at the connection between the inner plate A column portion 4200 and the front finger beam 5910, and the inner plate A column portion 4200 is also provided with a second inner plate reinforcing rib 4220 in a straight row of teeth.
  • the plate reinforcement rib 4210 transfers the force flow of the head-on collision upward to the first inner plate upper beam portion 4100 to release the force, and the lower portion of the first inner plate reinforcement rib 4210 transfers the force flow of the head-on collision downward to the second inner plate reinforcement rib 4220, and the second inner plate reinforcement rib 4220 can quickly disperse the force flow of the head-on collision and transfer it to the rear of the vehicle body.
  • the rear end edge of the inner plate C-pillar portion 4500 is provided with a curved third inner plate reinforcement rib 4510 extending from top to bottom, and a flange 4520 for overlapping with the rear wheel cover is added to the edge of the third inner plate reinforcement rib 4510. Increase the torsional rigidity of the whole vehicle, improve driving comfort, handling and safety.
  • the inner plate threshold portion 4600 is provided with a fourth inner plate reinforcement rib 4610, and the fourth inner plate reinforcement rib 4610 is connected to the second inner plate reinforcement rib 4220 through.
  • an inner panel B-pillar patch plate 4310 is provided on the upper portion of the inner panel B-pillar portion. The inner panel B-pillar patch plate 4310 is hot stamped together with the one-piece plate body, which can effectively enhance the protection of the heads of multiple occupants.
  • the left side outer panel reinforcement plate 5000L and the right side outer panel reinforcement plate 5000R are both formed by hot stamping of an integrated plate body with two closed door rings;
  • the left side outer panel reinforcement plate 5000L and the right side outer panel reinforcement plate 5000R each include an outer panel A column portion 5100, an outer panel B column portion 5300, an outer panel C column portion 5500, an outer panel sill portion 5600, a first outer panel side beam portion 5200 and the second outer panel side beam portion 5400
  • the outer panel A-pillar portion 5100 includes the upper end portion of the outer panel A-pillar and the lower end portion of the outer panel A-pillar
  • the outer panel B-pillar portion 5300 includes the upper end portion of the outer panel B-pillar and the lower end portion of the outer panel B-pillar
  • the outer panel C-pillar portion 5500 includes the upper end portion of the outer panel C-pillar and the lower end portion of the outer panel C-pillar
  • the outer panel sill portion 5600 is located between the lower end portion of the outer panel
  • the left side outer panel reinforcement plate 5000L and the right side outer panel reinforcement plate 5000R both further include an outer panel A-pillar upper patch plate 5016 and an outer panel A-pillar lower patch plate 5017;
  • the outer panel A-pillar upper patch plate 5016 starts from the upper end of the outer panel A-pillar and extends along the first outer panel side beam portion 5200 to the upper end of the outer panel B-pillar, and the outer panel A-pillar upper patch plate 5016 is hot stamped together with the integrated plate body;
  • the outer panel A-pillar lower patch plate 5017 is disposed at the outer panel A-pillar portion 5100 and is located between the upper end of the outer panel A-pillar and the lower end of the outer panel A-pillar, and the outer panel A-pillar lower patch plate 5017 is hot stamped together with the integrated plate body.
  • the positions of the outer panel A-pillar upper patch plate 5016 and the outer panel A-pillar lower patch plate 5017 include but are not limited to the above-mentioned positions, and can be reasonably distributed according to collision simulation analysis.
  • the patch plate 5016 on the outer plate A-pillar is formed together with the entire first outer plate side beam portion 5200 to form a bending resistance section.
  • the outer panel A-pillar upper patch plate 5016 can assist the first outer panel upper side beam to diffuse the collision energy to the outer panel B-pillar portion 5300, preventing the first outer panel side beam from bending and failing during the force transmission process.
  • the outer panel A-pillar lower patch plate 5017 can assist the outer panel A-pillar portion 5100 to transfer and diffuse the energy to the door anti-collision beam 5900 set on the door.
  • the outer edges of the left side outer panel reinforcement plate 5000L and the right side outer panel reinforcement plate 5000R and the inner edges of the first outer closed door ring and the second outer closed door ring are all provided with flange connection surfaces 5014
  • the outer edges of the left side inner panel 4000L and the right side inner panel 4000R and the inner edges of the first inner closed door ring and the second inner closed door ring are all provided with flange connection surfaces 5014
  • the left side outer panel reinforcement plate 5000L and the left side inner panel 4000L, the right side outer panel reinforcement plate 5000R and the side inner panel are respectively connected through the flange connection surfaces 5014.
  • the width H7 of the flange connection surface 5014 is 10-25mm to prevent the problem of unqualified flatness caused by the excessive length of the flange surface. Effectively improve the overall stiffness of the rear door ring and the mode of the rear wheel cover, and improve the user's driving experience.
  • the double door ring of the side outer panel reinforcement plate is integrated, the part size becomes larger and the part stamping depth increases, which often exceeds the maximum demolding depth of the current hot stamping forming equipment, and the forming difficulty increases. Therefore, it is necessary to design the double door ring structure adaptively, specifically:
  • the sharp point at the corner where the outer panel A-pillar portion 5100 and the outer panel sill portion 5600 are connected is processed into a smoothly transitioned inclined surface 5007 through C-angle treatment. This reduces the resistance during sheet forming, improves the bending fluidity of sheet forming, and reduces the forming depth of the sharp point, reducing the degree of difficulty.
  • connection between the outer panel A-pillar portion 5100 and the outer panel threshold portion 5600 forms a first corner 5008, and the connection between the outer panel B-pillar portion 5300 and the outer panel threshold portion 5600 forms a second corner 5009.
  • the inner fillet radius R1 of the first corner 5008 is greater than or equal to 2.5 times the depth H1 of the hot stamping at the first corner 5008, and the inner fillet radius R2 of the second corner 5009 is greater than or equal to 2.5 times the depth H2 of the hot stamping at the second corner 5009.
  • a secondary step surface 5012 for reducing the forming depth is provided at the first corner 5008; and a secondary step surface 5012 for reducing the forming depth is provided at the second corner 5009.
  • the provision of the step surface can reduce the forming depth of the corner area and meet the hot stamping depth requirement.
  • the four corners 5011 need to meet the following parameter requirements: the inner fillet radius R3 of the third corner 5010 is greater than or equal to 2.5 times the hot stamping depth H3 of the third corner 5010 , and the inner fillet radius R4 of the fourth corner 5011 is greater than or equal to 2.5 times the hot stamping depth H4 of the fourth corner 5011 .
  • a secondary step surface 5012 for reducing the forming depth is provided at the third corner 5010; and/or, a secondary step surface 5012 for reducing the forming depth is provided at the fourth corner 5011.
  • the setting of the step surface can reduce the forming depth of the corner area and meet the hot stamping depth requirements.
  • the forming depth of the front and rear double door ring door opening areas is relatively deep.
  • the radii of the front and rear door openings are made as large as possible. Therefore, in some embodiments, please refer to FIG. 17, the cross-sectional bending radius R5 of the outer panel door sill portion 5600 formed by hot stamping is ⁇ 6mm; please refer to FIG. 16, the cross-sectional bending radius R6 of the outer panel C-pillar portion 5500 formed by hot stamping is ⁇ 8mm.
  • the cross section of the outer plate C-pillar 5500 is a step-shaped with two reverse bends, and the outer edge of the outer plate C-pillar 5500 is provided with a flange 4520 connected to the rear wheel cover, and the width H5 of the flange 4520 is 15-25 mm to ensure that the flange 4520 does not wrinkle when the flange 4520 is formed. Since the lower part of the outer plate C-pillar 5500 is affected by the shape and the tire envelope, the lower part of the outer plate C-pillar 5500 is smaller in size, so the width H6 of the step surface of the outer plate C-pillar 5500 connected to the flange 4520 is ⁇ 30 mm to ensure the mold strength.
  • continuous through ribs 5015 are provided on the outer panel rocker portion 5600, the outer panel A-pillar portion 5100 and the first outer panel upper side beam portion 5200 to improve the cross-sectional bending resistance; as shown in Figure 18a, the through ribs 5015 form an "E"-shaped force transmission structure in the outer panel A-pillar portion 5100, and an anti-collision beam can be connected to the "E"-shaped force transmission structure.
  • part of the collision energy of the outer panel A-pillar portion 5100 is transmitted and diffused through the anti-collision beam, thereby reducing the force release pressure toward the upper end of the outer panel A-pillar and the first upper side beam, and the force release pressure toward the lower end of the outer panel A-pillar and the outer panel rocker portion 5600, and the local bending resistance section formed by the through ribs 5015 in the outer panel A-pillar portion 5100 is a " ⁇ " shape, as shown in Figure 19b.
  • the local bending-resistant section formed by the through rib 5015 at the outer panel rocker portion 56004 is in the shape of a letter " ⁇ ", as shown in c in Figure 17.
