KR101374094B1 - Method for manufacturing body of vehicle - Google Patents

Abstract

The present invention relates to a method for manufacturing a vehicle body, the method of manufacturing a vehicle body using a composite material, the step of manufacturing a FRP mold with the same size as the vehicle body (S10); Stacking an envelope material in the FRP mold (S20); Assembling a plurality of frames in the FRP mold (S30); Stacking a foam core in the FRP mold (S40); Including (S50) step of laminating the inner shell material in the FRP mold; In the step (S30), including the roof (ROOF), front (FRONT) and rear (REAR) of the vehicle body, both sides (SIDE) It is characterized by assembling the frame in the order of), it is possible to avoid the interference with the dam attached to the FRP mold inner surface, it is possible to improve the work efficiency by separating and assembling the frame respectively.

Description

Method for manufacturing body of vehicle

The present invention relates to a vehicle body manufacturing method capable of avoiding interference with a dam attached to the inner surface of the FRP mold.

Electric vehicles and natural gas vehicles are being developed to reduce fuel efficiency and exhaust gas emissions of automobiles. In the case of electric vehicles and natural gas vehicles, weight reduction of vehicles is required to improve fuel efficiency.

Particularly in automobiles, parts made of metal materials account for about 70% of the total weight, so there is a limitation in reducing the weight of the vehicle by changing the design.

Therefore, the vehicle body constituting the appearance of the vehicle can be replaced by a composite material that is a lightweight material rather than a metal material.

Conventionally, a vehicle body using a composite material and a manufacturing method thereof are disclosed in Korean Patent No. 0609280, Korean Patent No. 0971873, Korean Patent Publication No. 2011-0045918, Korean Patent Publication No. 2011-0116718, and the like.
According to Korean Patent No. 0609280, a mold is manufactured to have the same shape and size as the car body so that the side wall portion 2, the ceiling portion 3 and the end portion 4 constituting the railway car body can be integrally manufactured ). At this time, an opening for installing a glass window on the side wall part 2, an air conditioning installation opening part of the ceiling part 3, and a connection passage opening part of the end part 4 are formed by attaching a separator to the manufactured mold, After the position is set, the openings are to be excluded when laminating the skin material and core material.

However, the FRP mold used in manufacturing a vehicle body using a composite material is composed of an upper mold and a lower mold, and there is a problem in that demoulding is very difficult because the projected shape of the vehicle body is directly implemented on the RF LP mold.

The present invention has been made to solve the above-mentioned problems, and an object of the present invention is to provide a vehicle body manufacturing method that can avoid interference with a dam attached to the inner surface of the FRP mold to implement the protruding shape of the vehicle body. .

The present invention provides a method for manufacturing a vehicle body using a composite material, comprising the steps of: manufacturing a FRP mold with the same size as the vehicle body (S10); Stacking an envelope material in the FRP mold (S20); Assembling a plurality of frames in the FRP mold (S30); Stacking a foam core in the FRP mold (S40); Including (S50) step of laminating the inner shell material in the FRP mold; In the step (S30), including the roof (ROOF), front (FRONT) and rear (REAR) of the vehicle body, both sides (SIDE) It provides a vehicle body manufacturing method characterized in that the frame is assembled in the order of).

In the present invention, between the step (S10) and the step (S20), in order to implement a protruding shape of the vehicle body (S11) step of attaching a plurality of dams in the FRP mold; It provides a vehicle body manufacturing method characterized in that.

In the present invention, in the step (S10), the FRP mold is manufactured to be composed of an upper mold and a lower mold, wherein the upper mold is manufactured to be divided into a first upper mold and a second upper mold. to provide.

In the present invention, between the step (S20) and the step (S30), (S21) step of primary molding the laminated material laminated through the step (S20); further comprising the, (S50) step Thereafter, the step (S21) of secondary molding the laminated material laminated through the steps (S30) to (S50); provides a vehicle body manufacturing method characterized in that it further comprises.

According to the vehicle body manufacturing method of the present invention, there are the following effects.

The frame is assembled in the order of the ROOF part, FRONT part, REAR part, and both side parts of the car body, so that the dam is attached to the inner surface of the FRP mold to realize the projected shape of the car body. Interference can be avoided and work efficiency can be improved by separating and assembling the frames separately.

1 is a flowchart showing a method of manufacturing a vehicle body using a composite material according to a preferred embodiment of the present invention.
Fig. 2 is a perspective view showing a vehicle body using a composite material molded according to the procedure of Fig. 1; Fig.
3 is a perspective view illustrating an FPC structure used for manufacturing a vehicle body using a composite material according to a preferred embodiment of the present invention.
Fig. 4 is a perspective view showing the bottom of Fig. 3; Fig.
Fig. 5 is a perspective view showing the upper figure of Fig. 3; Fig.
Figure 6 is a perspective view to show the attachment of a dam to the F-alpha mold of Figure 3;
Figure 7 is a perspective view to show the assembly of the frame into the F-alpha mold of Figure 3;
8 is a perspective view showing a jacket material of a vehicle body.
Fig. 9 is a perspective view showing an end effector of the vehicle body. Fig.
10 is a perspective view showing a frame of a vehicle body.
11 is a perspective view showing a foam core of a vehicle body.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. Prior to this, terms and words used in the present specification and claims should not be construed as limited to ordinary or dictionary terms, and the inventor should appropriately interpret the concepts of the terms appropriately The present invention should be construed in accordance with the meaning and concept consistent with the technical idea of the present invention.

