KR20220142293A - Carrier of front end module and manufacturing method thereof - Google Patents

Abstract

The present invention relates to a carrier for a front end module, disposed at the interior of the front of a vehicle. The carrier for the front end module of the present invention comprises: a first carrier having a rectangular frame shape, and including an upper member, lower members spaced apart from each other in the lower direction of the upper member, and side members respectively connecting both ends of the upper member and the lower member; and a second carrier coupled to the first carrier and reinforcing rigidity of the first carrier. The first carrier and the second carrier are made of a plastic material.

Description

Carrier for front-end module and manufacturing method thereof

The present invention relates to a carrier for a front-end module, and more particularly, to a carrier for a front-end module disposed inside a front of a vehicle and a manufacturing method thereof.

Recently, the automobile industry is carrying out technology development in various fields for the production of eco-friendly vehicles for the purpose of high fuel efficiency and reduction of carbon dioxide (CO2).

However, it will take a lot of time and money to replace all vehicles using existing internal combustion engines. Accordingly, automakers are developing eco-friendly vehicles by reducing carbon dioxide (CO2) and improving fuel efficiency through lightweighting vehicles using lightweight materials in the short term. is focusing on

On the other hand, the development of modular parts for the purpose of improving assembly is common in automobile manufacturers.

In the past, all automobile parts were delivered and assembled on the automobile assembly line to manufacture the vehicle, but recently, the supplier pre-assembles some parts through modularization, then supplies it to the automobile assembly line and finally assembles it, saving time and energy. are cutting costs.

The modular parts may be classified into a front end module, a front chassis module, an end chassis module, a door module, a roof module, and a powertrain module.

In particular, the front end module, which is a modularized front end module, is an assembly of parts installed in the front part of the vehicle. The components include a radiator, fan shroud, cooling fan and headlight, The parts will be mounted on the carrier for the front-end module together.

On the other hand, recently, in order to reduce the weight of the vehicle, a hybrid front-end module in which a plastic material is substituted for some components of a carrier for a front-end module made of only a metal material is used.

That is, in the hybrid front-end module, the first carrier, which is the main frame, is made of a plastic material, and the second carrier, which is the sub-frame, can firmly support the first carrier, and secure sufficient rigidity and strength against physical loads. It is usually made of skill material.

However, since the materials of the first carrier and the second carrier are different from each other, there is a problem in that chemical bonding to each other is impossible.

Due to the above problems, the first carrier made of a plastic material and the second carrier made of a metal material are inevitably coupled to each other by a physical coupling method such as a coupling groove and a coupling protrusion. As a result, the first carrier and the second carrier An additional process is required to form a coupling groove and a coupling protrusion on the carrier, respectively.

In addition, there is a problem in that the weight of the vehicle is increased due to the characteristics of the material due to the second carrier made of a metal material, thereby reducing fuel efficiency.

The present invention for solving the above-described problems is to provide a carrier for a front end module capable of increasing the bonding force between the first carrier and the second carrier and lowering the overall weight of the vehicle without a separate additional process, and a method for manufacturing the same. have.

The above and other objects, advantages and features of the present invention, and a method for achieving them will become apparent with reference to the embodiments described below in detail in conjunction with the accompanying drawings.

A carrier for a front end module according to an embodiment of the present invention for achieving the above object includes an upper member, a lower member spaced apart from each other at a distance in a downward direction of the upper member, and both ends of the upper member and the lower member A first carrier in the shape of a rectangular frame consisting of side members for connecting to each other; and a second carrier coupled to the first carrier to reinforce rigidity of the first carrier, wherein the first carrier and the second carrier are made of a plastic material.

The first carrier and the second carrier are coupled to each other by an insert injection method.

The first carrier is made of a combination of polyamide (PA; POLYAMIDE) and glass fiber (GF), and the second carrier is a combination of polyamide and carbon fiber (CF: CARBON FIBER). is done

The first carrier is composed of about 60 to 50% by weight, and the second carrier is composed of a specific gravity of about 40 to 50% by weight.

The second carrier may include a base forming a body; extension portions extending from both ends of the base portion; a first locking portion bent outward from both ends of the extension portion; and a second locking portion recessed in a state in which a hole is formed in the center of the flat portion of the base portion is formed.

The first locking part and the second locking part are over-molded by the first carrier.

