CN112873703A - 混合式前围横梁及其制造方法 - Google Patents
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
- B62D25/08—Front or rear portions
- B62D25/14—Dashboards as superstructure sub-units
- B62D25/145—Dashboards as superstructure sub-units having a crossbeam incorporated therein
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
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- B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14598—Coating tubular articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14631—Coating reinforcements
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- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14836—Preventing damage of inserts during injection, e.g. collapse of hollow inserts, breakage
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
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- 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
- B62D25/081—Cowls
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
- B62D29/001—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material
- B62D29/004—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material the metal being over-moulded by the synthetic material, e.g. in a mould
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
- B62D29/04—Superstructures, understructures, or sub-units thereof, characterised by the material thereof predominantly of synthetic material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29K2705/00—Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
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- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/001—Profiled members, e.g. beams, sections
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3005—Body finishings
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- B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract
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。
Description
相关申请的交叉引用
本申请要求于2019年11月29日提交的韩国专利申请第10-2019-0157778号的优先权和权益,其全部内容通过引用合并于此。
技术领域
本发明涉及一种混合式前围横梁(hybrid cowl cross bar),尤其涉及一种具有增强刚度结构的混合式前围横梁及其具有简化工艺流程的制造方法。
背景技术
前围横梁是车辆驾驶舱模块的一个组件,用于引导和支撑驾驶舱的各种组件,例如转向轴、仪表板、空调系统、安全气囊、音响系统等。此外,前围横梁是配置用于防止车辆横向弯曲或扭曲并且增加车身寿命的框架。而且,前围横梁提供了在其上安装驾驶舱各个组件的引导面,并在正面碰撞中安全地保护乘客。