Therefore, the embodiments described in this specification and the configurations shown in the drawings are merely the most preferred embodiments of the present invention and do not represent all the technical ideas of the present invention. Therefore, It is to be understood that equivalents and modifications are possible.

The method for manufacturing a vehicle body and a vehicle body using a composite material according to the present invention can be applied to an external appearance of a vehicle such as an electric bus (EV bus), and can be easily applied to a vehicle body made of a composite material.

However, the present invention can be applied not only to a ground electric bus, but also to a vehicle or a railway vehicle to which a vehicle body made of various composite materials is applied.

As shown in Fig. 2, the exterior of the vehicle body 100 of the electric bus according to the preferred embodiment of the present invention is formed with a door hole 110 in which a door is disposed on the front side of the side surface, A plurality of window holes 130 in which windows are arranged are arranged in a row. And a wheel hole 150 in which a wheel is disposed is formed at a lower end of the side surface.

The body 100 constructed as described above is preferably made of a composite material of a shell material 500, an inner skin material 570, a plurality of aluminum frames 530 and a foam core 550.

As shown in Fig. 8, the outer cover material 500 constitutes the outer surface of the vehicle body 100 and is made of an adhesive film and a glass fiber prepreg.

As shown in Fig. 9, the inner wrapper 570 constitutes the inner surface of the vehicle body 100 and is made of glass fiber prepreg.

A plurality of aluminum frames 530 are provided between the outer covering material 500 and the inner covering material 570 as shown in Fig. 10, and are arranged at predetermined intervals to form a frame.

The foam cores 550 fill the spaces between the aluminum frames 530 arranged at predetermined intervals as shown in Fig.

The foam core 550 is made of a balsa foam 551 and in particular the SIDE portion of the body 100 is made of a foam foam 551 and a PVC foam 555 desirable.

That is, polyvinyl chloride foam 555 is laminated on both side portions of the vehicle body 100, and then the foam foam 551 as a whole is laminated on the vehicle body 100.

As described above, the vehicle body 100 is made of the composite material of the outer cover material 500, the inner skin material 570, the plurality of aluminum frames 530 and the foam core 550, thereby reducing the weight of the vehicle, It is possible to secure a sufficient strength even when it is formed, simplify the process, and improve the productivity.

Hereinafter, a method of manufacturing a vehicle body using a composite material according to a preferred embodiment of the present invention may be performed as shown in FIG.

First, an FALP mold is manufactured in the same size as the vehicle body. (S10)

As shown in FIG. 3, the FPC 220 is an open mold having an open top, and is made up of a top mold 210 and a bottom mold 250.

5, the upper mold 210 is formed to be a lower portion of the window hole 130 formed on the side of the vehicle body 100. As shown in FIG. 4, And the upper portion of the window hole 130 including the window hole 130 is formed.

Further, as shown in FIG. 5, it is more preferable that the upper die 210 is divided into two parts, that is, the first upper die 211 and the second upper die 212.

The first upper mold 211 is formed to be in front of the door hole 110 formed on the side surface of the vehicle body 100 and the second upper mold 212 is formed to face the rear side of the door hole 110 including the door hole 110 It is more preferable to make it.

In addition, it is preferable that the inner surface of the FPC 220 having the upper mold 210 and the lower mold 250 is formed to be flat. That is, it is possible to manufacture and assemble a separate material such as the dam 300, which will be described later, without implementing a shape protruding outside the vehicle body 100 on the FPC 220.

The FFP mold 200 constructed as described above is assembled as follows.

The divided first upper mold 211, second upper mold 212 and lower mold 250 are assembled into a state as shown in FIG. That is, the lower mold 250 is disposed at the lower portion of the window hole 130 to form the upper portion of the window hole 130 so that the outer shape of the vehicle body 100 can be formed. The first and second upper molds 211 and 212 ) Constitute the lower portion of the window hole (130).

The assembled FOUP mold 200 has only the door hole 110 opened and the window hole 130 has a protruding surface formed on the inner surface of the lower mold 250, And the wheel hole 150 is formed with a protruding surface on the inner surface of the upper mold 210 so that the wheel hole 150 is formed at the time of manufacturing.

As described above, the upper die 210 is divided into the two parts of the first upper die 211 and the second upper die 212, and it is essential to prevent the demoulding due to the undercut shape of the vehicle body 100 So that the demoulding can be smoothly performed, the work efficiency can be improved, and the productivity can be increased.

A leak test is performed on the assembled FFP mold 200 as described above.

That is, a test is performed on a portion corresponding to both sides (SIDE) of the vehicle body 100 and a vacuum molding (vacuum bagging) is performed on the divided surfaces of the first upper mold 211, the second upper mold 212, ), And the degree of vacuum is checked using a vacuum tester to confirm that the vacuum molding is correct.