At an end of the second locking part, a protrusion extends at right angles from the second locking part.

A method of manufacturing a carrier for a front-end module according to an embodiment of the present invention comprises the steps of forming a first carrier in the form of a plate using a combination of polyamide (PA; POLYAMIDE) and glass fiber (GF: GLASS FIBER); forming a second carrier in the form of a plate with a combination of polyamide and carbon fiber (CF: CARBON FIBER); heating the first carrier and the second carrier in the form of a plate with a heater; respectively inserting the first carrier and the second carrier in the form of a plate into a mold; pressing the first carrier and the second carrier; cooling the pressurized first carrier and the second carrier; taking out the cooled first carrier and the second carrier from the mold, respectively; processing the trimming (TRIMMING) and the hole (HOLE) in the taken out the first carrier and the second carrier; and coupling the first carrier and the second carrier in an insert manner.

The first carrier comprises about 30 wt% of glass fiber compared to polyamide, and the second carrier comprises about 60 wt% of carbon fiber based on polyamide.

The step of creaming and processing the hole is processed through a waterjet method.

The step of coupling the first carrier and the second carrier in an insert manner is performed at an injection temperature of about 250 to 280 degrees, and a melting temperature of about 220 degrees.

According to the present invention, since the first carrier and the second carrier are made of the same material as each other, it is possible to effectively couple the first carrier and the second carrier without a separate physical coupling structure, for example, a structure such as a coupling groove and a coupling protrusion. It works.

And, by forming the material of the second carrier for reinforcing the first carrier with a plastic material, there is an effect that the overall weight of the front end module can be effectively reduced.

In addition, by overmolding the first and second locking portions of the first carrier and the second carrier, a physical coupling effect between the first carrier and the second carrier may be obtained.

Due to this, the second carrier and the second carrier of the present invention are made of the same material, so that they are easily coupled to each other in an insert manner and at the same time the first carrier is overmolded to the first and second locking parts, so that the first carrier There is an effect that can further increase the bonding force between the and the second carrier.

1 is an exploded perspective view showing an exploded state of a carrier for a front-end module of the present invention.
Figure 2 is a front view showing the front of the carrier for the front end module of the present invention.
Figure 3 is a schematic view showing the coupling structure of the carrier for the front-end module of the present invention.
Fig. 4 is a cross-sectional view taken along line A-A' shown in Fig. 2;
Figure 5 is a cross-sectional view showing a coupling structure of the second engaging portion and the first carrier according to another embodiment of the present invention.
6 is a flowchart illustrating a method of manufacturing a carrier for a front-end module according to an embodiment of the present invention.

Examples of the present invention are provided to more completely explain the present invention to those of ordinary skill in the art, and the following examples may be modified in various other forms, and the scope of the present invention is as follows It is not limited to an Example. Rather, these examples are provided so that this disclosure will be more thorough and complete, and will fully convey the spirit of the invention to those skilled in the art. In addition, in the following drawings, each component is exaggerated for convenience and clarity of description, and the same reference numerals refer to the same elements in the drawings. As used herein, the term “and/or” includes any one and all combinations of one or more of those listed items.

The terminology used herein is used to describe specific embodiments, not to limit the present invention.

As used herein, the singular form may include the plural form unless the context clearly dictates otherwise. Also, as used herein, “comprise” and/or “comprising” refers to the presence of the recited shapes, numbers, steps, actions, members, elements, and/or groups of those specified. and does not exclude the presence or addition of one or more other shapes, numbers, movements, members, elements and/or groups.

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

1 is an exploded perspective view showing the disassembled state of the carrier for the front end module of the present invention, Figure 2 is a front view showing the front of the carrier for the front end module of the present invention, Figure 3 is the carrier for the front end module of the present invention is a schematic view showing the coupling structure of the, Figure 4 is a cross-sectional view taken along A-A' shown in Figure 2, Figure 5 is a coupling structure of the second engaging portion and the first carrier according to another embodiment of the present invention A cross-sectional view is shown.

1 to 5 , a carrier for a front-end module according to an embodiment of the present invention includes a first carrier 100 and a second carrier 200 .

The first carrier 100 connects the upper member 110 and the lower member 120 spaced apart from the upper member 110 in the downward direction, and both ends of the upper member 110 and the lower member 120 , respectively. It consists of a side member (130).

