KR100522847B1 - Method for fabricating a vehicle bumper beam using solid aluminum foam and bumper beam produced by the same - Google Patents

Abstract

By foaming the aluminum extrusion member before foaming in the mold to produce a bumper beam for the vehicle, to improve the rigidity and shock absorbency to ensure the safety of the vehicle and at the same time to reduce the weight of the vehicle body;

Mixing the aluminum material and the metal foaming agent at a predetermined ratio to prepare a solid extruded aluminum extrusion member through compression and extrusion; A foam preparation step of cutting the solid-state foamed aluminum extrusion member to a predetermined standard and placing the same in a predetermined mold; And a bumper beam manufacturing step of producing a bumper beam of the target shape by using the foamed aluminum extruded extruded member prepared in the foam preparation step in the foam preparation step by heat-treating within the set frame and using the same. Provided is a method of manufacturing a vehicle bumper beam using aluminum.

Description

Manufacture method of vehicle bumper beam using solid foamed aluminum and vehicle bumper beam using the same {METHOD FOR FABRICATING A VEHICLE BUMPER BEAM USING SOLID ALUMINUM FOAM AND BUMPER BEAM PRODUCED BY THE SAME}

The present invention relates to a method for manufacturing a vehicle bumper beam and a vehicle bumper beam manufactured by using the same, and more specifically, foamed aluminum, that is, foamed aluminum extruded aluminum extruded members in a mold to foam the vehicle bumper beam using the same. The present invention relates to a method for manufacturing a vehicle bumper beam using solid foamed aluminum to secure vehicle safety by improving rigidity and shock absorbency, and at the same time, to reduce the weight of the vehicle body, and a vehicle bumper beam using the same.

BACKGROUND ART In general, a vehicle bumper is a shock absorbing member disposed at a predetermined portion of the front and rear ends of a vehicle in order to absorb the impact and to protect the occupant when the vehicle collides with another vehicle or an object.

Such a vehicle (front) bumper, as shown in Figure 1, the bumper beam 20 is mounted in the vehicle width direction through the vehicle body mounting stay 10 to the front and rear (rear bumper not shown) of the vehicle, An impact absorbing member (not shown) disposed in front of the bumper beam 20, and a bumper cover 30 for concealing and protecting the bumper beam 20 and the shock absorbing member.

The present invention relates to the above bumper beams and a method of manufacturing the same.

In the related art, the (front) bumper beam 20 is formed by molding a panel material into a predetermined shape so as to form the hollow portion 21 therein, as shown in FIGS. 1 and 2 above. The bumper rails 25 and 27 are welded to each other, and one side thereof is generally formed by integrally welding the body mounting stay 10 for mounting on the vehicle body.

The bumper beam 20 is designed in consideration of the shock absorbency enough to cushion the vehicle, the shape is deformed while absorbing the shock sufficiently to protect the occupant, so as to form a body The stiffness of the degree is required, and the reinforcement panel 23 is integrally welded to the hollow portion 21 inside the bumper beam 20 for this rigidity.

However, in recent years, the manufacture of the bumper beam 20 is not limited to its rigidity and shock absorbency, and researches are being actively made to manufacture the bumper beam 20 as a lightweight material in accordance with the trend of lightening the vehicle. In the course of the study, the application of foamed aluminum is considered.

The above-mentioned foamed aluminum is the most representative metal material that can contribute to the weight reduction of the vehicle, which is due to the characteristics of aluminum, and is excellent in impact absorption, sound absorbing and soundproofing, corrosion resistance, etc. as well as light weight. Due to the light weight and the advantage that the existing automobile production line equipment can be used slightly or as it is attracting attention as an alternative material for lightening the vehicle.

