KR101703781B1 - Manufacturing method of high strength resin cowl cross member - Google Patents

Abstract

Disclosed is a method for manufacturing a high strength resin cowl cross member. According to the present invention, the method for manufacturing a high strength resin cowl cross member includes: a bar forming step of forming a cowl cross bar comprising a uni-directional (UD) tape by separating the UD tape from a pipe after laminating the UD tape in the radial direction of the pipe by winding the UD tape on the outer circumference of the pipe; and a bar insertion step of integrally injection-molding a bracket by inserting the cowl cross bar into an injection mold. According to the present invention, the method for manufacturing a high strength resin cowl cross member forms a stable connection force by having a simple connection structure of the cowl cross bar and the bracket even if the cowl cross bar and the bracket are made of a resin material.

Description

Technical Field [0001] The present invention relates to a high strength resin cowl cross member,

The present invention relates to a method of manufacturing a high-strength resin cowl cross member, and more particularly, to a method of manufacturing a high-strength resin cowl cross member in which a cow crossbar and a bracket are formed as a simple coupling structure, ≪ / RTI >

The COWL CROSS MEMBER is used as a skeleton to prevent warpage and distortion of the vehicle in the left and right direction and to enhance the durability of the car body. It provides a guide surface on which various electric parts of the instrument panel are mounted, .

The cowl cross member is made of a hollow pipe made of steel material and has a cowl crossbar arranged in the transverse direction of the vehicle body in front of the driver's seat and the front passenger seat as main components. The mounting brackets formed at both ends of the cowl crossbar Respectively.

The cowl crossbar is coupled with a plurality of brackets for supporting a steering column, an instrument panel, an airbag device, and the like. Conventionally, a plurality of brackets are welded to a cowl crossbar made of a metal material. Recently, in the automobile manufacturing industry, a bracket made of a plastic material is applied to solve the weakening of welding strength due to vehicle vibration and to reduce the total weight of the vehicle .

In this connection, Korean Patent Laid-Open Publication No. 2005-0017204 discloses a support bracket structure for fixing a steering column of an automobile, and Japanese Laid-Open Patent Publication No. 2005-0017204 discloses a cowl crossbar which is screwed at a predetermined position of a cowl crossbar, And a support bracket coupled to one side of the support plate and made of a steel reinforcing plate to reinforce the rigidity of the support plate. The brake pedal is hingably connected to a lower portion of the support bracket.

Japanese Patent Application Laid-Open No. 2005-0017204 has an advantage in that the number of components is reduced by increasing the rigidity while reducing the weight of the support bracket for fixing the steering column and hinging the brake pedal portion at the lower portion thereof.

Korean Patent Publication No. 568710 discloses a structure of a center support bracket, and Korean Patent Publication No. 568710 discloses a cowl cross member having an upper end coupled to a cowl cross member, A pair of side portions extending downward from both ends of the upper end portion; A center support bracket integrally formed with a plastic material for connecting the middle portion of the side portion and allowing the mounting of the acoustic system, the upper portion having a bent shape for seating the cowl cross member And the upper end is formed with a through hole, and the rivet passes through the through hole and the cowl cross member through the washer to fix the cowl cross member to the upper end portion.

Patent No. 568710 discloses a method for manufacturing a molded product by integrally molding plastic using a plastic material so that it is possible to reduce the weight of the part to improve the fuel consumption and the vibration damping effect due to the characteristics of the plastic material itself. And there is no mold design cost for designing a large number of plates in the past, which is advantageous in reducing the cost of the product.

However, in Japanese Unexamined Patent Application Publication No. 2005-0017204 and No. 568710, holes are formed in the cowl crossbar and the bracket to fasten brackets made of different materials of plastic to metal cowl crossbars, and bolts, nuts, or rivets The coupling structure by the physical fastening means may be such that the rigidity of the coupling structure is long lasting as the stress due to vehicle vibration and external impact is concentrated on the hole into which the fastening means is inserted or the physical fastening means itself There was a problem that noise easily occurred.

In addition, in Patent Publication Nos. 2005-0017204 and 568710, a plurality of brackets for supporting a steering column, an instrument panel, an airbag device, and the like must be respectively formed. Therefore, an injection mold has to be separately prepared for each bracket, This increases the workload and the production cost.