  • the " ⁇ "-shaped bending-resistant interface can effectively improve the overall impact resistance of the vehicle body structure and ensure the safety of the driver.
  • the cross-sections of the left front longitudinal beam section 1002 and the right front longitudinal beam section 1003 of the cabin frame are both in the shape of a " ⁇ " force transmission structure with the opening facing upward.
  • the left front longitudinal beam section 1002 and the right front longitudinal beam section 1003 of the cabin frame are provided with a front longitudinal beam sealing plate 1004 at the upward openings.
  • the openings of the traditional front longitudinal beam section facing both sides are changed to an opening It is upward, which facilitates hot stamping of the whole in the same stamping direction at one time, and the front longitudinal beam sealing plate 1004 can be assembled along the stamping direction, which makes production more convenient.
  • the cabin frame 1000 also includes a first cabin patch plate 1005 and a second cabin patch plate 1006, which are arranged in the rear section 1001 of the cabin frame and are stamped and formed integrally with the overall sheet material to achieve a reasonable definition of three zones, absorb most of the energy through the crumple energy absorption zone and the bending zone, improve the safety of the rigid body at the root of the left and right front longitudinal beam sections, and protect the safety of the occupants.
  • the dash panel 3000 includes a dash panel upper plate portion 3100, a dash panel lower plate portion 3200, and a reinforcing beam portion 3300 located between the dash panel upper plate portion 3100 and the dash panel lower plate portion 3200.
  • the reinforcing beam portion 3300 also includes a dash panel middle reinforcing cross beam 3310, a dash panel left reinforcing beam 3320, and a dash panel right reinforcing beam 3330.
  • a middle channel reinforcing rib 3210 is provided in the middle of the dash panel lower plate portion 3200. As shown in FIGS.
  • a cavity with a triangular cross section is formed between the footrest position of the dash panel lower plate portion 3200 and the rear section 1001 of the cabin frame.
  • the cavity structure is highly stable, partially improving the rigidity of the footrest position, and together with the reinforced cross beam 3310 in the front wall panel, forms a double cross beam structure for the front wall.
  • the double cross beam structure has stronger lateral stability and a larger moment of inertia of the cavity section, thereby improving the torsional rigidity of the body-in-white and the collision performance of the whole vehicle.
  • the double cross beam structure is directly welded from two hot-formed parts, which reduces the number of welding points compared to the traditional double cross beam welded from multiple parts, thus avoiding quality problems caused by welding failure.
  • the front panel 3000 is further provided with a first front panel patch plate 3400 and a second front panel patch plate 3500
  • the first front panel patch plate 3400 is arranged on the left part of the upper plate portion 3100 of the front panel and overlaps with the reinforcing beam portion 3300 downward
  • the second front panel patch plate 3500 is arranged in the middle part of the lower plate portion 3200 of the front panel and overlaps with the reinforcing beam portion 3300 upward
  • the first front panel patch plate 3400 and the second front panel patch plate 3500 are integrally hot stamped with the overall sheet material of the front panel 3000.
  • the rear floor frame 6000 includes a left beam 6100, a right beam 6200, and a front cross beam 6300, a middle cross beam 6400, and a rear cross beam 6500 located between the left beam 6100 and the right beam 6200.
  • the left beam 6100 and the right beam 6200 are symmetrically distributed and arranged along the front-rear direction of the vehicle body.
  • the front cross beam 6300 is closed and connected to the front ends of the left beam 6100 and the right beam 6200.
  • the rear cross beam 6500 is arranged close to the rear ends of the left beam 6100 and the right beam 6200.
  • the middle cross beam 6400 is located between the front cross beam 6300 and the rear cross beam 6500.
  • the front cross beam 6300, the middle cross beam 6400, and the rear cross beam 6500 are spaced and vertically distributed between the left beam 6100 and the right beam 6200.
  • the material strength and thickness of the left beam 6100, the right beam 6200, the front cross beam 6300, the middle cross beam 6400 and the rear cross beam 6500 can be flexibly combined according to the strength requirements, which can reduce the number of parts and reduce the weight of the vehicle body, while also improving the strength of the vehicle body.
  • the left rear floor side beam and the right rear floor side beam adopt a unequal material thickness design, and are divided into different sections along the longitudinal direction of the vehicle body according to different strength requirements.
  • the left beam 6100 includes the left beam front section 6101, the left first transition area 6102, The left connecting section 6103 of the middle cross beam, the second left transition zone 6104, the middle section 6105 of the left beam, the third left transition zone 6106, the left connecting section 6107 of the rear cross beam, the fourth left transition zone 6108 and the rear section 6109 of the left beam
  • the right beam 6200 includes the front section 6201 of the right beam, the first right transition zone 6202, the right connecting section 6203 of the middle cross beam, the second right transition zone 6204, the middle section 6205 of the right beam, the third right transition zone 6206, the right connecting section 6207 of the rear cross beam, the fourth right transition zone 6208 and the rear section 6209 of the right beam.
  • Each transition zone has a smooth transition and the front and rear sections have different material thickness structures, so that the strength performance between the front and rear sections is smoothly transitioned, and no sudden change in strength performance is caused, which further improves the strength performance of the vehicle body.
  • the material thickness of the left beam 6100 and the right beam 6200 can be flexibly combined according to the strength requirements of different sections, and the weight reduction effect is better than that of patch plates and tailor-welded plates, and the parts performance is better.
  • the rear floor frame 6000 is formed by hot stamping of integral sheet metal welded by laser, and has ultra-high strength.
  • the design of hot stamping of the rear floor frame 6000 reduces the development of tooling such as stamping dies, single-piece inspection fixtures and welding fixtures, reduces the number of stamping times and the amount of post-process welding, improves the production efficiency, dimensional accuracy and strength of parts, and reduces the cost of part development.
  • the left rear wheel housing 7000L and the right rear wheel housing 7000R both include a rear wheel housing outer panel 7300 and a rear wheel housing inner panel 7100
  • the front portion of the rear wheel housing inner panel 7100 is provided with a first overlapping edge 7103 and a second overlapping edge 7104 connected to the left and right side panel inner panels
  • the upper portion of the rear wheel housing inner panel 7100 is provided with a third overlapping edge 7105 overlapping the D-pillar
  • the rear portion of the rear wheel housing inner panel 7100 is provided with a fourth overlapping edge 7106 overlapping the rear wheel housing outer panel
  • the lower portion of the rear wheel housing inner panel 7100 is provided with a fifth overlapping edge 7107 overlapping the rear floor frame 6000.
  • the wheel housing inner plate may be appropriately provided with a reinforcing rib structure and a patch plate structure, such as the rear wheel housing patch plate 7200, the rear wheel housing rear reinforcing rib 7101 and the front wheel housing front reinforcing rib 7102 shown in Figures 24 and 25.
  • the outer plate C-pillar portion 5500 of the left and right side enclosure outer plate reinforcing plate and the inner plate C-pillar portion 4500 of the left and right side enclosure inner plate are provided with the flange 4520, the flange 4520 of the inner plate C-pillar portion 4500 overlaps with the first overlap edge 7103 of the rear wheel housing inner plate 7100 and the rear wheel housing outer plate, the flange 4520 of the outer plate C-pillar portion 5500 overlaps with the plate surface of the rear wheel housing outer plate, and a cavity structure with a closed cross section is formed between the outer plate C-pillar portion 5500 and the inner plate C-pillar portion 4500.
  • the left front wheel cover 2000L and the right front wheel cover 2000R both include a shock absorber mounting portion 2110, a wheel cover portion 2120, a wheel cover rear reinforcement portion 2130, a wheel cover front reinforcement portion 2140, a first front wheel cover patch plate 2200, and a second front wheel cover patch plate 2300.
  • the first front wheel cover patch plate 2200 is attached to the inner side of the shock absorber mounting portion 2110 and the wheel cover portion 2120
  • the second front wheel cover patch plate 2300 is attached to the inner side of the wheel cover portion 2120.
  • a first reinforcing rib 2121, a second reinforcing rib 2122, a third reinforcing rib 2123, and a fourth reinforcing rib 2141 are further provided.
  • FIG. 26 is a process flow chart of a method for manufacturing a vehicle body structure according to an exemplary embodiment of the present invention.
  • This exemplary embodiment also provides a method for manufacturing a vehicle body structure, comprising the following steps:
  • the sheets are hot stamped to form an integrated left side inner panel 4000L, right side inner panel 4000R, left side outer panel reinforcement plate 5000L, right side outer panel reinforcement plate 5000R, cabin frame 1000, left front wheel cover 2000L, right front wheel cover 2000R, front panel 3000, rear floor frame 6000, left rear wheel cover 7000L, and right rear wheel cover 7000R.