Therefore, the present invention was created by the request to improve the safety of the vehicle and significantly reduce the weight of the vehicle by applying a new concept of ultra-lightweight, high-safety foamed aluminum as described above. By foaming the aluminum extruded member before foaming in the mold and using it to manufacture a bumper beam for vehicles, it is possible to improve the rigidity and shock absorption to secure the safety of the vehicle and at the same time reduce the weight of the vehicle body. The present invention provides a method for manufacturing a vehicle bumper beam and a vehicle bumper beam using the same.

In order to achieve the above object, the present invention provides a method for manufacturing a bumper beam having a set target shape, comprising: preparing an aluminum extrusion member before foaming through a compression and extrusion process by mixing an aluminum material and a metal foaming agent at a set ratio; A foam preparation step of cutting the solid-state foamed aluminum extrusion member to a predetermined standard and placing the same in a predetermined mold; And a bumper beam manufacturing step of producing a bumper beam of the target shape by using the foamed aluminum extruded extruded member prepared in the foam preparation step in the foam preparation step by heat-treating within the set frame and using the same. Provided is a method of manufacturing a vehicle bumper beam using aluminum.

The present invention also provides a vehicle bumper beam manufactured by the method for manufacturing a vehicle bumper beam using the solid foam aluminum.

Hereinafter, the five preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.

3 to 12 are block diagrams and process diagrams of the manufacturing process according to the manufacturing method of the vehicle bumper beam using solid foam aluminum according to each embodiment of the present invention,

Example 1

Referring to the first embodiment of the present invention with reference to FIGS. 3 and 4, first, an aluminum material (1, aluminum powder) and a metal foaming agent (3, foaming powder; generally using TiH_2) are used in a mixing ratio ( 99: 1), followed by compression through a compressor (5, generally using a 1500 ton press), followed by extrusion through an extruder (7) extruded solid aluminum before foaming The member 9 is prepared (S110).

Next, the solid extruded aluminum extrusion member 9 is cut to a set standard and sealed in a state arranged in the set frame 11 to form a foam preparation process (S120), wherein the set standard is When the solid foamed aluminum extruded member 9 is foamed within the set mold 11, the foam volume is determined in consideration of the correlation with the volume of the set mold 11, and it is important to adjust the foam center at this time. Do.

Here, the set frame 11 is made of a standardized form.

As described above, the solid-state pre-foamed aluminum extrusion member 9 prepared according to the set specification is heated and foamed by heating for about 30 minutes at a temperature of about 700 ° C. while the foam preparation is completed in the set frame 11. When the bumper beam is manufactured, the bumper beam manufacturing step (S130) of manufacturing the bumper beam of the target shape is performed.

The bumper beam manufacturing step (S130) is foamed through heat treatment in a state arranged inside the set frame (11) (S130a), the foamed foamed aluminum (13) during the cooling process in a natural atmosphere for a set time Solidified through (S130b).

[Graph 1]

Looking at the physical properties of the solidified foamed aluminum 15 obtained by this process, the Poisson's ratio is about 0.31 ~ 0.34, the stress strain is shown in Graph 1 and Graph 2, first, the diameter is The maximum compressive strength can be seen in Graph 1, which shows the stress strain obtained by compressing 36 mm of solidified foamed aluminum according to density.

In addition, the maximum compressive strength in the case of including the outer shell and the outer shell is shown in Graph 2 showing the stress strain obtained by compressing the solidified foamed aluminum having a diameter of 36 mm into the sts pipe.

[Graph 2]

Accordingly, after the solidified foamed aluminum 15 having the physical properties as described above is taken out from the set frame 11 and cut into the external shape of the bumper beam (S130c-1), the outside of the bumper beam The bumper beam 19 is completed (S130c) by attaching the vehicle body mounting stay 17 directly to the foamed aluminum 15 cut into the shape (S130c-2).

Example 2

Referring to the second embodiment of the present invention with reference to Figures 5 and 6, first, the aluminum material (1, aluminum powder) and the metal foaming agent (3, foaming powder; generally using TiH_2) through the mixer set ratio ( 99: 1), followed by compression through a compressor (5, generally using a 1500 ton press), followed by extrusion through an extruder (7) to extrude solid aluminum The member 9 is prepared (S210).

