阅读说明：本技术 混合式前围横梁及其制造方法 (Hybrid front wall beam and manufacturing method thereof ) 是由 崔益根 于 2020-11-27 设计创作，主要内容包括：本发明涉及一种混合式前围横梁,其通过改进的执行插入注射成型的方法来制造,而不在注射成型期间向金属管的内部施加液压,以简化混合前围横梁的制造工艺流程,并且确保前围横梁的刚度。根据本发明的一个方面,增强材料插入到金属管中,金属管为前围横梁的材料。类似于常规的前围横梁,金属管可以由诸如铝、镁或钢的材料制成。增强材料可以通过挤压合成树脂或复合材料(例如,PP+GF50％)来制造。可以在增强材料内部形成筋,以提高在金属管被插入注射时抵抗注射压力的能力并确保刚度。(The present invention relates to a hybrid cowl cross member manufactured by an improved method of performing insert injection molding without applying hydraulic pressure to the inside of a metal pipe during injection molding, to simplify a manufacturing process flow of the hybrid cowl cross member, and to secure rigidity of the cowl cross member. According to an aspect of the present invention, the reinforcement material is inserted into the metal pipe, which is the material of the cowl cross member. Similar to conventional front wall cross members, the metal tube may be made of a material such as aluminum, magnesium, or steel. The reinforcement may be made by extruding a synthetic resin or composite (e.g., PP + GF 50%). Ribs may be formed inside the reinforcing material to improve the ability to resist injection pressure and ensure rigidity when the metal pipe is insert-injected.)

1. A hybrid cowl cross member comprising:

a metal tube; and

a reinforcing material inserted into the metal tube.

2. The hybrid cowl cross member according to claim 1, wherein the reinforcement material is made of at least one material selected from a synthetic resin and a composite material.

3. The hybrid cowl cross member of claim 2, wherein the composite material is PP + GF 50%.

4. A hybrid cowl cross member comprising:

a metal tube; and

a reinforcing material inserted into the metal tube,

wherein ribs are provided inside the reinforcing material to improve the ability to resist injection pressure and ensure rigidity when the metal tube is insert-injected.

5. The hybrid cowl cross member according to claim 4, wherein the reinforcement material is made of at least one material selected from a synthetic resin and a composite material.

6. The hybrid cowl cross member of claim 5, wherein the composite material is PP + GF 50%.

7. The hybrid cowl cross member of claim 4, wherein the rib is shaped like a cross.

8. A method of manufacturing a hybrid cowl cross member, the method comprising:

providing a metal tube and a reinforcing material to be inserted into the metal tube;

inserting the reinforcing material into the provided metal pipe to manufacture a cowl cross member semi-finished product;

inserting the front wall beam semi-finished product into a mold; and

insert injection molding is performed outside the metal pipe in the mold.

9. The method of claim 8, wherein in providing the reinforcement material, the reinforcement material is manufactured by one of an injection molding method, an extrusion molding method, and a machining method.

10. The method of claim 8, wherein inserting the reinforcement material into the provided metal tube comprises: fixing the reinforcing material inserted into the metal pipe using a coupling member.

Technical Field

The present invention relates to a hybrid cowl cross member (hybrid cowl cross bar), and more particularly, to a hybrid cowl cross member having a structure for enhancing stiffness and a method of manufacturing the same with a simplified process flow.

Background

The front wall cross member is a component of a vehicle cabin module for guiding and supporting various components of the cabin, such as a steering shaft, an instrument panel, an air conditioning system, an airbag, an audio system, and the like. Further, the cowl cross member is a frame configured to prevent the vehicle from being bent or twisted laterally and to increase the life of the vehicle body. Also, the cowl cross member provides a guide surface on which various components of the cabin are mounted, and safely protects passengers in a frontal collision.

The cowl cross member is manufactured using a pipe made of metal such as aluminum, magnesium, or steel or by injecting synthetic resin or composite material. In recent years, the cowl cross member is made of a mixed material including a composite material or a mixed substance to reduce cost and weight.

Fig. 1 shows an example of a hybrid front wall crossbeam. The manufacturing process flow of the hybrid front wall beam is as follows. The aluminum tube is bent into a desired shape and inserted into a mold. Before the synthetic resin is injected into the tube, the inside of the tube is expanded by applying hydraulic pressure (referred to as a hydroforming process). The hydraulic pressure applied is in the range of about 600 bar (bar) to 900 bar. In this case, insert injection molding is performed on the outside of the tube. Here, the injection pressure is approximately 1300 bar.