  • the left side panel inner panel 4000L and the left side panel outer panel reinforcement plate 5000L are connected to form the left side panel assembly
  • the right side panel inner panel 4000R and the right side panel outer panel reinforcement plate 5000R are connected to form the right side panel assembly
  • the cabin frame 1000 is connected with the left front wheel, the right front wheel and the front panel 3000 to form the cabin assembly
  • the rear floor frame 6000 is connected with the left rear wheel cover 7000L and the right rear wheel cover 7000R to form the rear floor assembly
  • the front cabin assembly is connected with the left side panel assembly, the right side panel assembly and the rear floor assembly to form the body structure.
  • This exemplary embodiment provides a car, comprising the vehicle body structure described in any of the above exemplary embodiments.
  • this technical solution plans the layout of the vehicle body structure, re-plans the division of vehicle body parts, and combines hot stamping technology to integrate dozens of parts into one.
  • the internal weld point connection of the traditional structure is eliminated in the one-piece hot stamping part, and the internal lap welding edge is eliminated.
  • Materials of different material grades or thicknesses are connected by laser welding or unequal thickness plates to achieve the performance requirements of different areas of the vehicle body and maximize the utilization of material sheets; the internal reinforcement plate structure of the one-piece hot stamping part is changed from the traditional reinforcement plate and the main body parts are formed separately and then spot welded to a patch plate structure in which the reinforcement plate and the main body material are spot welded first and then hot stamped as a whole.
  • This highly integrated hot stamping body structure breaks the traditional thinking and highly integrates the subordinate components of the cabin welding assembly, rear floor welding assembly and left and right side panel welding assembly, including a highly integrated one-piece hot stamping cabin frame 1000, one-piece hot stamping front wheel cover, one-piece hot stamping front panel 3000, one-piece hot stamping side panel inner panel double door ring reinforcement plate, one-piece hot stamping side panel outer panel reinforcement plate reinforcement ring, one-piece hot stamping rear wheel cover inner panel 7100 and one-piece hot stamping rear floor frame 6000.
  • the front cabin welding assembly of the traditional automobile body structure in which each sub-assembly is roughly composed of 110-180 individual parts due to the difference in vehicle models.
  • the cabin assembly can be composed of an integral hot stamping cabin frame 1000, left and right front wheel covers, a front panel 3000 and 5-8 traditional sheet metal welding parts, and the total number of parts does not exceed 40.
  • the left and right side panel welding assemblies of the traditional automobile body structure in which each sub-assembly is roughly composed of 150-200 individual parts due to the difference in vehicle models.
  • the left and right side panel assemblies include the left and right side panel inner panels, the left and right side panel outer panel reinforcement plates, and the rear wheel housing inner panel 7100, and the total number of parts does not exceed 50.
  • the rear floor welding assembly of the traditional automobile body structure in which each sub-assembly is roughly composed of 100-150 individual parts due to the difference in vehicle models.
  • the rear floor welding assembly is composed of an integral hot stamping rear floor frame 6000, plus the rear floor panel, and the total number of parts does not exceed 30.
  • the collision force transmission path: F1/F2/F3 is mainly composed of a The body is composed of a thermoformed cabin frame 1000.