In order to solve the above-mentioned problems, there has been an effort to produce a cow cross member as an injection molded article. However, it is difficult for the cow cross member made of an injection molded article to have strength equivalent to that of a cow cross member made of a metallic material, There is a problem that the structure of the joint is complicated to form a sufficient coupling force between the bracket and the bracket.

(0001) Korean Patent Publication No. 2005-0017204 (published on February 22, 2005) (0002) Korean Patent Publication No. 568710 (Registered on Mar. 31, 2006)

It is an object of the present invention to provide a method of manufacturing a high-strength resin cowl cross member in which a cow crossbar and a bracket are formed as a simple coupling structure so as to form a firm coupling force even if the cow crossbar and the bracket are made of a resin material.

According to the present invention, there is provided a bar forming step of winding a UD tape on an outer circumferential surface of a pipe and laminating the UD tape in a radial direction of the pipe and then separating the UD tape from the pipe to form a cow crossbar made of the UD tape ; And a bar insert step of inserting the cowl crossbar into an injection mold to injection-mold the bracket integrally.

In the bar forming step, the pipe rotates about a central axis, and the UD tape is reciprocated in a direction parallel to the central axis of the pipe, and is stacked on the outer circumferential surface of the pipe.

Wherein the UD tape reciprocates so that the thermoplastic resin is impregnated with reinforcing fiber in one direction so as to be wound at an angle within 55 degrees with respect to the central axis of the pipe, Of the reinforcing fibers forming the angle of the reinforcing fibers.

In the bar insert step, the bracket may be integrally injection-molded so as to surround the cowl crossbar, and the UD tapes laminated by the thermal energy transmitted from the bracket during the injection molding may be attached to each other.

In the insert step, the outer circumferential surface of the cowl crossbar is divided into a joint region surrounding the bracket and a reinforcement region other than the joint region, and a reinforcement coating integral with the bracket is integrally formed And the UD tapes laminated by thermal energy transmitted from the bracket and the reinforcing film during injection molding may be made to adhere to each other.

Wherein the bracket comprises: a mounting portion surrounding the periphery of the cowl crossbar; And an extension part extending from the mounting part to which a part of the vehicle is coupled. The extension part may include a closed loop type skeleton and a plurality of connecting ribs connecting the skeleton from the inside of the skeleton.

In the bar forming step, the UD tape is formed by impregnating a thermoplastic resin in one direction with the thermoplastic resin, and is reciprocated so as to be wound at an angle within 55 degrees with respect to the central axis of the pipe. In the cowl crossbar, Wherein the reinforcing rib is formed with a mesh structure of an angle of less than 55 degrees with respect to the axis, and in the bar insert step, a reinforcing rib of a mesh structure forming an angle of not more than 55 degrees with the central axis of the pipe, Or the like.

According to the present invention, even if the cowl crossbars and the brackets are made of a resin material, the cowl crossbars and the brackets can be formed as a simple joining structure to form a rigid joining force by forming the cowl crossbars by winding the UD tape around the outer periphery of the pipe, It is possible to provide a method of manufacturing a high strength resin cow cross member.

1 is a flowchart of a method of manufacturing a high-strength resin cowl cross member according to an embodiment of the present invention.
Fig. 2 is a view showing a bar forming step of the method for manufacturing a high-strength resin cowl cross member shown in Fig. 1; Fig.
3 is a view showing a cowl crossbar manufactured in a bar forming step of the method for manufacturing a high strength resin cowl cross member shown in Fig.
Fig. 4 is a view showing the insert step of the method of manufacturing the high strength resin cow cross member of Fig. 1; Fig.
5 is a view showing an insert step of a method of manufacturing a high-strength resin cowl cross member according to another embodiment of the present invention.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. In the following description of the present invention, the well-known functions or constructions are not described in order to simplify the gist of the present invention.

The method of manufacturing a high strength resin cowl cross member of the present invention is such that even if the cowl crossbar and the bracket are made of a resin material, the cowl crossbar and the bracket are formed as a simple coupling structure to form a strong coupling force.

Fig. 1 is a flow chart of a method of manufacturing a high-strength resin cowl cross member according to an embodiment of the present invention, Fig. 2 is a view showing a bar forming step of the method for manufacturing a high strength resin cow cross member in Fig. Fig. 4 is a view showing a bar insert step of a method for manufacturing a high-strength resin cowl cross member shown in Fig. 1, and Fig. 5 is a view showing a cow cross bar manufactured according to another embodiment of the present invention Fig. 8 is a view showing an insert step of a method for manufacturing a high-strength resin cowl cross member.