前围横梁使用由诸如铝、镁或钢之类的金属制成的管来制造或通过注射合成树脂或复合材料来制造。近年来,前围横梁由包括复合材料或混合物质的混合材料制成,以降低成本和重量。
图1示出了混合式前围横梁的示例。所示的混合型前围横梁的制造工艺流程如下。将铝管弯曲成所需的形状并插入模具中。在将合成树脂注射到管之前,通过施加液压使管的内部膨胀(称为液压成型工艺)。施加的液压范围约为600巴(bar)至900bar。在这种情况下,在管的外侧进行插入注射成型。这里,注射压力约为1300bar。
在上述制造工艺流程中,向铝管内部施加液压的原因是为了防止由于插入注射成型期间的注射压力导致的铝管变形而引起尺寸变化和注射泄漏。图2示出了注射泄漏的示例(左)。图2还示出了管的各个部分中压力的不均匀性。
如上所述,按照常规,制造前围横梁的工艺流程的数量由于液压成型工艺而增加,并且需要建造能够进行液压成型的注射设备,从而导致过多的成本。另一方面,当不施加液压时,管中发生过度变形。
发明内容
本发明旨在提供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,以简化混合式前围横梁的制造工艺流程,并且确保前围横梁的刚度,从而解决上述问题。
为了解决这些问题,根据本发明的一个方面,提供了一种混合式前围横梁,其中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(rib),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。筋可以以各种形状制造,例如十字形、线形、诸如三角形或四边形的多边形、不规则形状等。
根据本发明的另一方面,提供了一种制造混合式前围横梁的方法,该方法包括:提供金属管,提供增强材料,将增强材料插入提供的金属管中以制造前围横梁的半成品,将前围横梁的半成品插入模具中,并在模具中金属管的外侧进行插入注射成型。
增强材料可以根据其内部形状通过注射成型、挤压成型或切削加工来制造。此外,插入到金属管中的增强材料可以使用粘合剂或其他耦合部件固定。
根据下面参考附图详细描述的实施例,本发明的上述构造和操作将变得更加明显。
附图说明
通过参考附图详细描述本发明的示例性实施例,本发明的上述以及其他目的、特征和优点对于本领域普通技术人员将变得更加明显,其中:
图1为混合式前围横梁的示例性视图;
图2示出了用于说明常规的混合式前围横梁的问题的视图;
图3为根据本发明的混合式前围横梁的分解图;
图4为增强材料(20)的剖面图;
图5为示出前围横梁半成品的外部的视图,该前围横梁半成品中增强材料(20)被插入金属管(10);以及
图6为根据本发明制造并最终装配的混合式前围横梁产品的示例性视图。
具体实施方式
根据下面参考附图详细描述的实施例,将更加清楚地理解本发明的优点和特征以及用于实现本发明的方法。然而,本发明不限于以下实施例,而是可以以各种不同的形式实现。准确地说,提供这些实施例仅是为了完成本发明的公开并使本领域技术人员理解本发明的范畴。本发明由权利要求的范畴定义。同时,在本说明书中使用的术语是为了描述实施例,而不是意图限制本发明。如本文所用,除非上下文另外定义,否则单数表达包括复数表达。将进一步理解的是,术语“包括”、“包括有”、“包含”和/或“包含有”(如果在本文中使用)指定存在所陈述的组件、步骤、操作和/或元件,但是其不排除一个或多个其他组件、步骤、操作和/或元素的存在或添加。
在下文中,将参考附图详细描述本发明的示例性实施例。在为每个附图中的元件添加附图标记时,应当注意,已经用于表示其他附图中类似元件的类似附图标记在可能的情况下用于这些元件。此外,在描述本发明时,将排除与公知功能或构造有关的详细描述,以免不必要地使本发明的主题不清楚。
图3为根据本发明的混合式前围横梁的分解图。
将管形或棒形的增强材料20插入金属管10中。金属管10由诸如铝、镁或钢的材料制成。增强材料20通过挤压合成树脂或复合材料(例如,PP+GF50%)来制造。
如上所述,当金属管10以多层结构(其中增强材料20插入金属管10中)制造时,与具有与金属管10相同规格的金属管相比,可以减小厚度或直径,从而获得成本降低、重量减轻以及设计灵活性提高的附加效果。
图4为增强材料20的剖面图。
通过在挤压管中应用十字形(“+”)筋30,当被插入注射到金属管10中时,可以提高抵抗注射压力的能力,并且可以确保在制造后将前围横梁应用于实际车辆时抗车辆碰撞的刚度和抗下垂刚度(rigidity against sagging)。
图4中所示的筋30的形状像十字(“+”),但不限于此。为了达到提高增强材料20的刚度的目的,筋30可以以各种形状制造,例如简单的线形(“—”)、诸如三角形或四边形的多边形、不规则形状(星形或椭圆形)或其他形状。
图5示出了在增强材料20被插入金属管10中的状态下的前围横梁半成品。这里,术语“前围横梁半成品”是指在通过将前围横梁半成品引入用于插入注射成型的模具中进行插入注射成型之前的产品。在将前围横梁半成品引入模具中之后,无需进行在常规工艺流程中所需的施加液压的液压成型工艺即可立即在合成树脂上进行插入注射成型。
图6是根据本发明制造并最终装配的混合式前围横梁产品的示例性视图。各种必要的支架和支撑件装配在插入注射的横梁上。