  • the collision force transmission path: F4 is mainly welded by an integrated thermoformed side outer panel reinforcement plate and a side inner panel;
  • the collision force transmission path: F5/F6 is mainly composed of an integrated thermoformed rear floor frame 6000; it avoids matching quality problems caused by part size errors; it avoids collision performance differences caused by differences in the consistency of multiple parts; it reduces the number of welds, thereby reducing the probability of weld failure, thereby improving collision stability and improving vehicle safety.

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Abstract

一种车身结构，制造方法及汽车，该方法包括包括:将左右侧围内板(4000L，4000R）、左右侧围外板加强板（5000L，5000R）、机舱骨架（1000）、左右前轮罩（2000L，2000R）、前围板（3000）、后地板骨架（6000）和左右后轮罩（7000L，7000R)的落料片拼接为一体式板体，再分别进行热冲压成型，最后连接形成车身结构。由此，避免了因零件尺寸误差，造成的匹配质量问题；避免了因多零件状态一致性差异，造成的碰撞性能差异；减少了焊点数量，从而减少焊点失效概率，进而提升碰撞稳定性，提升整车安全。

Description

一种车身结构及其制造方法和汽车 技术领域
本发明涉及汽车车身结构技术领域，具体涉及一种车身结构及其制造方法和汽车。
背景技术
近年来随着电动汽车的迅猛发展，为了提升续航里程，电动汽车需要配备更大更多的电池包，因此，相较于同等规格的燃油车，电动汽车整车重量要大幅度地增加，这将导致在同样试验条件下，车辆的碰撞初期整车动能增加，即电动汽车的车身结构需要能够承担更大的力和吸收更多的运动能量来提升安全性。进一步，在智能化的电动汽车中，电池包和智能化电子装置的布置需占用大量空间，传统燃油车的各种经典的车身碰撞安全结构不适用，因此设计一种既能满足电池包和智能化电子装置布置又能满足车辆安全的新型车身结构势在必行。进一步，随着消费者对汽车产品的价值观变化，汽车产品的快速更新换代成为汽车发展的一个趋势。因此高性能、高精度、短周期、低成本、轻量化是各大车企急需快速解决的重难点瓶颈问题。为解决以上问题，汽车高度集成化是电动汽车未来发展的必然趋势。
总的而言，传统汽车车身由数百个零部件经过多工序焊接，由单件焊接为分总成，由分总成焊接为总成，即形成前机舱焊接总成、前地板焊接总成、后地板焊接总成、侧围焊接总成、顶盖焊接总成等等几大总成，最后在主线合拼为白车身总成。由于生产过程中，还要各个单件上再布置加强板件，造成单件数量超过五百个，同时还需要上千套模具和几百套夹具通过超过六千个焊点焊接而成，每个单件单独成型和焊接工序多、工时费用高。存在零部件数量繁多且制造工序复杂，零部件之间搭接匹配关系复杂，尺寸链过长，关键接附点结构不连续等问题，同时，由于采用点焊连接，总成内部的各个单件之间需要预留搭接的搭接面，搭接区域占用较大面积，增加了材料用量及产品重量。这些问题严重制约着白车身向高性能、高精度、轻量化、短周期、低成本方向发展。
发明内容
本发明的目的之一在于提供一种车身结构，以解决现有技术中车身结构集成零件过多的问题；目的之二在于提供一种车身结构的制造方法；目的之三在于提供一种汽车。
为了实现上述目的，本发明采用的技术方案如下：
第一方面，提供一种车身结构，其关键在于，包括：
左右侧围内板，包括由整体板料一体热冲压成型的左侧围内板和右侧围内板，所述左侧围内板和右侧围内板对称分设于两侧；
左右侧围外板加强板，包括由整体板料一体热冲压成型的左侧围外板加强板和右侧围外板加强 板，所述左侧围外板加强板和右侧围外板加强板对称分设于两侧，所述左侧围外板加强板设于左侧围内板外侧，所述右侧围外板加强板设于右侧围内板的外侧；
机舱骨架，设于左侧围内板和右侧围内板之间并位于所述左右侧围内板的前段，所述机舱骨架包括机舱骨架左前纵梁段、机舱骨架右前纵梁段和机舱骨架后段组合形成的整体板料一体热冲压成型；
左右前轮罩，包括由整体板料一体热冲压成型的左前轮罩和右前轮罩，所述左前轮罩和右前轮罩分设于机舱骨架两侧；
前围板，由整体板料一体热冲压成型并设于所述机舱骨架后段并位于左侧围内板和右侧围内板之间；
后地板骨架，由整体板料一体热冲压成型，所述后地板骨架设于所述左侧围内板和右侧围内板之间并位于所述左右侧围内板的后段；
左右后轮罩，包括由整体板料一体热冲压成型的左后轮罩和右后轮罩，所述左后轮罩和右后轮罩分设于后地板骨架两侧。
基于第一方面，在一些实施方式中，所述左侧围内板和右侧围内板均以具有两个封闭门环的一体式板体热冲压而成；所述左侧围内板和右侧围内板均包括：
内板A柱部，包括内板A柱上端部和内板A柱下端部；
内板B柱部，包括内板B柱上端部和内板B柱下端部；
内板C柱部，包括内板C柱上端部和内板C柱下端部；
内板门槛部，位于所述内板A柱下端部与内板C柱下端部之间，所述内板B柱下端部与内板门槛部的中部连接；
第一内板上边梁部，位于内板B柱上端部与内板A柱上端部之间；
第二内板上边梁部，位于内板B柱上端部与内板C柱上端部之间；
所述内板A柱部、第一内板上边梁部、内板B柱部和内板门槛部形成第一内封闭门环，所述内板C柱部、第二内板上边梁部、内板B柱部、内板门槛部形成第二内封闭门环。
基于第一方面，在一些实施方式中，所述内板B柱部的上部设有内板B柱补丁板，所述内板B柱补丁板与所述一体式板体一同热冲压成型。
基于第一方面，在一些实施方式中，所述左侧围外板加强板和右侧围外板加强板均以具有两个封闭门环的一体式板体热冲压而成；所述左侧围外板加强板和右侧围外板加强板均包括：
外板A柱部，包括外板A柱上端部和外板A柱下端部；
外板B柱部，包括外板B柱上端部和外板B柱下端部；
外板C柱部，包括外板C柱上端部和外板C柱下端部；
外板门槛部，位于所述外板A柱下端部与外板C柱下端部之间，所述外板B柱下端部与外板门槛部的中部连接；
第一外板上边梁部，位于外板B柱上端部与外板A柱上端部之间；
第二外板上边梁部，位于外板B柱上端部与外板C柱上端部之间；
所述外板A柱部、第一外板上边梁部、外板B柱部和外板门槛部形成第一外封闭门环，所述外板C柱部、第二外板上边梁部、外板B柱部、外板门槛部形成第二外封闭门环。
基于第一方面，在一些实施方式中，所述左侧围外板加强板和右侧围外板加强板均还包括外板A柱上补丁板和外板A柱下补丁板；所述外板A柱上补丁板起始于所述外板A柱上端部并沿第一外板上边梁部延伸至外板B柱上端部，所述外板A柱上补丁板与所述一体式板体一同热冲压成型；所述外板A柱下补丁板设于所述外板A柱部并位于外板A柱上端部与外板A柱下端部之间，所述外板A柱下补丁板与所述一体式板体一同热冲压成型。
基于第一方面，在一些实施方式中，所述左侧围外板加强板、右侧围外板加强板的外边以及第一外封闭门环和第二外封闭门环的内边均设有法兰连接面，所述左侧围内板、右侧围内板的外边以及第一内封闭门环和第二内封闭门环的内边均设有法兰连接面，所述左侧围外板加强板与左侧围内板、所述右侧围外板加强板与由侧围内板分别通过所述法兰连接面连接。
基于第一方面，在一些实施方式中，所述机舱骨架左前纵梁段和机舱骨架右前纵梁段的断面均呈开口朝上的“凵”字形传力结构。
基于第一方面，在一些实施方式中，所述机舱骨架左前纵梁段和机舱骨架右前纵梁段朝上的开口处设有前纵梁封板。
基于第一方面，在一些实施方式中，所述机舱骨架还包括第一机舱补丁板和第二机舱补丁板，所述第一机舱补丁板和第二机舱补丁板设于所述机舱骨架后段并与整体板料一体冲压成型。
基于第一方面，在一些实施方式中，所述前围板包括前围板上板部、前围板下板部和位于前围板上板部与前围板下板部之间的加强梁部，所述前围板下板部的脚踏位置与机舱骨架后段之间形成断面呈三角形的腔体。
基于第一方面，在一些实施方式中，所述前围板还包括第一前围补丁板和第二前围补丁板，所述第一前围补丁板设于所述前围板上板部部左部并向下与所述加强梁部搭接，所述第二前围补丁板设于所述前围板下板部部的中部并向上与所述加强梁部搭接，所述第一前围补丁板和第二前围补丁板与前围板的整体板料一体热冲压成型。
基于第一方面，在一些实施方式中，所述后地板骨架包括左边梁部、右边梁部和位于左边梁部和右边梁部之间的前横梁部、中横梁部和后横梁部，所述前横梁部封闭连接于所述左边梁部和右边梁部的前端，所述后横梁部靠近设置于所述左边梁部和右边梁部的后端，所述中横梁部位于前横梁 部和后横梁部之间。