Next, the solid extruded aluminum extrusion member 9 is cut to a set standard and sealed in a state arranged in the set frame 11 to form a foam preparation process (S220), wherein the set standard is When the solid pre-foamed aluminum extrusion member 9 foams within the set mold 11, the foam volume is determined in consideration of the correlation with the volume of the set mold 11, and at this time, it is necessary to match the foam center. It is important.

Here, the set frame 11 is made of a standardized form.

As described above, the solid-state pre-foamed aluminum extrusion member 9 prepared according to the set standard is foamed by heating for about 30 minutes at a temperature of about 700 ° C. in a state of being ready for foaming in the set frame 11. When the bumper beam is manufactured, the bumper beam manufacturing step S230 may be performed.

The bumper beam manufacturing step (S230) is foamed through heat treatment in a state arranged inside the set frame (11) (S230a), and then the foamed foamed aluminum 13 to solidify through a cooling process for a set time It becomes (S230b).

Here, the physical properties of the solidified foamed aluminum 15 are as described in Example 1 above.

Then, the bumper rails 21 and 23 for constituting the bumper beam of the set target shape are prepared (S230c).

Accordingly, the solidified foamed aluminum 15 is taken out from the set frame 11 and cut into the shape of the inner space of the bumper rails 21 and 23 (S230d-1), and then the bumper rail 21. And inserting the foamed aluminum 15 cut into the inner space of the space 23 into the space in the bumper rails 21 and 23 (S230d-2), and then mounting the vehicle body on the bumper rails 21 and 23. The bumper beam 19 is completed by attaching the dragon stay 17 (S230d-3) (S230d).

Example 3

7 and 8, first, an aluminum material (1, aluminum powder) and a metal foaming agent (3, foamed powder; generally using TiH_2) are used in a mixer to set the ratio ( 99: 1), followed by compression through a compressor (5, generally using a 1500 ton press), followed by extrusion through an extruder 7 to extrude solid aluminum before foaming The member 9 is prepared (S310).

Next, the solid extruded aluminum extruded member 9 is cut to a set standard and sealed in a state arranged in the set frame 11 to form a foam preparation process (S320), wherein the set standard is When the solid pre-foamed aluminum extrusion member 9 foams within the set mold 11, the foam volume is determined in consideration of the correlation with the volume of the set mold 11, and at this time, it is necessary to match the foam center. It is important.

Here, the set frame 11 is formed of a mold having a cavity set in the form of the bumper beam outline of the target shape.

As described above, the solid-state pre-foamed aluminum extrusion member 9 prepared according to the set specification is heat-treated in a state of being ready for foaming in the mold 11 (the set mold), that is, about 30 minutes at a temperature of about 700 ° C. When heated and foamed, the bumper beam manufacturing step (S330) of manufacturing the bumper beam of the target shape is performed by using the same.

The bumper beam manufacturing step (S330) is to foam the solid aluminum extrusion member 9 before foaming through heat treatment inside the mold 11 (S330a), and solidify the foamed foamed aluminum 13 again. In order to manufacture the bumper beam 19 by taking out the foamed aluminum 15 solidified in the form of the bumper beam in the mold 11 and attaching the vehicle body stay 17 directly to the mold 11 (S330c). will be.

Here, the physical properties of the solidified foamed aluminum 15 are as described in Example 1 above.

Example 4

9 and 10, the fourth embodiment of the present invention, first, the aluminum material (1, aluminum powder) and the metal foaming agent (3, foaming powder; generally using TiH_2) through the mixer set ratio ( 99: 1), followed by compression through a compressor (5, generally using a 1500 ton press), followed by extrusion through an extruder 7 to extrude solid aluminum before foaming. The member 9 is prepared (S410).