If the matching surfaces of the first and second upper molds 211 and 212 and the lower mold 250 are not uniform, a putting operation and a tapping operation are performed.

Next, in order to realize the protruding shape of the vehicle body 100, as shown in FIG. 6, a plurality of dams 300 are attached to the inside of the FPC 220. (S11)

It is preferable that the dam 300 is attached to the inner surface of the FPC 220 with an adhesive such as an instant adhesive, and it is preferably made of aluminum (Al).

In this embodiment, the number of the dams 300 is 120 to 130, and the number of the dams 300 may be varied depending on the protruded shape of the body.

By manufacturing and attaching a separate material such as the dam 300 without implementing the protruded shape outside the automobile body 100 on the FPC 20, the demoulding is easy and the surface of the product is excellent. .

Further, by attaching the dam 300 as an adhesive on the inner surface of the FPC 220, the adhesive can be melted at the time of molding in the oven, so that the demoulding can be smoothly performed, thereby improving the working efficiency.

Next, the envelope material 500 is laminated in the FPC mold 200 after the mold-releasing process. (S20)

That is, after the AFP mold 200 is washed with acetone, the liquid release agent is applied once, the solid wax is applied three times, and the liquid release agent is applied three times, followed by drying for 30 minutes after application.

Thereafter, an adhesive film which is the outer cover material 500 is laminated, and then a glass fiber prepreg is laminated.

Next, vacuum molding is performed, followed by primary molding in an oven. (S21)

At this time, the molding temperature is suitably about 125 degrees, and it is molded in the oven for 1 hour and 30 minutes, and the total molding time is about 5 hours including the oven preheating and cooling time.

Next, as shown in FIG. 7, a plurality of frames 530 are assembled in the FPC 220. (S30)

The frame 530 is preferably made of aluminum (Al) for weight reduction.

The assembling procedure of the aluminum frame 530 is preferably performed in the order of the ROOF portion, the FRONT portion, the REAR portion, and the SIDE portion of the vehicle body 100.

By assembling the aluminum frame 530 in the above-described order, interference with the dam 300 attached to the inner surface of the FPC 220 can be avoided, and the aluminum frame 530 can be separately assembled to improve the work efficiency .

Next, the foam cores 550 are laminated, filling between the aluminum frames 530 arranged at predetermined intervals in the FPC mold 200. (S40)

That is, polyvinyl chloride foam 555 is laminated on both side portions of the vehicle body 100, and then the foam foam 551 as a whole is laminated on the body 100.

Finally, an endcoup material 570 is laminated in the FPC mold 200. (S50)

That is, a glass fiber prepreg is laminated.

As described above, the envelope material 500, the frame 530, the foam core 550, and the end cap material 570 are subjected to secondary molding through oven molding. (S60)

That is, after vacuum bagging, secondary molding is performed in an oven. At this time, the molding temperature is suitably about 125 degrees, and it is molded in the oven for 1 hour and 30 minutes, and the total molding time is about 5 hours including the oven preheating and cooling time.

When molding in the oven, the adhesive used in adhering the dam 300 melts, and demoulding is advantageous.

Next, the body 100 having undergone secondary molding is demolded. (S70)

In the demolding procedure, the first upper mold 211 is demolded, the second upper mold 212 is demoulded, and then the molded body 100 is demolded from the lower mold 250.

Finally, the demolding body 100 is completed by applying paint or the like.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. It is to be understood that various changes and modifications may be made without departing from the scope of the appended claims.

100: body 110: door hole
130: Window hole 150: Wheel hole
200: FFPM mold 210: HYPER
211: first phase image 212: second phase image
250: Lower mold 300: Dam
500: sheath material 530: aluminum frame
550: foam core 570:

Claims (4)

In the method for manufacturing a vehicle body 100 using a composite material,
Manufacturing an FRP mold 200 with the same size as the vehicle body 100 (S10);
Stacking the envelope 500 in the FRP mold 200 (S20);
Assembling a plurality of frames (530) in the FRP mold (200);
Stacking a foam core (550) in the FRP mold (200) (S40);
Including the step (S50) for laminating the inner shell material 570 in the FRP mold 200;
In the step (S30),
The frame 530 is assembled in the order of the roof (ROOF) part, the front part (FRONT) part, the rear part (REAR) part, and the side parts (SIDE) part of the vehicle body 100,
In the step (S10),
The FRP mold 200 is manufactured to be composed of an upper mold 210 and a lower mold 250,
The upper mold 210 is manufactured to be divided into the first upper mold 211 and the second upper mold 212, and when demolding, the first upper mold 211 is demolded first, and the second upper mold 212 is demolded later. Vehicle body manufacturing method characterized in that. The method of claim 1,
Between the step (S10) and the (S20),
And (S11) attaching a plurality of dams (300) inside the FRP mold (200) to implement the protruding shape of the vehicle body (100). delete The method of claim 1,
Between (S20) and the step (S30), the step (S21) of primary molding the laminated material laminated through the step (S20);
After the step (S50), the step of (S60) for secondary molding the laminated material laminated through the (S30) to (S50) step; vehicle body manufacturing method characterized in that it further comprises.

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