基于第一方面，在一些实施方式中，所述左后轮罩和右后轮罩均包括后轮罩外板和后轮罩内板，所述后轮罩内板前部设有与左右侧围内板连接第一搭接边和第二搭接边，所述后轮罩内板上边设有与D柱搭接的第三搭接边，所述后轮罩内板后部设有与后轮罩外板搭接的第四搭接边，所述后轮罩内板的下部设有与后地板骨架搭接的第五搭接边。
基于第一方面，在一些实施方式中，所述左右侧围外板加强板的外板C柱部和左右侧围内板的内板C柱部均对应设有翻边，所述内板C柱部的翻边与后轮罩内板第一搭接边和后轮罩外板搭接，所述外板C柱部的翻边与后轮罩外板的板面搭接，并在外板C柱部和内板C柱部形成断面呈封闭的腔体结构。
基于第一方面，在一些实施方式中，所述左前轮罩和右前轮罩均包括减震器安装部、轮罩部、轮罩后加强部、轮罩前加强部、第一前轮罩补丁板和第二前轮罩补丁板，所述第一前轮罩补丁板附着于减震器安装部和轮罩部的内侧，所述第二前轮罩补丁板附着于轮罩部内侧。
第二方面，提供一种车身结构的制造方法，其关键在于，包括以下步骤：
S1、在整块的左侧围内板板料、右侧围内板板料、左侧围外板加强板板料、右侧围外板加强板板料、机舱骨架板料、左前轮罩板料、右前轮罩板料、前围板板料、后地板骨架板料、左后轮罩板料、右后轮罩板料上分别安装相应的补丁板；
S2、对安装好补丁板后的各个板料进行热冲压成型并分别形成一体式的左侧围内板、右侧围内板、左侧围外板加强板、右侧围外板加强板、机舱骨架、左前轮罩、右前轮罩、前围板、后地板骨架、左后轮罩、右后轮罩；
S3、左侧围内板和左侧围外板加强板连接形成左侧围总成，右侧围内板和右侧围外板加强板连接形成右侧围总成，机舱骨架与左前轮、右前轮和前围板连接形成机舱总成，后地板骨架与左后轮罩和右后轮罩连接形成后地板总成，然后将前机舱总成与左侧围总成、右侧围总成和后地板总成连接形成车身结构。
第三方面，提供一种汽车，其关键在于：包括第一方面任一实施方式所述的车身结构。
本发明的有益效果：本发明方案将车身结构各个单件集成为一体式板料，再热冲压形成一体式零件，再由各个零件焊接形成高度集成的车身结构；将传统的多零件多工序多焊点焊接而成更改为简单的几个一体成型的热成型零件焊接而成，避免了因零件尺寸误差，造成的匹配质量问题；避免了因多零件状态一致性差异，造成的碰撞性能差异；减少了焊点数量，从而减少焊点失效概率，进而提升碰撞稳定性，提升整车安全。
附图说明
图1为本发明一示例性实施例所示的一种车身结构的零件布局示意图；
图2为本发明一示例性实施例所示的一种车身结构的立体图；
图3为机舱骨架的结构示意图；
图4为图3中F-F剖面图；
图5为左右前轮罩的结构示意图；
图6为图5的后视图；
图7为前围板的结构示意图；
图8为机舱骨架与左右前轮罩及前围板的装配示意图；
图9为图8中H-H剖视图；
图10为左右侧围内板的结构示意图；
图11为图10的G-G剖面图；
图12为左右侧围外板加强板的结构示意图；
图13为图12的后视图；
图14为左右侧围外板加强板的立体图；
图15为图13中A-A剖面图；
图16为图13中B-B剖面图；
图17为图13中C-C剖面图；
图18为贯穿肋筋的结构示意图；
图19为图13中D-D剖面图；
图20为图13中E-E剖面图；
图21为左右侧围外板加强板与前指梁、后轮罩、车门防撞梁的示意图；
图22为图21中I-I剖面图；
图23为后地板骨架的结构示意图；
图24为后轮罩内板的结构示意图；
图25为图24中上部的局部放大图；
图26为本发明一示例性实施例所示的一种车身结构的制备方法的工艺流程图；
图27为本发明车身结构的泄力示意图；
其中1000-机舱骨架、1001-机舱骨架后段、1002-机舱骨架左前纵梁段、1003-机舱骨架右前纵梁段、1004-前纵梁封板、1005-第一机舱补丁板、1006-第二机舱补丁板、2000L-左前轮罩、2000R-右前轮罩、2110-减震器安装部、2120-轮罩部、2121-第一加强筋、2122-第二加强筋、2123-第三加强筋、2130-轮罩后加强部、2140-轮罩前加强部、2141-第四加强筋、2200-第一前轮罩补丁板、2300-第二前轮罩补丁板、3000-前围板、3100-前围板上板部、3200-前围板下板部、3210-中通道加强筋、 3300-加强梁部、3310-前围板中加强横梁、3320-前围板左加强梁、3330-前围板右加强梁、3400-第一前围补丁板、3500-第二前围补丁板、4000L-左侧围内板、4000R-右侧围内板、4100-第一内板上边梁部、4200-内板A柱部、4300-内板B柱部、4400-第二内板上边梁部、4500-内板C柱部、4600-内板门槛部、4210-第一内板加强筋、4220-第二内板加强筋、4310-内板B柱补丁板、4510-第三内板加强筋、4520-翻边、4610-第四内板加强筋、5000L-左侧围外板加强板、5000R-右侧围外板加强板、5100-外板A柱部、5200-第一外板上边梁部、5300-外板B柱部、5400-第二外板上边梁部、5500-外板C柱部、5600-外板门槛部、5017-外板A柱下补丁板、5016-外板A柱上补丁板、5900-车门防撞梁、5910-前指梁、5007-斜面、5008-第一拐角；5009-第二拐角、5010-第三拐角、5011-第四拐角、5012-二级台阶面、5013-翻边、5014-法兰连接面；5015-贯穿肋筋、6000-后地板骨架、6100-左边梁、6101-左边梁前段、6102-左一过渡区、6103-中横梁左连接段、6104-左二过渡区、6105-左边梁中段、6106-左三过渡区、6107-后横梁左连接段、6108-左四过渡区、6109-左边梁后段、6200-右边梁、6201-右边梁前段、6202-右一过渡区、6203-中横梁右连接段、6204-右二过渡区、6205-右边梁中段、6206-右三过渡区、6207-后横梁右连接段、6208-右四过渡区、6209-右边梁后段、6300-前横梁、6400-中横梁、6500-后横梁、6001-左前焊缝、6002-右前焊缝、6003-左中焊缝、6004-右中焊缝、6005-左后焊缝、6006-右后焊缝、7000L-左后轮罩、7000R-右后轮罩、7100-后轮罩内板、7200-后轮罩补丁板、7300后轮罩外板、7101-后轮罩后部加强筋、7102-后轮罩前部加强筋、7103-第一搭接边、7104-第二搭接边、7105-第三搭接边、7106-第四搭接边、7107-第五搭接边、7201-补丁板上连接边、7202-补丁板第一连接处、7203-补丁板第二连接处。
具体实施方式
以下将参照附图和优选实施例来说明本发明的实施方式，本领域技术人员可由本说明书中所揭露的内容轻易地了解本发明的其他优点与功效。本发明还可以通过另外不同的具体实施方式加以实施或应用，本说明书中的各项细节也可以基于不同观点与应用，在没有背离本发明的精神下进行各种修饰或改变。应当理解，优选实施例仅为了说明本发明，而不是为了限制本发明的保护范围。
需要说明的是，以下实施例中所提供的图示仅以示意方式说明本发明的基本构想，遂图式中仅显示与本发明中有关的组件而非按照实际实施时的组件数目、形状及尺寸绘制，其实际实施时各组件的型态、数量及比例可为一种随意的改变，且其组件布局型态也可能更为复杂。
图1为本发明一示例性实施例所示的一种车身结构的结构示意图；图2为本发明一示例性实施例所示的一种车身结构的立体图。
请参阅附图1和2所示：本示例性实施例提出了一种车身结构，包括左右侧围内板、左右侧围外板加强板、机舱骨架1000、左右前轮罩、前围板3000、后地板骨架6000和左右后轮罩。
请参阅附图1和2所示：所述左右侧围内板包括由整体板料一体热冲压成型的左侧围内板 4000L和右侧围内板4000R，所述左侧围内板4000L和右侧围内板4000R对称分设于两侧。所述左右侧围外板加强板包括由整体板料一体热冲压成型的左侧围外板加强板5000L和右侧围外板加强板5000R，所述左侧围外板加强板5000L和右侧围外板加强板5000R对称分设于两侧，所述左侧围外板加强板5000L设于左侧围内板4000L外侧，所述右侧围外板加强板5000R设于右侧围内板4000R的外侧。所述机舱骨架1000设于左侧围内板4000L和右侧围内板4000R之间并位于所述左右侧围内板的前段，所述机舱骨架1000包括机舱骨架左前纵梁段1002、机舱骨架右前纵梁段1003和机舱骨架后段1001组合形成的整体板料一体热冲压成型。所述左右前轮罩包括由整体板料一体热冲压成型的左前轮罩2000L和右前轮罩2000R，所述左前轮罩2000L和右前轮罩2000R分设于机舱骨架1000两侧。所述前围板3000由整体板料一体热冲压成型并设于所述机舱骨架后段1001并位于左侧围内板4000L和右侧围内板4000R之间。所述后地板骨架6000由整体板料一体热冲压成型，所述后地板骨架6000设于所述左侧围内板4000L和右侧围内板4000R之间并位于所述左右侧围内板的后段。所述左右后轮罩包括由整体板料一体热冲压成型的左后轮罩7000L和右后轮罩7000R，所述左后轮罩7000L和右后轮罩7000R分设于后地板骨架6000两侧。