Next, the solid extruded aluminum extrusion member 9 is cut to a set standard and sealed in a state arranged in the set frame 11 to form a foam preparation process (S420), wherein the set standard is When the solid pre-foamed aluminum extrusion member 9 foams within the set mold 11, the foam volume is determined in consideration of the correlation with the volume of the set mold 11, and at this time, it is necessary to match the foam center. It is important.

Here, the set frame 11 is formed of a mold having a cavity set in the form of a space portion in the bumper rail.

As described above, the solid-state pre-foamed aluminum extrusion member 9 prepared according to the set specification is heat-treated in a state of being ready for foaming in the mold 11 (the set mold), that is, about 30 minutes at a temperature of about 700 ° C. When heated and foamed, a bumper beam manufacturing step (S430) of manufacturing the bumper beam of the target shape is performed by using the same.

The bumper beam manufacturing step (S430) is foamed by heat treatment in a state in which the solid pre-expanded aluminum extrusion member 9 is disposed in the mold (S430a), and then set the foamed foamed aluminum 13 During the time it is solidified again through the cooling process (S430b).

Then, the bumper rails 21 and 23 for constituting the bumper beam of the set target shape are prepared (S430c).

Accordingly, the foamed aluminum 15 solidified in the form of the inner space of the bumper rails 21 and 23 in the mold 11 is taken out from the mold 11 to form the space in the bumper rails 21 and 23. Inserted in (S430d), and then the vehicle body mounting stay 17 is attached to the bumper rails (21, 23) (S430e) to produce a bumper beam (19).

Here, the physical properties of the solidified foamed aluminum 15 are as described in Example 1 above.

Example 5

11 and 12, a first embodiment of an aluminum material (1, aluminum powder) and a metal foaming agent (3, foamed powder; generally using TiH_2) is set through a mixer. 99: 1), followed by compression through a compressor (5, generally using a 1500 ton press), followed by extrusion through an extruder (7) to extrude solid aluminum The member 9 is prepared (S510).

Next, the solid extruded aluminum extruded member 9 is cut to a set standard and sealed in a state arranged in a set frame (21 and 23 in the present embodiment), thereby forming a foam preparation process (S520). , The setting standard is determined in consideration of the correlation of the foam volume with the volume of the set frame 11, when the solid-state aluminum extrusion member 9 is foamed in the set frame (21, 23), At this time, it is important to match the center of foaming.

Here, the set frame is a bumper rail in an assembled state for forming the set bumper beam of the target shape by using the bumper rails 21 and 23 having the inner space of the bumper rails 21 and 23 as cavities. To prepare (21, 23) first (S530a), including this step, as described above, the solid pre-expanded aluminum extrusion member (9) prepared in a set standard in the assembled bumper rail (21, 23) When the foam is prepared in a state in which it is prepared to be foamed and then heated and foamed at a temperature of about 700 ° C. for about 30 minutes, the bumper beam manufacturing step S530 of manufacturing the bumper beam of the target shape is performed using the foam. .

That is, the bumper beam manufacturing step (S530) is foamed through heat treatment in a state in which the solid pre-expanded aluminum extrusion member 9 is disposed inside the space portions of the bumper rails 21 and 23 (S530b), The foamed foamed aluminum 13 is to be solidified again through a cooling process for a set time (S530c).

Accordingly, the bumper beam 19 is manufactured by attaching the vehicle body mounting stay 17 to the bumper rails 21 and 23 including the foamed aluminum 15 solidified therein (S530d).

Solid foamed aluminum of the present invention, as in the above-mentioned five embodiments, to form the bumper beam 19 by foaming the solid pre-expanded aluminum extrusion member 9 in the set molds 11, 21, 23. The manufacturing method of the bumper beam for a vehicle is not limited to the manufacturing of the bumper beam for a specific vehicle, and is used for the production of each part of the vehicle which is intended to reduce weight while maintaining the rigidity and shock absorbing properties of the fillers and the members constituting the vehicle body. It may be applied, and the scope of application may vary.