1, the method (S100) for manufacturing a high-strength resin cowl cross member of the present invention is a method for manufacturing a cowl crossbar 110 and a bracket 120, And is formed to include a bar forming step S100 and a bar insert step S120.

The bar forming step S100 is a step of forming a cow cross bar 110 composed of a UD tape as shown in Fig. 2, in which the UD tape UD is wound around the outer peripheral surface of the pipe P In the radial direction of the pipe (P).

UD tape (UD) is an intermediate substrate prepared by impregnating a thermoplastic resin (RS) such as PP or PA6 with reinforcing fiber (CF) such as glass or carbon fiber in one direction and winding it in tape form. Generally, Is used as a local stiffener.

In addition, UD tape (UD) is manufactured by a continuous process and can uniformly adjust the resin (RS) content, has characteristics showing uniform physical properties, has a higher content of reinforcing fibers than LFT (Long Fiber Reinforced Thermoplastics) It is possible to produce high-performance molded products. In addition, it has excellent strength, rigidity and impact resistance.

2, in the bar forming step S100, the UD tape UD is fitted in a circular bar B parallel to the pipe P, and the UD tape UD is wound in a direction in which the UD tape UD is wound The UD tape UD is wound around the outer peripheral surface of the pipe P by rotating the pipe P by a rotating device (not shown).

The pipe P rotates about the center axis X and the UD tape UD is stacked on the outer circumferential surface of the pipe P while reciprocating in a direction parallel to the central axis X of the pipe P. [

Although not shown, the circular bar B is attached to a torsion spring (not shown) or a tension belt (not shown) so that a tension is formed on the UD tape UD between the pipe P and the circular bar B. .

A rotational force is formed on the circular bar B opposite to the direction in which the UD tape UD is unwound by the torsion spring or the tension belt. The UD tape UD is wound on the torsion spring or the tension belt So that the tensioned state can be maintained.

The end of the UD tape UD is coupled to the outer circumferential surface of the pipe P in a state of forming an angle a within 55 degrees with the central axis X of the pipe P and the circular bar B is connected to the UD tape UD is parallel to the central axis X of the pipe P so as to be wound on the outer peripheral surface of the pipe P while maintaining an angle alpha within 55 degrees with the central axis X of the pipe P As shown in FIG.

3 shows a state in which the cowl crossbar 110 made of the UD tape UD is separated from the pipe P after the bar forming step S100 is completed. Since the cowl crossbar 110 is formed in a circular tube shape, when the external force is applied to one end of the cowl crossbar 110 in the axial direction of the pipe P, the cowl crossbar 110 can be easily separated from the pipe P .

As described above, in the bar forming step S100, the UD tape UD is wound at an angle? Within 55 degrees in both directions with respect to the central axis X of the pipe P, and as shown in Fig. 3 Likewise, the cow crossbar 110 is formed with a meshed structure of the reinforcing fibers CF forming an angle of less than 55 degrees with the central axis X of the pipe P. [

In the bar forming step S100, the circular bar B reciprocates at the same speed in both directions parallel to the pipe P. Accordingly, the net structure of the reinforcing fibers CF forms a uniform mesh structure per unit area that is not concentrated on any one portion along the longitudinal direction of the cowl crossbar 110, and also forms a mesh structure in the radial direction of the cowl crossbar 110 And forms a mesh-like structure uniformly per unit area on the inside and outside.

Therefore, the cowl crossbar 110 manufactured through the bar forming step S100 is superior in strength, rigidity and impact resistance to the cowl crossbars manufactured by the injection molding of the conventional resin material by the mesh structure of the reinforcing fibers CF The production cost can be reduced and the production time can be shortened by manufacturing the cowl crossbar 110 by using the pipe P, the circular bar B and the rotary device without using the injection mold M.

As shown in FIG. 1, when the bar forming step S100 is completed, a bar insert step S120 is performed. The bar insert step S120 is a step of integrally molding the bracket 120 by inserting the cowl crossbar 110 into the injection mold M as shown in Fig. The bracket 120 is integrally injection-molded so as to surround the periphery of the cow crossbar 110. As shown in FIG.