请参阅附图10所示：在一些实施例中，所述左侧围内板4000L和右侧围内板4000R均以具有两个封闭门环的一体式板体热冲压而成；所述左侧围内板4000L和右侧围内板4000R均包括：内板A柱部4200、内板B柱部4300、内板C柱部4500、内板门槛部4600、第一内板上边梁部4100和第二内板上边梁部4400。所述内板A柱部4200包括内板A柱上端部和内板A柱下端部；所述内板B柱部4300包括内板B柱上端部和内板B柱下端部；所述内板C柱部4500包括内板C柱上端部和内板C柱下端部；所述内板门槛部4600位于所述内板A柱下端部与内板C柱下端部之间，所述内板B柱下端部与内板门槛部4600的中部连接；所述第一内板上边梁部4100位于内板B柱上端部与内板A柱上端部之间；所述第二内板上边梁部4400位于内板B柱上端部与内板C柱上端部之间。所述内板A柱部4200、第一内板上边梁部4100、内板B柱部4300和内板门槛部4600形成第一内封闭门环，所述内板C柱部4500、第二内板上边梁部4400、内板B柱部4300、内板门槛部4600形成第二内封闭门环。侧围内板将传统集成于机舱总成的内板A柱部4200集成在了侧围内板上，同时将传统集成于后地板总成的内板门槛部4600集成在了侧围内板上，从而使侧围内板形成封闭稳定的“日”字形结构。并使得侧围内板零件高度集成化为一个热冲压成型零件，从而大大的减少零件开发数量，并且大幅度减少了模具、检具、夹具的数量。进一步减少生产工序有效提升侧围焊接总成精度并降低生产成本，实现轻量化的需求，并提升车身的刚度以及正面和侧面碰撞性能，能够充分保障汽车在受到被动撞击后，降低车内乘客的受伤程度。
请参阅附图10所示：具体实施过程中，在所述内板A柱部4200与前指梁5910连接处设有第一内板加强筋4210，所述内板A柱部4200还设有直排齿形的第二内板加强筋4220，所述第一内 板加强筋4210将正碰的力流向上朝第一内板上边梁部4100传递泄力，第一内板加强筋4210的下部将正碰的力流向下朝第二内板加强筋4220传递，所述第二内板加强筋4220能将正碰的力流迅速分散并朝车体后部传递。所述内板C柱部4500的后端边缘从上向下延伸设有一条曲线型的第三内板加强筋4510，并在所述第三内板加强筋4510的边缘增加用于与后轮罩搭接的翻边4520。增加整车扭转刚度，提高驾驶舒适性、操控性和安全性。所述内板门槛部4600上设有第四内板加强筋4610，所述第四内板加强筋4610与第二内板加强筋4220贯穿连通。另外，如图11所示，所述内板B柱部的上部设有内板B柱补丁板4310，所述内板B柱补丁板4310与所述一体式板体一同热冲压成型，可有效加强多乘员头部的保护。
请参阅附图12和13和14所示：在一些实施例中，所述左侧围外板加强板5000L和右侧围外板加强板5000R均以具有两个封闭门环的一体式板体热冲压而成；所述左侧围外板加强板5000L和右侧围外板加强板5000R均包括外板A柱部5100、外板B柱部5300、外板C柱部5500、外板门槛部5600、第一外板上边梁部5200和第二外板上边梁部5400，所述外板A柱部5100包括外板A柱上端部和外板A柱下端部；所述外板B柱部5300包括外板B柱上端部和外板B柱下端部；所述外板C柱部5500包括外板C柱上端部和外板C柱下端部；所述外板门槛部5600位于所述外板A柱下端部与外板C柱下端部之间，所述外板B柱下端部与外板门槛部5600的中部连接；所述第一外板上边梁部5200位于外板B柱上端部与外板A柱上端部之间；所述第二外板上边梁部5400位于外板B柱上端部与外板C柱上端部之间；所述外板A柱部5100、第一外板上边梁部5200、外板B柱部5300和外板门槛部5600形成第一外封闭门环，即前门环，所述外板C柱部5500、第二外板上边梁部5400、外板B柱部5300、外板门槛部5600形成第二外封闭门环，即后门环，从而形成封闭稳定的“日”字形结构，将传统的近20个零件集成为1个一体式零件，大幅度的减少了模具、夹具、检具的数量，缩短了工序，减短了尺寸链长度，加快产品精度达成，减少调试时间，缩短产品开发周期，减少了人力资源的投入，有利于产品的快速迭代。另外，通过对第二外封闭门环的集成，形成整体式连续C柱结构，有效的提升整车扭转性能，改善驾驶体验感。
请参阅附图12所示：在一些实施例中，所述左侧围外板加强板5000L和右侧围外板加强板5000R均还包括外板A柱上补丁板5016和外板A柱下补丁板5017；所述外板A柱上补丁板5016起始于所述外板A柱上端部并沿第一外板上边梁部5200延伸至外板B柱上端部，所述外板A柱上补丁板5016与所述一体式板体一同热冲压成型；所述外板A柱下补丁板5017设于所述外板A柱部5100并位于外板A柱上端部与外板A柱下端部之间，所述外板A柱下补丁板5017与所述一体式板体一同热冲压成型。所述外板A柱上补丁板5016和所述外板A柱下补丁板5017设置的位置包括但不限于上述设置位置，可根据碰撞仿真分析合理分布。另外，为了满足不同部位的不同碰撞需求，所述外板A柱上补丁板5016与整个所述第一外板上边梁部5200一同成型形成的抗弯截 面为圆拱形。外板A柱上补丁板5016可以辅助第一外板上边梁将碰撞能量扩散至外板B柱部5300，防止第一外板上边梁在传力过程中折弯失效。外板A柱下补丁板5017可以辅助于外板A柱部5100将能量向车门上设置的车门防撞梁5900传递扩散。
请参阅附图17所示：在一些实施例中，所述左侧围外板加强板5000L、右侧围外板加强板5000R的外边以及第一外封闭门环和第二外封闭门环的内边均设有法兰连接面5014，所述左侧围内板4000L、右侧围内板4000R的外边以及第一内封闭门环和第二内封闭门环的内边均设有法兰连接面5014，所述左侧围外板加强板5000L与左侧围内板4000L、所述右侧围外板加强板5000R与由侧围内板分别通过所述法兰连接面5014连接。所述法兰连接面5014的宽度H7为10-25mm，以防止因法兰面过长而引起的平面度不合格的问题。有效的提升后门环的整体刚度和后轮罩的模态，提高用户行驶体验感。
具体实施过程中，对于左右侧围外板加强板，还进行了以下设计：
首先，由于侧围外板加强板双门环集成后，零件尺寸变大，零件冲压深度增加，往往会超过目前热冲压成型设备的最大脱模深度，成型难度增加，因此需要对双门环结构进行适应性的设计，具体的有：
请参阅附图14和15所示，外板A柱下端部存在尖点位置，尖点位置会出现因材料过度变薄而开裂的现象，因此在一些实施中，所述外板A柱部5100与外板门槛部5600连接的拐角处的尖点位置通过C角处理形成平缓过渡的斜面5007。从而降低板料成型时的阻力，提升板料成型的弯曲流动性，同时缩小了该尖点位置的成型深度，降低程度难度。
请参阅附图13所示，前门环的内环下部的两个拐角位置由于产品限制造成型面变化急剧，成型难度大，为保证门洞拐角处成型不开裂，因此在一些实施例中，所述第一外封闭门环中，所述外板A柱部5100与外板门槛部5600连接处形成第一拐角5008，所述外板B柱部5300与外板门槛部5600连接处形成第二拐角5009，所述第一拐角5008的内圆角半径R1大于或等于2.5倍第一拐角5008处热冲压成型的深度H1，所述第二拐角5009的内圆角半径R2大于或等于2.5倍第二拐角5009处热冲压成型的深度H2。
请参阅附图13所示，为了进一步能够满足R1≥2.5H1及R2≥2.5H2，降低实施难度，因此在具体实施过程中，在所述第一拐角5008处设置用于降低成型深度的二级台阶面5012；在所述第二拐角5009处设置用于降低成型深度的二级台阶面5012。另外，台阶面的设置能够降低拐角区域的成型深度，满足热冲压深度要求。
请参阅附图13所示，后门环的内环下部的两个拐角位置由于产品限制造成型面变化急剧，成型难度大，为保证门洞拐角处成型不开裂，因此在一些实施例中，所述外板C柱部5500与外板门槛部5600连接处形成的第三拐角5010、所述外板B柱部5300与外板门槛部5600连接处形成的第 四拐角5011需满足如下参数要求：所述第三拐角5010的内圆角半径R3大于或等于2.5倍第三拐角5010处热冲压成型的深度H3，所述第四拐角5011的内圆角半径R4大于或等于2.5倍第四拐角5011处热冲压成型的深度H4。
请参阅附图13所示，为了进一步能够满足R3≥2.5H3及R4≥2.5H4，降低实施难度，因此在具体实施过程中，所述第三拐角5010处设有用于降低成型深度的二级台阶面5012；和/或，所述第四拐角5011处设有用于降低成型深度的二级台阶面5012。另外，台阶面的设置能够降低拐角区域的成型深度，满足热冲压深度要求。
前后双门环门洞区域成型深度较深，为避免成型时板料阻力过大，影响整个门洞成型性能，甚至局部开裂，前后门洞圆角尽量做大，因此在一些实施例中，请参阅附图17所示，所述外板门槛部5600热冲压成型形成的截面的弯角半径R5≥6mm；请参阅附图16所示，所述外板C柱部5500的热冲压成型形成的截面的弯角半径R6≥8mm。
请参阅附图16所示，在一些实施例中，所述外板C柱部5500的截面为具有两个反向弯角的台阶形，所述外板C柱部5500外侧边缘设有与后轮罩连接的翻边4520，所述翻边4520的宽度H5为15-25mm，以保证翻边4520成型时，翻边4520不起皱。由于外板C柱部5500的下部受造型和轮胎包络的影响，导致外板C柱部5500的下部尺寸较小，因此与所述翻边4520相接的所述外板C柱部5500台阶面的宽度H6≥30mm，以保证模具强度。
请参阅附图21所示：其次，由于在偏置碰撞过程中，能量会经前纵梁第一传力通道F1和前指梁5910第二传力通道F2传输至外板A柱部5100，为了进一步提升车身结构的整体抗冲击能力，对其结构进行了进一步设计，具体的有：