As described above, according to the manufacturing method of the vehicle bumper beam using the solid foamed aluminum according to the present invention, by forming a solid before-foamed aluminum extrusion member in the frame and using it to produce a vehicle bumper beam, rigidity and impact It is possible to increase the safety of the vehicle by improving the absorbency, and at the same time, it is possible to meet the requirements of the weight reduction of the vehicle body.

1 is an exploded perspective view of a typical vehicle front bumper;

2 is a cross-sectional view taken along the line A-A of FIG.

Figure 3 is a block diagram of the manufacturing process according to the manufacturing method of a vehicle bumper beam using solid foamed aluminum according to a first embodiment of the present invention.

4 is a process chart according to the manufacturing method of a vehicle bumper beam using solid foamed aluminum according to the first embodiment of the present invention.

5 is a block diagram of a manufacturing process according to the manufacturing method of a vehicle bumper beam using solid foamed aluminum according to a second embodiment of the present invention.

6 is a flowchart illustrating a method of manufacturing a bumper beam for a vehicle using solid foamed aluminum according to a second exemplary embodiment of the present invention.

7 is a block diagram of a manufacturing process according to the manufacturing method of a vehicle bumper beam using solid foamed aluminum according to a third embodiment of the present invention.

8 is a flowchart illustrating a method of manufacturing a bumper beam for a vehicle using solid foamed aluminum according to a third exemplary embodiment of the present invention.

9 is a block diagram of a manufacturing process according to the manufacturing method of a vehicle bumper beam using solid foamed aluminum according to a fourth embodiment of the present invention.

10 is a flowchart illustrating a method of manufacturing a bumper beam for a vehicle using solid foamed aluminum according to a fourth exemplary embodiment of the present invention.

11 is a block diagram of a manufacturing process according to the manufacturing method of a vehicle bumper beam using solid foamed aluminum according to a fifth embodiment of the present invention.

12 is a flowchart illustrating a method of manufacturing a bumper beam for a vehicle using solid foamed aluminum according to a fifth exemplary embodiment of the present invention.

Claims (8)