根据本发明,全面提高了抗噪声振动粗糙度(noise vibration harshness,NVH)刚度(A)、抗碰撞刚度(B)和抗下垂刚度(C)。然而,为了提高刚度,非但成本未增加并且工艺流程不复杂,反而省去了液压成型工艺过程。因此,降低了工艺流程方面的成本,也简化了工艺流程。
在下文中,将全面描述用于混合式前围横梁的插入注射成型的制造工艺流程。
首先,提供金属管10。诸如铝、镁或钢的材料可以用作金属材料。
提供增强材料20。增强材料20可以由具有高刚度的合成树脂或复合材料(例如,PP+GF50%)制成。增强材料20可以根据其内部形状通过注射成型、挤压成型或切削加工来制造。
将增强材料20插入所提供的金属管10中。冷插入或热插入都可以,并且金属管10和增强材料20的尺寸以及它们之间的间隙将根据使用哪种插入方法来确定。此外,是否在金属管10和增强材料20之间使用粘合剂或耦合部件(例如,螺钉或其他)将根据本领域技术人员的设计规范来确定。
将如上所述制造的前围横梁半成品插入模具中。
在模具中的管的外侧进行插入注射成型。在这种情况下,不需要采用液压来使管的内部膨胀的液压成型。因此,按照常规已经施加的大约1300bar的注射压力被减小到小于大约1000bar的压力,或者减小到1000bar的压力甚至小于1000bar的压力的几百bar的压力。
之后,在进行保压或其他工艺流程之后,打开模具(开模)取出成型产品,并且将诸如转向柱、支架和支撑件之类的必要组件装配到成型产品中。使用量规(如Go-No量规)进行最终检查,以发布混合式前围横梁的成品。
根据本发明,由于不包括常规的混合式前围横梁所需的液压成型工艺,因此减少了制造工艺流程的数量,并且不需要液压成型设备,从而提高了前围横梁的刚度并全面改善了抗NVH刚度、抗碰撞刚度和抗下垂刚度。
已经参考本发明的示例性实施例详细描述了本发明的构造,但是本领域技术人员将理解,可以在不改变本发明的技术精神或必要特征的情况下,以不同于本说明书中公开内容的其他特定形式来实现本发明。因此,应当理解,上述实施例在所有方面都是示例性的,而不是限制性的。本发明的范围由权利要求而不是详细描述来表示,并且应当解释为,权利要求的范围以及从其等同物衍生的所有改变或修改形式都包括在本发明的范围内。
Claims (10)
1.一种混合式前围横梁,包括:
金属管;以及
插入所述金属管的增强材料。
2.根据权利要求1所述的混合式前围横梁,其中所述增强材料由选自合成树脂和复合材料中的至少一种材料制成。
3.根据权利要求2所述的混合式前围横梁,其中所述复合材料为PP+GF50%。
4.一种混合式前围横梁,包括:
金属管;以及
插入所述金属管的增强材料,
其中在所述增强材料的内部提供有筋,以提高在所述金属管被插入注射时抵抗注射压力的能力并确保刚度。
5.根据权利要求4所述的混合式前围横梁,其中所述增强材料由选自合成树脂和复合材料中的至少一种材料制成。
6.根据权利要求5所述的混合式前围横梁,其中所述复合材料为PP+GF50%。
7.根据权利要求4所述的混合式前围横梁,其中所述筋的形状类似十字形。
8.一种混合式前围横梁的制造方法,所述方法包括:
提供金属管和待插入所述金属管的增强材料;
将所述增强材料插入所提供的所述金属管中以制造前围横梁半成品;
将所述前围横梁半成品插入模具中;以及
在所述模具中在所述金属管的外侧进行插入注射成型。
9.根据权利要求8所述的方法,其中在提供所述增强材料时,所述增强材料通过注射成型方法、挤压成型方法和切削加工方法中的一种方法制造。
10.根据权利要求8所述的方法,其中将所述增强材料插入所提供的所述金属管中包括:使用耦合部件来固定插入到所述金属管中的所述增强材料。
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KR1020190157778A KR20210067799A (ko) | 2019-11-29 | 2019-11-29 | 하이브리드 카울크로스바 및 그 제조방법 |
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KR102584568B1 (ko) * | 2021-10-26 | 2023-10-05 | 한국생산기술연구원 | 주조용 인서트 파이프 |
KR20230079785A (ko) | 2021-11-29 | 2023-06-07 | 현대자동차주식회사 | 알루미늄 소재 축관 인발 공법 및 카울 크로스바 |
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- 2020-11-26 DE DE102020131396.9A patent/DE102020131396A1/de active Pending
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DE102020131396A1 (de) | 2021-06-02 |
US11753081B2 (en) | 2023-09-12 |
US20210163072A1 (en) | 2021-06-03 |
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