In the above-described manufacturing process flow, the reason why the hydraulic pressure is applied to the inside of the aluminum pipe is to prevent dimensional change and injection leakage due to deformation of the aluminum pipe caused by the injection pressure during the insert injection molding. Fig. 2 shows an example of injection leakage (left). Fig. 2 also shows the non-uniformity of pressure in various portions of the tube.

As described above, conventionally, the number of processes for manufacturing the cowl cross member is increased due to the hydroforming process, and an injection apparatus capable of performing the hydroforming is required to be built, thereby causing excessive costs. On the other hand, when no hydraulic pressure is applied, excessive deformation occurs in the tube.

Disclosure of Invention

The present invention is directed to providing a hybrid cowl cross member manufactured by an improved method of performing insert injection molding without applying hydraulic pressure to the inside of a metal pipe during injection molding, to simplify a manufacturing process flow of the hybrid cowl cross member, and to secure rigidity of the cowl cross member, thereby solving the above-mentioned problems.

To solve these problems, according to one aspect of the present invention, there is provided a hybrid cowl cross member in which a reinforcing material is inserted into a metal pipe, which is a material of the cowl cross member. Similar to conventional front wall cross members, the metal tube may be made of a material such as aluminum, magnesium, or steel. The reinforcement may be made by extruding a synthetic resin or composite (e.g., PP + GF 50%).

Ribs (rib) may be formed inside the reinforcing material to improve the ability to resist injection pressure and ensure rigidity when the metal pipe is insert-injected. The ribs may be fabricated in various shapes, for example, a cross shape, a line shape, a polygon such as a triangle or a quadrangle, an irregular shape, and the like.

According to another aspect of the present invention, there is provided a method of manufacturing a hybrid cowl cross member, the method including: the method includes the steps of providing a metal pipe, providing a reinforcing material, inserting the reinforcing material into the provided metal pipe to manufacture a semi-finished product of the cowl cross member, inserting the semi-finished product of the cowl cross member into a mold, and performing insert injection molding outside the metal pipe in the mold.

The reinforcing material may be manufactured by injection molding, extrusion molding or cutting processing according to the inner shape thereof. In addition, the reinforcing material inserted into the metal pipe may be fixed using an adhesive or other coupling member.

The above-described configuration and operation of the present invention will become more apparent from the embodiments described in detail below with reference to the accompanying drawings.

Drawings

The above and other objects, features and advantages of the present invention will become more apparent to those skilled in the art by describing in detail exemplary embodiments thereof with reference to the attached drawings, in which:

FIG. 1 is an exemplary view of a hybrid cowl cross member;

fig. 2 shows a view for explaining a problem of a conventional hybrid cowl cross member;

FIG. 3 is an exploded view of a hybrid cowl cross member according to the present disclosure;

FIG. 4 is a cross-sectional view of the reinforcing material (20);

fig. 5 is a view showing the outside of a cowl cross member semi-finished product in which a reinforcing material (20) is inserted into a metal pipe (10); and

FIG. 6 is an exemplary illustration of a hybrid cowl cross member product manufactured and ultimately assembled in accordance with the present invention.

Detailed Description

Advantages and features of the present invention and methods for implementing the present invention will be more clearly understood from the embodiments described in detail below with reference to the accompanying drawings. However, the present invention is not limited to the following embodiments, but may be implemented in various different forms. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. The invention is defined by the scope of the claims. Meanwhile, terms used in the present specification are for describing embodiments, and are not intended to limit the present invention. As used herein, singular expressions include plural expressions, unless the context defines otherwise. It will be further understood that the terms "comprises," "comprising," "includes" and/or "including," if used herein, specify the presence of stated components, steps, operations, and/or elements, but do not preclude the presence or addition of one or more other components, steps, operations, and/or elements.

Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings. In adding reference numerals to elements in each figure, it should be noted that like reference numerals that have been used to identify like elements in other figures are used for these elements where possible. In addition, in describing the present invention, detailed descriptions related to well-known functions or constructions will be excluded so as not to unnecessarily obscure the subject matter of the present invention.

Fig. 3 is an exploded view of a hybrid cowl cross member according to the present invention.

A reinforcing material 20 in the form of a tube or rod is inserted into the metal pipe 10. The metal pipe 10 is made of a material such as aluminum, magnesium, or steel. The reinforcement 20 is made by extrusion of a synthetic resin or composite material (for example PP + GF 50%).