delete delete Preparing a solid pre-foamed aluminum extrusion member through a compression and extrusion process by mixing an aluminum material and a metal foaming agent at a set ratio to produce a bumper beam having a set target shape; A foam preparation step of cutting the solid-state foamed aluminum extrusion member to a predetermined standard and placing the same in a predetermined mold; And a bumper beam manufacturing step of producing a bumper beam of the target shape by using the foamed aluminum extruded extruded member prepared in the foam preparation step in the foam preparation step by heat-treating within the set frame and using the same. In the manufacturing method of a vehicle bumper beam using aluminum, The bumper beam manufacturing step is a foaming step of making the set frame to a standardized form of the standard form, and foaming the solid-state pre-expanded aluminum extrusion member through heat treatment inside the set frame; Solidifying step of solidifying the foamed foamed aluminum; Comprising a bumper beam completion step of cutting the solidified foamed aluminum in the form of the set target shape to complete the bumper beam using the cut aluminum foam of the target shape, The bumper beam completion step includes cutting the target shape to an external shape of the bumper beam and cutting the solidified foamed aluminum into an external shape of the bumper beam; And a component assembly step of attaching the body mounting stay directly to the foamed aluminum cut into the outer shape of the bumper beam. Preparing a solid pre-foamed aluminum extrusion member through a compression and extrusion process by mixing an aluminum material and a metal foaming agent at a set ratio to produce a bumper beam having a set target shape; A foam preparation step of cutting the solid-state foamed aluminum extrusion member to a predetermined standard and placing the same in a predetermined mold; And a bumper beam manufacturing step of producing a bumper beam of the target shape by using the foamed aluminum extruded extruded member prepared in the foam preparation step in the foam preparation step by heat-treating within the set frame and using the same. In the manufacturing method of a vehicle bumper beam using aluminum, The bumper beam manufacturing step is a foaming step of making the set frame to a standardized form of the standard form, and foaming the solid-state pre-expanded aluminum extrusion member through heat treatment inside the set frame; Solidifying step of solidifying the foamed foamed aluminum; A bumper beam completion step of cutting the solidified foamed aluminum into the set target shape to complete a bumper beam using the cut target shaped foamed aluminum; And preparing a bumper rail of the bumper beam of the set target shape. The bumper beam completion step includes cutting the target shape into a space portion inside the bumper rail, and cutting the solidified foamed aluminum into a shape of an internal space portion of the bumper rail; Inserting foamed aluminum cut into a shape of an inner space of the bumper rail into a space in the bumper rail; And And attaching the vehicle body stay to the bumper rail. Preparing a solid pre-foamed aluminum extrusion member through a compression and extrusion process by mixing an aluminum material and a metal foaming agent at a set ratio to produce a bumper beam having a set target shape; A foam preparation step of cutting the solid-state foamed aluminum extrusion member to a predetermined standard and placing the same in a predetermined mold; And a bumper beam manufacturing step of producing a bumper beam of the target shape by using the foamed aluminum extruded extruded member prepared in the foam preparation step in the foam preparation step by heat-treating within the set frame and using the same. In the manufacturing method of a vehicle bumper beam using aluminum, The bumper beam manufacturing step is a foaming step of foaming the solid pre-foamed aluminum extrusion member through a heat treatment inside the mold to the mold having a cavity set in the form of the target bumper beam shape of the target shape ; A solidification step of solidifying the foamed aluminum foamed in the mold; And And extracting the foamed aluminum solidified in the form of the bumper beam in the mold and attaching a stay for mounting the vehicle body directly to the foamed aluminum. Preparing a solid pre-foamed aluminum extrusion member through a compression and extrusion process by mixing an aluminum material and a metal foaming agent at a set ratio to produce a bumper beam having a set target shape; A foam preparation step of cutting the solid-state foamed aluminum extrusion member to a predetermined standard and placing the same in a predetermined mold; And a bumper beam manufacturing step of producing a bumper beam of the target shape by using the foamed aluminum extruded extruded member prepared in the foam preparation step in the foam preparation step by heat-treating within the set frame and using the same. In the manufacturing method of a vehicle bumper beam using aluminum, The bumper beam manufacturing step may further include preparing a bumper rail of the bumper beam of the set target shape. A foaming step of forming the set mold as a mold having a cavity set in the form of a space portion in the bumper rail and foaming the solid pre-expanded aluminum extrusion member through heat treatment inside the mold; A solidification step of solidifying the foamed aluminum foamed in the mold; Inserting the foamed aluminum solidified in the form of a space in the bumper rail into the space in the bumper rail; And And attaching the vehicle body stay to the bumper rail. Preparing a solid pre-foamed aluminum extrusion member through a compression and extrusion process by mixing an aluminum material and a metal foaming agent at a set ratio to produce a bumper beam having a set target shape; A foam preparation step of cutting the solid-state foamed aluminum extrusion member to a predetermined standard and placing the same in a predetermined mold; And a bumper beam manufacturing step of producing a bumper beam of the target shape by using the foamed aluminum extruded extruded member prepared in the foam preparation step in the foam preparation step by heat-treating within the set frame and using the same. In the manufacturing method of a vehicle bumper beam using aluminum, The bumper beam manufacturing step Preparing a bumper rail of the bumper beam of the set target shape; The set frame is a foaming step of foaming the solid-state pre-expanded aluminum extrusion member through a heat treatment in the space of the bumper rail as a frame of the bumper rail as a cavity in the bumper rail; A solidification step of solidifying the foamed aluminum foamed in the space portion of the bumper rail; And And attaching the vehicle body stay to the bumper rail. The bumper beam for a vehicle produced by the manufacturing method of the bumper beam for vehicles using the solid foam aluminum of any one of Claims 3-7.