That is, the first carrier 100 is formed in a rectangular frame shape as a whole.

On the other hand, the upper member 110 constituting the first carrier 100 may be detachably assembled from the side member 130 to facilitate maintenance, such as after-sales service of the cooling module.

The first carrier 100 is equipped with a cooling module, a headlamp, a bumper beam, and the like, and is coupled to the vehicle by a coupling method such as bolting or welding.

Specifically, the first carrier 100 has a suction port formed in the center, and a cooling module is mounted on the suction port.

The cooling module is cooled by the air introduced through the intake port when the vehicle is driven.

In addition, a headlamp is mounted on the side member 130 of the first carrier 100 , and both ends of the bumper beam are coupled to the front center portion of the side member 130 so that the bumper beams are arranged to be long left and right.

The first carrier 100 serves as a body portion of the front end module, and responds to repeated vibrations and low-speed collisions that occur during driving of the vehicle.

Accordingly, deformation of the shape of the cooling module coupled to the first carrier 100 due to the load by the headlamp and the bumper beam and repeated vibration and low-speed collision applied from the outside cannot but be prevented.

That is, in the present invention, the second carrier 200 is coupled to the first carrier 100 to minimize such deformation.

The second carrier 200 is coupled to the first carrier 100 to reinforce the rigidity of the first carrier 100 .

The second carrier 200 is in contact with the upper member 110, the lower member 120, and the side member 130 constituting the first carrier 100 in a face-to-face manner, respectively, and is coupled by an insert injection method.

To this end, the first carrier 100 and the second carrier 200 are each made of a plastic material.

For this reason, the first carrier 100 and the second carrier 200 may be easily bonded to each other by a chemical bonding method.

Specifically, the first carrier 100 is made of a combination of polyamide (PA; POLYAMIDE) and glass fiber (GF: GLASS FIBER).

And, the second carrier 200 is made of a combination of polyamide and carbon fiber (CF: CARBON FIBER).

And, the first carrier 100 is made of about 30% by weight of glass fibers compared to polyamide, and the second carrier 200 is composed of about 60% by weight of carbon fibers compared to polyamide.

That is, by forming the material of the second carrier 200 reinforcing the first carrier 100 with a plastic material, it is possible to effectively reduce the overall weight of the front end module.

In particular, when the first carrier 100 and the second carrier 200 are formed of a plastic material, and the contact surfaces of the first carrier 100 and the second carrier 200 are coupled in an insert manner, specifically, FIG. 3 As shown in Fig., the injection temperature is about 250 to 280 degrees, and the melting temperature is about 220 degrees.

For this reason, the first carrier 100 and the second carrier 200 are made of the same material as each other, and are chemically bonded by an insert injection method at an appropriate temperature, so that a separate physical bonding structure, for example, a coupling groove and a coupling protrusion, etc. It is possible to effectively couple the first carrier 100 and the second carrier 200 without a structure.

For this reason, in the present invention, a manufacturing process for forming a physical coupling structure such as a coupling groove and a coupling protrusion is omitted, and thus manufacturing cost and manufacturing time can be significantly reduced.

On the other hand, the polyamide constituting the first carrier 100 and the second carrier 200 has high heat resistance and, in particular, high impact resistance due to the characteristics of the material, the first carrier to which the load and the physical force applied from the outside are transmitted. (100) and the second carrier 200 is most suitable as a material.

In addition, the glass fiber constituting the first carrier 100 is excellent in sound absorption and electrical insulation.

Accordingly, it is possible to effectively reduce vibrations repeatedly generated during vehicle driving from the cooling module directly coupled to the first carrier 100 , the headlamp, and the bumper beam.

In addition, the carbon fiber constituting the second carrier 200 is lighter than metal, has superior strength and carbon properties compared to metal, and has excellent heat resistance and impact resistance.

Accordingly, the second carrier 200 can effectively reinforce the first carrier 100 due to the characteristics of the material.

Such, the first carrier 100 of the present invention is made of about 60 to 50% by weight, the second carrier 200 is made of a specific gravity of about 40 to 50% by weight.

More preferably, the first carrier 100 may be composed of 55% by weight, and the second carrier 200 may be composed of 45% by weight.

Therefore, the weight of the present invention can be reduced by about 25% compared to the conventional one.

The second carrier 200 includes a base portion 210 , an extension portion 220 , and a first locking part 230 and a second locking part 240 .