The laminated UD tape UD constituting the cowl cross bar 110 is inserted into the injection mold M to insert the cowl crossbar 110 into the bracket 120. The laminated UD tape UD constituting the cowl crossbar 110 is transferred from the bracket 120 to the bracket 120, The strength is improved on the joining portion of the cowl crossbar 110 and the bracket 120. [

The thermoplastic resin RS of the UD tape UD is attached to the bracket 120 in the radial direction of the cowl cross bar 110 on the joining portion of the bracket 120 so that the thermoplastic resin RS is pressed in the radial direction of the cow crossbar 110 This enhances the binding force of the bracket 120 and the cowl crossbar 110 on the joint by inducing a net structure of the reinforcing fibers CF to protrude toward the bracket 120.

Various techniques have been disclosed to fasten brackets made of different materials of plastics to cowl crossbars made of metal such as those disclosed in Unexamined Patent Application Publication Nos. 2005-0017204 and 568710. However, The coupling structure has a problem that the rigidity of the coupling structure can not be maintained for a long time due to the concentration of stress due to vehicle vibration and external impact on the hole into which the coupling means is inserted or the physical coupling means itself and noise is generated easily.

Meanwhile, attempts have been made to fabricate a cow cross member as an injection molded article in order to avoid the problem of the coupling structure of the different materials. However, it is difficult for the cow cross member made of the injection molded article to have the strength equivalent to that of the cow cross member made of metal, There is a problem in that the structure of the joining portion becomes complicated in order to form a sufficient coupling force between the cowl cross member and the bracket.

A method (S100) for producing a high-strength resin cowl cross member of the present invention is a method for manufacturing a cowl crossbar 110 in which a UD tape (UD) having excellent strength, rigidity and impact resistance is laminated on the outer circumferential surface of a pipe The cow crossbar 110 is inserted into the injection mold M and the bracket 120 is integrally injection molded so that the cow cross member 100 made of a resin material having a simplified joining structure can be easily manufactured, The bracket 120, and the cow cross member 100 with improved strength of the mutual coupling structure.

As shown in FIG. 4, the bracket 120 is configured to include a mounting portion 121 and an extension portion 122.

The mounting portion 121 refers to the portion of the cowl crossbar 110 that surrounds the circumference and the extension portion 122 refers to the portion of the vehicle that extends from the mounting portion 121 to which the parts of the vehicle are coupled. Although not shown, depending on the use of the bracket 120, the extension 122 may be associated with an air conditioning system, an electrical system, a steering system or a vehicle body of a vehicle.

The extension portion 122 is configured to include a closed loop type skeleton F and a plurality of connecting ribs FR that connect the skeleton F from the inside of the skeleton F to each other. The extension part 122 has a strength that is equivalent to that of the bracket 120 made of metal by improving the strength by the closed loop type framework F and the connecting rib FR connecting the same.

5, a method S100 for manufacturing a high-strength resin cowl cross member according to another embodiment of the present invention is characterized in that in the bar insert step S120, the reinforcing coating 230 is integrally injected together with the bracket 220 Can be molded.

As shown in Fig. 5 (a), the outer circumferential surface of the cow crossbar 210 is divided into a joining region A1 and a strengthening region A2. The joining region A1 refers to the outer circumferential surface of the cow crossbar 210 around which the bracket 220 is wrapped and the strengthening region A2 refers to the outer circumferential surface of the cow crossbar 210 other than the joining region A1.

5 (b), a method S100 of manufacturing a high-strength resin cowl cross member according to another embodiment of the present invention includes a step of forming a reinforcing film 230 Is formed integrally by injection molding in the form of wrapping around the reinforcement region A2 and is formed by heat energy transmitted from the bracket 220 and the reinforcement coating 230 during the injection molding to the reinforcement region A2, The UD tapes UD stacked over the entire outer circumferential surface of the cross bar 210 are joined together.

Therefore, the strength of the entire cowl crossbar 210 is improved by attaching the entire UD tape UD along the longitudinal direction of the cowl cross bar 210. In addition, the reinforcing film 230 not only protects the reinforcing area A2 from external force or foreign matter in the reinforcing area A2, but also prevents damage and dislocation of the UD tape UD.

The thermoplastic resin RS of the UD tape UD is bonded to the cowl crossbar 210 in the radial direction of the cowl crossbar 210 in the bonding region A1 and the reinforcing region A2, The cowl crossbar 210 is slightly compressed in the radial direction by inducing a net structure of the reinforcing fibers CF to protrude toward the bracket 220 and the reinforcing coating 230, And the bracket 220 and the reinforcing coating 230 are improved.