As described above, when the metal pipe 10 is manufactured in a multi-layered structure in which the reinforcing material 20 is inserted into the metal pipe 10, the thickness or diameter can be reduced as compared with a metal pipe having the same specification as the metal pipe 10, thereby obtaining additional effects of cost reduction, weight reduction, and improvement in design flexibility.

Fig. 4 is a cross-sectional view of the reinforcing material 20.

By applying the cross ("+") rib 30 in the extruded tube, when insert-injected into the metal tube 10, the capability against injection pressure can be improved, and rigidity against vehicle collision and sagging rigidity (rigidity against vehicle collision) can be ensured when the cowl cross member is applied to an actual vehicle after manufacture.

The ribs 30 shown in fig. 4 are shaped like a cross ("+"), but are not limited thereto. For the purpose of increasing the rigidity of the reinforcing material 20, the ribs 30 may be manufactured in various shapes, for example, simple linear shapes ("-"), polygons such as triangles or quadrangles, irregular shapes (stars or ellipses), or other shapes.

Fig. 5 shows the cowl cross member semi-finished product in a state where the reinforcing material 20 is inserted into the metal pipe 10. Here, the term "cowl cross member semi-finished product" refers to a product before insert injection molding by introducing the cowl cross member semi-finished product into a mold for insert injection molding. After the cowl cross member semi-finished product is introduced into the mold, insert injection molding can be performed on the synthetic resin immediately without performing a hydroforming process that applies hydraulic pressure, which is required in a conventional process flow.

FIG. 6 is an exemplary illustration of a hybrid cowl cross member product manufactured and ultimately assembled in accordance with the present invention. The various necessary supports and supports are mounted on the cross-beam of the insert injection.

According to the invention, the Noise Vibration Harshness (NVH) rigidity (A), the collision-resistant rigidity (B) and the sagging-resistant rigidity (C) are improved comprehensively. However, in order to improve the rigidity, not only the cost is not increased and the process flow is not complicated, but also the hydroforming process is omitted. Therefore, the cost in the process flow is reduced, and the process flow is also simplified.

Hereinafter, a manufacturing process flow for insert injection molding of the hybrid cowl cross member will be fully described.

First, a metal tube 10 is provided. Materials such as aluminum, magnesium, or steel may be used as the metal material.

A reinforcing material 20 is provided. The reinforcing material 20 may be made of a synthetic resin or a composite material (for example, PP + GF 50%) having high rigidity. The reinforcing material 20 may be manufactured by injection molding, extrusion molding, or cutting processing according to the inner shape thereof.

The reinforcing material 20 is inserted into the provided metal pipe 10. Either cold insertion or hot insertion is possible, and the sizes of the metal pipe 10 and the reinforcing material 20 and the gap therebetween will be determined depending on which insertion method is used. Further, whether an adhesive or a coupling member (e.g., a screw or others) is used between the metal tube 10 and the reinforcing material 20 will be determined according to design specifications of those skilled in the art.

The cowl cross member semi-finished product manufactured as described above is inserted into a mold.

Insert injection molding is performed outside the tube in the mold. In this case, hydroforming, which employs hydraulic pressure to expand the interior of the tube, is not required. Thus, the injection pressure of about 1300bar, which has conventionally been applied, is reduced to a pressure of less than about 1000bar, or to a pressure of 1000bar or even to a pressure of several hundred bar of less than 1000 bar.

Thereafter, after the pressure holding or other process flow is performed, the mold is opened (opened) to take out the molded product, and necessary components such as a steering column, a bracket, and a support are fitted into the molded product. A final check is performed using a gauge (e.g., Go-No gauge) to release the finished hybrid cowl cross beam.

According to the present invention, since the hydroforming process required for the conventional hybrid cowl cross member is not included, the number of manufacturing process flows is reduced, and the hydroforming apparatus is not required, thereby improving the rigidity of the cowl cross member and comprehensively improving the NVH resistance rigidity, the collision resistance rigidity, and the sagging resistance rigidity.

The configuration of the present invention has been described in detail with reference to the exemplary embodiments of the present invention, but it will be understood by those skilled in the art that the present invention may be implemented in other specific forms than those disclosed in the present specification without changing the technical spirit or essential features of the present invention. It is therefore to be understood that the above embodiments are illustrative in all respects and not restrictive. The scope of the present invention is indicated by the appended claims rather than the detailed description, and it should be construed that the scope of the claims and all changes or modifications derived from equivalents thereof are included in the scope of the present invention.