请参阅附图13和18所示，在一些实施例中，在所述外板门槛部5600、外板A柱部5100和第一外板上边梁部5200上设有连续的贯穿肋筋5015，提升截面抗弯曲能力；如图18中a所示，所述贯穿肋筋5015在外板A柱部5100局部形成“E”字形传力结构，“E”字形传力结构处可连接设置防撞梁，通过“E”字形传力结构将外板A柱部5100的部分碰撞能量通过防撞梁传递扩散，减小向外板A柱上端部和第一上边梁方向的泄力压力及向外板A柱下端部和外板门槛部5600方向的泄力压力，且该贯穿肋筋5015在外板A柱部5100形成的局部抗弯截面为“ㄇ”字形，如图19中b所示。所述贯穿肋筋5015在外板门槛部56004形成的局部抗弯截面为“ㄇ”字形，如图17中c所示。“ㄇ”字形的抗弯曲界面能够有效提升车身结构的整体抗冲击性能，保证驾驶人员的安全。
请参阅附图3和4所示：在一些实施例中，所述机舱骨架左前纵梁段1002和机舱骨架右前纵梁段1003的断面均呈开口朝上的“凵”字形传力结构。所述机舱骨架左前纵梁段1002和机舱骨架右前纵梁段1003朝上的开口处设有前纵梁封板1004。将传统前纵梁断面朝向两侧的开口改为开口 朝上，便于整体一次按同一冲压方向热冲压成型，而且前纵梁封板1004可沿冲压方向上件，生产更加方便。
请参阅附图3和4所示：在一些实施例中，在一些实施例中，所述机舱骨架1000还包括第一机舱补丁板1005和第二机舱补丁板1006，所述第一机舱补丁板1005和第二机舱补丁板1006设于所述机舱骨架后段1001并与整体板料一体冲压成型，达成合理定义三区，通过溃缩吸能区、折弯区吸收大部分能量，提高左右前纵梁段根部刚性体安全性，保护乘员安全。
请参阅附图7所示：在一些实施例中，在一些实施例中，所述前围板3000包括前围板上板部3100、前围板下板部3200和位于前围板上板部3100与前围板下板部3200之间的加强梁部3300，所述加强梁部3300还包括前围板中加强横梁3310、前围板左加强梁3320、前围板右加强梁3330，所述前围板下板部3200的中部设有中通道加强筋3210。如图8和9所示：所述前围板下板部3200的脚踏位置与机舱骨架后段1001之间形成断面呈三角形的腔体。该腔体结构稳定性较强，局部提升脚踏位置刚性，并与前围板中加强横梁3310形成前围双横梁结构，该双横梁结构较传统的单横梁结构，横向稳定性更强，腔体截面惯性矩更大，从而提升白车身扭转刚度，提升整车碰撞性能。该双横梁结构直接由二个热成型零件焊接而成，较传统的由多个零件拼焊而成的双横梁，减少了焊点，避免因焊接失效而产生的质量问题。
请参阅附图7所示：在一些实施例中，为了进一步提升前围板3000不同区域的强度需求，所述前围板3000上还设有第一前围补丁板3400和第二前围补丁板3500，所述第一前围补丁板3400设于所述前围板上板部3100部左部并向下与所述加强梁部3300搭接，所述第二前围补丁板3500设于所述前围板下板部3200部的中部并向上与所述加强梁部3300搭接，所述第一前围补丁板3400和第二前围补丁板3500与前围板3000的整体板料一体热冲压成型。
请参阅附图23所示：在一些实施例中，所述后地板骨架6000包括左边梁6100部、右边梁6200部和位于左边梁6100部和右边梁6200部之间的前横梁6300部、中横梁6400部和后横梁6500部，所述左边梁6100部和右边梁6200部对称分布并均沿车身前后方向设置，所述前横梁6300部封闭连接于所述左边梁6100部和右边梁6200部的前端，所述后横梁6500部靠近设置于所述左边梁6100部和右边梁6200部的后端，所述中横梁6400部位于前横梁6300部和后横梁6500部之间。所述前横梁6300部、中横梁6400部和后横梁6500部间隔且垂直分布于左边梁6100部和右边梁6200部之间。
请参阅附图23所示：具体实施过程中，左边梁6100部、右边梁6200部、前横梁6300部、中横梁6400部和后横梁6500部的材料强度和料厚可根据强度要求灵活组合，可减少零件数量和降低车身重量，同时还能提升车身强度。所述左后地板边梁和右后地板边梁采用的是不等料厚设计，沿车身纵向根据不同强度要求分为不同分段，左边梁6100包括左边梁前段6101、左一过渡区6102、 中横梁左连接段6103、左二过渡区6104、左边梁中段6105、左三过渡区6106、后横梁左连接段6107、左四过渡区6108和左边梁后段6109，右边梁6200包括右边梁前段6201、右一过渡区6202、中横梁右连接段6203、右二过渡区6204、右边梁中段6205、右三过渡区6206、后横梁右连接段6207、右四过渡区6208和右边梁后段6209，各过渡区平缓过渡其前后段不同料厚结构设计，使其前后段之间强度性能平缓过渡，不会造成强度性能突变，进一步提升车身强度性能。左边梁6100和右边梁6200可根据不同分段强度要求灵活料厚组合，其减重效果较补丁板和拼焊板更佳同时零件性能更优。所述后地板骨架6000是由激光拼焊而成的整体板料一体热冲压成型，具有超高强度。一体热冲压成型后地板骨架6000设计减少了冲压模具、单件检具和焊接夹具等工装开发，减少了冲压冲次和后工序焊接量，提升了零件生产效率、尺寸精度和强度，降低零件开发成本。
请参阅附图24所示：在一些实施例中，所述左后轮罩7000L和右后轮罩7000R均包括后轮罩外板7300和后轮罩内板7100，所述后轮罩内板7100前部设有与左右侧围内板连接第一搭接边7103和第二搭接边7104，所述后轮罩内板7100上边设有与D柱搭接的第三搭接边7105，所述后轮罩内板7100后部设有与后轮罩外板搭接的第四搭接边7106，所述后轮罩内板7100的下部设有与后地板骨架6000搭接的第五搭接边7107。具体实施过程中，为了进一步增强后轮罩的强度，所述轮罩内板上还可适当设置加强筋结构和补丁板结构，如附图24和25所示的后轮罩补丁板7200和后轮罩后部加强筋7101和后轮罩前部加强筋7102。具体实施过程中，参阅附图21和22所示，所述左右侧围外板加强板的外板C柱部5500和左右侧围内板的内板C柱部4500均对应设置所述翻边4520，所述内板C柱部4500的翻边4520与后轮罩内板7100第一搭接边7103和后轮罩外板搭接，所述外板C柱部5500的翻边4520与后轮罩外板的板面搭接，并在外板C柱部5500和内板C柱部4500形成断面呈封闭的腔体结构。
请参阅附图5和6所示：在一些实施例中，所述左前轮罩2000L和右前轮罩2000R均包括减震器安装部2110、轮罩部2120、轮罩后加强部2130、轮罩前加强部2140、第一前轮罩补丁板2200和第二前轮罩补丁板2300，为了进一步提升局部强度，所述第一前轮罩补丁板2200附着于减震器安装部2110和轮罩部2120的内侧，所述第二前轮罩补丁板2300附着于轮罩部2120内侧。另外为了提升前轮罩的强度，还设有第一加强筋2121、第二加强筋2122、第三加强筋2123、第四加强筋2141
图26为本发明一示例性实施例所示的一种车身结构的制造方法的工艺流程图。
本示例性实施例还提出了一种车身结构的制造方法，包括以下步骤：
S1、在整块的左侧围内板4000L板料、右侧围内板4000R板料、左侧围外板加强板5000L板料、右侧围外板加强板5000R板料、机舱骨架1000板料、左前轮罩2000L板料、右前轮罩2000R 板料、前围板3000板料、后地板骨架6000板料、左后轮罩7000L板料、右后轮罩7000R板料上分别安装相应的补丁板；
S2、对安装好补丁板后的各个板料进行热冲压成型并分别形成一体式的左侧围内板4000L、右侧围内板4000R、左侧围外板加强板5000L、右侧围外板加强板5000R、机舱骨架1000、左前轮罩2000L、右前轮罩2000R、前围板3000、后地板骨架6000、左后轮罩7000L、右后轮罩7000R；
S3、左侧围内板4000L和左侧围外板加强板5000L连接形成左侧围总成，右侧围内板4000R和右侧围外板加强板5000R连接形成右侧围总成，机舱骨架1000与左前轮、右前轮和前围板3000连接形成机舱总成，后地板骨架6000与左后轮罩7000L和右后轮罩7000R连接形成后地板总成，然后将前机舱总成与左侧围总成、右侧围总成和后地板总成连接形成车身结构。
本示例性实施例提出了一种汽车，包括上述任一示例性实施例所述的车身结构。
总的而言，本技术方案对车身结构进行布局规划，对车体零部件重新规划分块，并结合热冲压成型技术，将数十个零部件集成为一个零部件。一体热冲压成型零部件的内部取消传统结构的焊点连接，取消内部搭接焊接边，通过用激光焊接或者不等料厚板的形式，将不同材料牌号或料厚的材料连接起来，以实现车身不同区域性能需求差异和最大化材料料片利用率；一体热冲压成型零部件内部加强板结构由传统的加强板和本体零件分别成型再点焊连接结构，更改为先加强板和本体材料点焊后，再一体热冲压成型的补丁板结构形式。此高度集成热冲压成型车身结构打破传统思维，对机舱焊接总成、后地板焊接总成以及左右侧围焊接总成下属零部件进行高度集成，包括高度集成的一体热冲压成型机舱骨架1000、一体热冲压成型前轮罩、一体热冲压成型前围板3000、一体热冲压成型侧围内板双门环加强板、一体热冲压成型侧围外板加强板加强环、一体热冲压成型后轮罩内板7100和一体热冲压成型后地板骨架6000七大版块。