The base portion 210 forms the body of the second carrier 200 and is in direct contact with the first carrier 100 .

The extension parts 220 extend from both ends of the case part, and when separate vehicle components are coupled to the carrier for the front end module, coupling and sealing are facilitated.

The first locking part 230 is bent outward from both ends of the extension part 220 , respectively, and the second locking part 240 is recessed in a state in which a hole is formed in the center of the flat part of the base part 210 . is made of

On the other hand, the first carrier 100 made of a combination of polyamide and glass fiber is formed in the first engaging portion 230 and the second engaging portion 240 of the second carrier 200 in an over-molding method. are combined

That is, the first locking part 230 and the second locking part 240 are overmolded to the first locking part 230 and the second locking part 240 in the first carrier 100 of the first carrier 100 . will be spanned by

Accordingly, the first carrier 100 and the second carrier 200 are overmolded to the first and second locking portions 230 and 240 of the second carrier 200 , so that the first carrier 100 and the second carrier 200 are overmolded. can be physically combined with each other.

For this reason, since the second carrier 200 and the second carrier 200 of the present invention are made of the same material, they are easily coupled to each other in an insert manner and at the same time, the first carrier 100 is coupled to the first engaging portion 230 and By being overmolded on the second locking part 240 , the bonding force between the first carrier 100 and the second carrier 200 may be further increased.

In particular, it is possible to more firmly prevent the base portion 210 from being separated from the first carrier 100 in the vertical direction based on the drawing by the first and second locking parts 230 and 240 .

Meanwhile, in another embodiment of the present invention, as shown in FIG. 5 , a protrusion 241 may be formed at an end of the second locking part 240 .

The protrusion 241 extends at a right angle from an end of the second locking part 240 .

That is, the protrusion 241 may more firmly prevent the base portion 210 from being separated from the first carrier 100 in the horizontal direction based on the drawing.

Hereinafter, a method of manufacturing a carrier for a front-end module will be described with reference to the drawings.

6 is a flowchart illustrating a method of manufacturing a carrier for a front-end module according to an embodiment of the present invention.

Referring to FIG. 6 , first, a plate-shaped first carrier 100 is formed by a combination of polyamide and glass fiber (S100).

Then, the second carrier 200 in the form of a plate is formed by a combination of polyamide and carbon fiber (S200).

Here, the first carrier 100 is preferably made of about 30% by weight of glass fibers compared to polyamide, and the second carrier 200 is made of about 60% by weight of carbon fibers compared to polyamide.

Subsequently, the plate-shaped first carrier 100 and the second carrier 200 are heated with a heater (S300), and the heated plate-shaped first carrier 100 and the second carrier 200 are respectively inserted into the mold. (S400).

Next, the first carrier 100 and the second carrier 200 in the form of a plate inserted into the mold and seated are pressed (S500).

Meanwhile, in the step of heating the first carrier 100 and the second carrier 200 through the heater, the heater heats the first carrier 100 and the second carrier 200 to a melting point or higher.

For this reason, when pressing the first carrier 100 and the second carrier 200 through the mold, the mold can manufacture the first carrier 100 and the second carrier 200 in a pre-designed shape.

Next, the first carrier 100 and the second carrier 200 heated by the heater are cooled (S600) and then taken out from the mold (S700).

Subsequently, the taken out first carrier 100 and the second carrier 200 are trimmed (TRIMMING) and the hole (HOLE) is processed (S800).

Here, the first carrier 100 and the second carrier 200 according to an embodiment of the present invention are trimmed and processed through a waterjet method.

Accordingly, the first carrier 100 and the second carrier 200 of the present invention can be precisely processed by trimming and processing the hole through the waternet, due to the characteristics of the method.

As described above, the first carrier 100 and the second carrier 200, which are trimmed and processed through a water jet, are coupled to each other by an insert injection method (S900).

That is, since the first carrier 100 and the second carrier 200 are formed of a plastic material, the overall weight of the front end module can be effectively reduced.

In addition, when the first carrier 100 and the second carrier 200 are coupled in an insert manner, the injection temperature is about 250 to 280 degrees, and the melting temperature is about 220 degrees.

For this reason, the first carrier 100 and the second carrier 200 are made of the same material as each other, and are coupled by an insert injection method at an appropriate temperature, thereby providing a separate physical coupling structure, for example, a structure such as a coupling groove and a coupling protrusion. Without the first carrier 100 and the second carrier 200 can be effectively coupled.