The reinforcing coating 230 is formed integrally with the bracket 220 and forms a binding force with respect to each other. As a result, the coupling force between the cowl crossbar 210 and the bracket 220 is strengthened.

5B, a method S100 for manufacturing a high-strength resin cowl cross member according to another embodiment of the present invention is characterized in that in the bar insert step S120, A reinforcing rib TR of a mesh structure forming an angle of less than 55 degrees with the central axis X may be formed in a protruding shape.

The reinforcing coating 230 forms a bonding force with the mesh structure of the reinforcing fibers CF in the reinforcing region A2 so that the central axis X of the pipe P and the longitudinal direction X of 55 degrees When the reinforcing rib TR of the mesh structure forming the angle of the reinforcement rib TR is formed in a protruding shape, the reinforcing rib TR is formed together with the reinforcing fiber CF, The strength of the cow crossbar 210 is further improved.

According to the present invention, even if the cowl crossbars and the brackets are made of a resin material, the cowl crossbars and the brackets can be formed as a simple joining structure to form a rigid joining force by forming the cowl crossbars by winding the UD tape around the outer periphery of the pipe, It is possible to provide a method of manufacturing a high strength resin cow cross member.

The present invention is carried out in the industrial core technology development project of the Ministry of Industry and Commerce (Project title: development of cowl cross beam (CCB) parts for 35% weight reduction automobile using high tensile polyamide fiber composite material (Project number: 10050523)) Has been.

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 embodiments, but, on the contrary, It is obvious to those who have. Accordingly, it should be understood that such modifications or alterations should not be understood individually from the technical spirit and viewpoint of the present invention, and that modified embodiments fall within the scope of the claims of the present invention.

S100: How to make a cow cross member
S110: Bar forming step S120: Bar insert step
100,200: Cow Cross member
110, 210: Cow crossbars 120, 220: Bracket
UD: UD tape 121, 221:
RS: Resin 122, 222: Extension
CF: reinforcing fiber F: skeleton
B: Circular bar FR: Connection rib
P: Pipe 230: Reinforced Coating
X: center axis TR: reinforcing rib
A1:
A2: Enhancement area

Claims (7)

A bar forming step of winding a UD tape on an outer circumferential surface of a pipe to laminate the pipe in a radial direction of the pipe and then separating the UD tape from the pipe to form a cow cross bar made of the UD tape; And
And a bar insert step of inserting the cowl crossbar into an injection mold to integrally mold the bracket,
In the bar forming step,
The pipe rotates around a central axis,
Wherein the UD tape is reciprocally moved in a direction parallel to the center axis of the pipe and is stacked on an outer circumferential surface of the pipe,
The UD tape is made of a thermoplastic resin impregnated with reinforcing fibers in one direction and reciprocates so as to be wound at an angle within 55 degrees with the central axis of the pipe,
Wherein the cowl crossbar has a mesh structure of the reinforcing fibers forming an angle of less than 55 degrees with the central axis of the pipe. delete delete The method according to claim 1,
In the bar insert step,
Wherein the bracket is integrally injection-molded so as to surround the periphery of the cowl crossbar,
Wherein the UD tapes laminated by thermal energy transmitted from the bracket during injection molding are bonded together. The method according to claim 1,
In the bar insert step,
Wherein an outer circumferential surface of the cowl crossbar is divided into a joint region surrounding the bracket and a reinforcement region other than the joint region,
And a reinforcing film integrally formed with the bracket is integrally injection-molded in a manner to enclose the reinforcing region,
Wherein the UD tapes laminated by thermal energy transmitted from the bracket and the reinforcing film at the time of injection molding are bonded to each other. The method according to claim 4 or 5,
The bracket
A mounting portion surrounding the periphery of the cowl crossbar; And
And an extension portion extending from the mounting portion to which a part of the vehicle is coupled,
Wherein the extending portion includes a closed loop type skeleton and a plurality of connecting ribs connecting the skeleton from the inside of the skeleton. 6. The method of claim 5,
In the bar forming step,
The UD tape is made of a thermoplastic resin impregnated with reinforcing fibers in one direction and reciprocates so as to be wound at an angle within 55 degrees with respect to the center axis of the pipe. A mesh structure of the reinforcing fibers forming an angle is formed,
In the bar insert step,
Wherein the reinforcement coating is formed in a shape in which a reinforcing rib of a mesh structure forming an angle of less than 55 degrees with the center axis of the pipe is protruded.

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