详细的，传统汽车车身结构的前机舱焊接总成，其中各分总成因车型差异，大致由110-180个单件组成。而本技术方案中机舱总成可由一体热冲压成型的机舱骨架1000、左右前轮罩、前围板3000和5-8个传统钣金焊接组成，总体零部件个数不超过40个。
传统汽车车身结构的左右侧围焊接总成，其中各分总成因车型差异，大致由150-200个单件组成。而本技术方案中左右侧围总成包括左右侧围内板和左右侧围外板加强板、后轮罩内板7100，总体零部件个数不超过50个。
传统汽车车身结构的后地板焊接总成，其中各分总成因车型差异，大致由100-150个单件组成。而本技术方案中后地板焊接总成由一体热冲压成型的后地板骨架6000，再加上后地板面板，总体零部件个数也不超过30个。
还有，结合附图27所示：碰撞传力路径优化：第一方面，碰撞传力路径：F1/F2/F3主要由一 体热成型机舱骨架1000构成，碰撞传力路径：F4主要由一体热成型侧围外板加强板和侧围内板焊接而成；碰撞传力路径：F5/F6主要由一体热成型后地板骨架6000构成；避免了因零件尺寸误差，造成的匹配质量问题；避免了因多零件状态一致性差异，造成的碰撞性能差异；减少了焊点数量，从而减少焊点失效概率，进而提升碰撞稳定性，提升整车安全。
上述实施例仅示例性说明本发明的原理及其功效，而非用于限制本发明。任何熟悉此技术的人士皆可在不违背本发明的精神及范畴下，对上述实施例进行修饰或改变。因此，但凡所属技术领域中具有通常知识者在未脱离本发明所揭示的精神与技术思想下所完成的一切等效修饰或改变，仍应由本发明的权利要求所涵盖。

Claims (17)

  1. 一种车身结构，其特征在于，包括：
    左右侧围内板，包括由整体板料一体热冲压成型的左侧围内板和右侧围内板，所述左侧围内板和右侧围内板对称分设于两侧；
    左右侧围外板加强板，包括由整体板料一体热冲压成型的左侧围外板加强板和右侧围外板加强板，所述左侧围外板加强板和右侧围外板加强板对称分设于两侧，所述左侧围外板加强板设于左侧围内板外侧，所述右侧围外板加强板设于右侧围内板的外侧；
    机舱骨架，设于左侧围内板和右侧围内板之间并位于所述左右侧围内板的前段，所述机舱骨架包括机舱骨架左前纵梁段、机舱骨架右前纵梁段和机舱骨架后段组合形成的整体板料一体热冲压成型；
    左右前轮罩，包括由整体板料一体热冲压成型的左前轮罩和右前轮罩，所述左前轮罩和右前轮罩分设于机舱骨架两侧；
    前围板，由整体板料一体热冲压成型并设于所述机舱骨架后段并位于左侧围内板和右侧围内板之间；
    后地板骨架，由整体板料一体热冲压成型，所述后地板骨架设于所述左侧围内板和右侧围内板之间并位于所述左右侧围内板的后段；
    左右后轮罩，包括由整体板料一体热冲压成型的左后轮罩和右后轮罩，所述左后轮罩和右后轮罩分设于后地板骨架两侧。
  2. 根据权利要求1所述的车身结构，其特征在于：所述左侧围内板和右侧围内板均以具有两个封闭门环的一体式板体热冲压而成；所述左侧围内板和右侧围内板均包括：
    内板A柱部，包括内板A柱上端部和内板A柱下端部；
    内板B柱部，包括内板B柱上端部和内板B柱下端部；
    内板C柱部，包括内板C柱上端部和内板C柱下端部；
    内板门槛部，位于所述内板A柱下端部与内板C柱下端部之间，所述内板B柱下端部与内板门槛部的中部连接；
    第一内板上边梁部，位于内板B柱上端部与内板A柱上端部之间；
    第二内板上边梁部，位于内板B柱上端部与内板C柱上端部之间；
    所述内板A柱部、第一内板上边梁部、内板B柱部和内板门槛部形成第一内封闭门环，所述内板C柱部、第二内板上边梁部、内板B柱部、内板门槛部形成第二内封闭门环。
  3. 根据权利要求2所述的车身结构，其特征在于：所述内板B柱部的上部设有内板B柱补丁板，所述内板B柱补丁板与所述一体式板体一同热冲压成型。
  4. 根据权利要求2或3所述的车身结构，其特征在于：所述左侧围外板加强板和右侧围外板加强板均以具有两个封闭门环的一体式板体热冲压而成；所述左侧围外板加强板和右侧围外板加强板均包括：
    外板A柱部，包括外板A柱上端部和外板A柱下端部；
    外板B柱部，包括外板B柱上端部和外板B柱下端部；
    外板C柱部，包括外板C柱上端部和外板C柱下端部；
    外板门槛部，位于所述外板A柱下端部与外板C柱下端部之间，所述外板B柱下端部与外板门槛部的中部连接；
    第一外板上边梁部，位于外板B柱上端部与外板A柱上端部之间；
    第二外板上边梁部，位于外板B柱上端部与外板C柱上端部之间；
    所述外板A柱部、第一外板上边梁部、外板B柱部和外板门槛部形成第一外封闭门环，所述外板C柱部、第二外板上边梁部、外板B柱部、外板门槛部形成第二外封闭门环。
  5. 根据权利要求4所述的车身结构，其特征在于：所述左侧围外板加强板和右侧围外板加强板均还包括外板A柱上补丁板和外板A柱下补丁板；所述外板A柱上补丁板起始于所述外板A柱上端部并沿第一外板上边梁部延伸至外板B柱上端部，所述外板A柱上补丁板与所述一体式板体一同热冲压成型；所述外板A柱下补丁板设于所述外板A柱部并位于外板A柱上端部与外板A柱下端部之间，所述外板A柱下补丁板与所述一体式板体一同热冲压成型。
  6. 根据权利要求1所述的车身结构，其特征在于：所述左侧围外板加强板、右侧围外板加强板的外边以及第一外封闭门环和第二外封闭门环的内边均设有法兰连接面，所述左侧围内板、右侧围内板的外边以及第一内封闭门环和第二内封闭门环的内边均设有法兰连接面，所述左侧围外板加强板与左侧围内板、所述右侧围外板加强板与由侧围内板分别通过所述法兰连接面连接。
  7. 根据权利要求1所述的车身结构，其特征在于：所述机舱骨架左前纵梁段和机舱骨架右前纵梁段的断面均呈开口朝上的“凵”字形传力结构。
  8. 根据权利要求7所述的车身结构，其特征在于：所述机舱骨架左前纵梁段和机舱骨架右前纵梁段朝上的开口处设有前纵梁封板。
  9. 根据权利要求1或7或8所述的车身结构，其特征在于：所述机舱骨架还包括第一机舱补丁板和第二机舱补丁板，所述第一机舱补丁板和第二机舱补丁板设于所述机舱骨架后段并与整体板料一体冲压成型。
  10. 根据权利要求1所述的车身结构，其特征在于：所述前围板包括前围板上板部、前围板下板部和位于前围板上板部与前围板下板部之间的加强梁部，所述前围板下板部的脚踏位置与机舱骨架后段之间形成断面呈三角形的腔体。
  11. 根据权利要求1或10所述的车身结构，其特征在于：所述前围板还包括第一前围补丁板和第二前围补丁板，所述第一前围补丁板设于所述前围板上板部部左部并向下与所述加强梁部搭接，所述第二前围补丁板设于所述前围板下板部部的中部并向上与所述加强梁部搭接，所述第一前围补丁板和第二前围补丁板与前围板的整体板料一体热冲压成型。
  12. 根据权利要求1所述的车身结构，其特征在于：所述后地板骨架包括左边梁部、右边梁部和位于左边梁部和右边梁部之间的前横梁部、中横梁部和后横梁部，所述前横梁部封闭连接于所述左边梁部和右边梁部的前端，所述后横梁部靠近设置于所述左边梁部和右边梁部的后端，所述中横梁部位于前横梁部和后横梁部之间。
  13. 根据权利要求4所述的车身结构，其特征在于：所述左后轮罩和右后轮罩均包括后轮罩外板和后轮罩内板，所述后轮罩内板前部设有与左右侧围内板连接第一搭接边和第二搭接边，所述后轮罩内板上边设有与D柱搭接的第三搭接边，所述后轮罩内板后部设有与后轮罩外板搭接的第四搭接边，所述后轮罩内板的下部设有与后地板骨架搭接的第五搭接边。
  14. 根据权利要求13所述的车身结构，其特征在于：所述左右侧围外板加强板的外板C柱部和左右侧围内板的内板C柱部均对应设有翻边，所述内板C柱部的翻边与后轮罩内板第一搭接边和后轮罩外板搭接，所述外板C柱部的翻边与后轮罩外板的板面搭接，并在外板C柱部和内板C柱部形成断面呈封闭的腔体结构。
  15. 根据权利要求1所述的车身结构，其特征在于：所述左前轮罩和右前轮罩均包括减震器安装部、轮罩部、轮罩后加强部、轮罩前加强部、第一前轮罩补丁板和第二前轮罩补丁板，所述第一前轮罩补丁板附着于减震器安装部和轮罩部的内侧，所述第二前轮罩补丁板附着于轮罩部内侧。
  16. 一种车身结构的制造方法，其特征在于，包括以下步骤：
    S1、在整块的左侧围内板板料、右侧围内板板料、左侧围外板加强板板料、右侧围外板加强板板料、机舱骨架板料、左前轮罩板料、右前轮罩板料、前围板板料、后地板骨架板料、左后轮罩板料、右后轮罩板料上分别安装相应的补丁板；
    S2、对安装好补丁板后的各个板料进行热冲压成型并分别形成一体式的左侧围内板、右侧围内板、左侧围外板加强板、右侧围外板加强板、机舱骨架、左前轮罩、右前轮罩、前围板、后地板骨架、左后轮罩、右后轮罩；
    S3、左侧围内板和左侧围外板加强板连接形成左侧围总成，右侧围内板和右侧围外板加强板连接形成右侧围总成，机舱骨架与左前轮、右前轮和前围板连接形成机舱总成，后地板骨架与左后轮罩和右后轮罩连接形成后地板总成，然后将前机舱总成与左侧围总成、右侧围总成和后地板总成连接形成车身结构。
  17. 一种汽车，其特征在于：包括权利要求1-15任一项所述的车身结构。
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