As described above, in the carrier for a front-end module according to an embodiment of the present invention, the first carrier 100 and the second carrier 200 are made of the same material as each other, so that a separate physical coupling structure, for example, a coupling groove And it is possible to effectively couple the first carrier 100 and the second carrier 200 without a structure such as a coupling protrusion.

In addition, by forming the material of the second carrier 200 reinforcing the first carrier 100 with a plastic material, it is possible to effectively reduce the overall weight of the front end module.

In addition, the first carrier 100 is overmolded to the first engaging portion 230 and the second engaging portion 240 of the second carrier 200 , so that the first carrier 100 and the second carrier 200 are It is possible to obtain a physical bonding effect with each other.

For this reason, since the second carrier 200 and the second carrier 200 of the present invention are made of the same material, they are easily coupled to each other in an insert manner and at the same time, the first carrier 100 is coupled to the first engaging portion 230 and By being overmolded on the second locking part 240 , the bonding force between the first carrier 100 and the second carrier 200 may be further increased.

As such, the embodiments disclosed in this specification should be considered from an exemplary point of view for description rather than a limiting point of view. The scope of the present invention is indicated in the claims rather than the foregoing description, and all differences within an equivalent scope should be construed as being included in the present invention.

100: first carrier 110: upper member
120: lower member 130: side member
200: second carrier 210: base portion
220: extension 230: first engaging portion
240: second engaging portion 241: protrusion

Claims (11)

a first carrier having a rectangular frame shape comprising an upper member, a lower member spaced apart from each other at a distance in a downward direction of the upper member, and side members connecting both ends of the upper member and the lower member; and
and a second carrier coupled to the first carrier to reinforce the rigidity of the first carrier,
The first carrier and the second carrier are a carrier for a front end module made of a plastic material.
According to claim 1,
The first carrier and the second carrier are for a front-end module coupled to each other by an insert injection method.
According to claim 1,
The first carrier is made of a combination of polyamide (PA; POLYAMIDE) and glass fiber (GF: GLASS FIBER),
The second carrier is a carrier for a front-end module made of a combination of polyamide and carbon fiber (CF: CARBON FIBER).
4. The method of claim 3,
The first carrier consists of about 60 to 50% by weight,
The second carrier is a carrier for a front-end module consisting of a specific gravity of about 40 to 50% by weight.
According to claim 1, wherein the second carrier,
a base portion constituting the body;
extension portions extending from both ends of the base portion;
a first locking portion bent outward from both ends of the extension portion; and
A carrier for a front-end module in which a second locking part is formed in a state in which a hole is formed in the center of the flat part of the base part.
6. The method of claim 5,
A carrier for a front-end module in which the first locking part and the second locking part are over-molded by the first carrier.
6. The method of claim 5,
A carrier for a front end module in which a protrusion extends at a right angle from the second locking part at an end of the second locking part.
Forming a first carrier in the form of a plate with a combination of polyamide (PA; POLYAMIDE) and glass fiber (GF: GLASS FIBER);
forming a second carrier in the form of a plate with a combination of polyamide and carbon fiber (CF: CARBON FIBER);
heating the first carrier and the second carrier in the form of a plate with a heater;
respectively inserting the first carrier and the second carrier in the form of a plate into a mold;
the mold pressing the first carrier and the second carrier;
cooling the pressurized first carrier and the second carrier;
taking out the cooled first carrier and the second carrier from the mold, respectively;
processing the trimming (TRIMMING) and the hole (HOLE) in the taken out the first carrier and the second carrier;
Method of manufacturing a carrier for a front end module comprising the step of coupling the first carrier and the second carrier in an insert manner.
9. The method of claim 8,
The method of manufacturing a carrier for a front-end module, wherein the first carrier comprises about 30% by weight of glass fiber compared to polyamide, and the second carrier comprises about 60% by weight of carbon fiber compared to polyamide.
9. The method of claim 8,
The step of creaming and processing the hole,
A method of manufacturing a carrier for a front-end module that is processed through the waterjet method.
9. The method of claim 8,
The step of coupling the first carrier and the second carrier in an insert manner comprises an injection temperature of about 250 to 280 degrees, and a melting temperature of about 220 degrees.

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