WO2020166973A1

WO2020166973A1 - Carbon exterior-seat back frame and manufacturing method therefor

Info

Publication number: WO2020166973A1
Application number: PCT/KR2020/001981
Authority: WO
Inventors: 문형준; 박상현; 김동관; 이승열; 김희준
Original assignee: 주식회사 엘지하우시스
Priority date: 2019-02-12
Filing date: 2020-02-12
Publication date: 2020-08-20
Also published as: KR20200098218A

Abstract

The present application relates to a carbon exterior-seat back frame and a manufacturing method therefor and, more specifically, to: a seat back frame for the front seat of a vehicle, manufactured by layering a carbon exterior on a carbon fiber reinforced plastic preform, and then coupling same through heating and pressurization; and a manufacturing method therefor.

Description

Carbon exterior seatback frame and its manufacturing method

The present application relates to a carbon exterior seatback frame and a manufacturing method thereof, and more particularly, to a first row seatback frame of a vehicle and a manufacturing method thereof, which is bonded by heating and pressing after laminating the carbon exterior to a carbon fiber reinforced plastic preform. will be.

Vehicle seats are important for ride comfort and safety, and provide comfort to passengers by adequately absorbing shocks or vibrations transmitted when driving a vehicle. In addition, it must have sufficient rigidity and strength to ensure passenger safety while satisfying these conditions.

The seat back flame refers to a rigid structure provided inside the seat of a vehicle. The seatback frame is the basic frame of the seatback that helps the user to take a comfortable and stable posture, and it is closely related to the safety of passengers and drivers, so it requires no deformation or damage to the characteristic level of force and impact.

In particular, the seatback frame in the first row of a passenger car may cause great damage to passengers by causing breakage or deformation of the seat due to the passenger's behavior when the vehicle suddenly stops or a collision occurs. Therefore, the seatback frame stipulates that there should be no damage to the seatback due to the inertia of the seatback's own weight in situations such as vehicle collision, collision, and sudden stop, or that there should be no permanent deformation or damage of the seatback when pulling or pushing with a certain force. You must satisfy the existing laws.

A back cover has been used in combination with such a seatback frame, but due to the back cover, passengers seated in the back seat often complain of lack of space, and there is a problem that is not beautiful in appearance.

Accordingly, there is a need for a study on an integrated seatback frame capable of providing an excellent external shape as an integrated back cover while securing weight reduction and excellent strength.

[Prior technical literature]

[Patent Literature]

(Patent Document 1) Korean Patent Registration No. 10-1616634 (April 29, 2016)

According to an embodiment of the present application, it is intended to provide a back cover-integrated seat back frame.

According to an embodiment of the present application, it is intended to provide a seatback frame having excellent rigidity and appearance.

One aspect of the present application relates to a method of manufacturing a carbon exterior seatback frame.

As an example, preparing a continuous fiber reinforced thermoplastic (CFT) preform; Laminating a skin layer of carbon fiber reinforced plastic (CFRP) material on the preform; Curing the CFT preform on which the skin layer of the CFRP material is stacked by heating and pressing in an autoclave; Insert-injecting the cured CFT preform to form a seatback frame; And forming a coating layer on one surface of the seatback frame.

As an example, the CFT preform is a preform subjected to sanding.

As an example, the CFT preform is bonded to a first frame made of continuous fiber-reinforced thermoplastic and a localized region of the first frame, and made of a long fiber-reinforced thermoplastic. Includes 2 frames.

As an example, the skin layer of the CFRP material is laminated in 3 to 4 layers.

As an example, the skin layer of the CFRP material is laminated to a thickness of 0.75 mm to 1 mm.

As an example, heating and pressing in the autoclave may include: laminating a CFT preform in which a skin layer of the CFRP material is stacked on a prepared mold; Packing the mold with a vacuum bag; Curing the mold packed in the vacuum bag by heating and pressing the mold in an autoclave; And removing the CFT preform from the mold.

As an example, the autoclave is operated at a temperature of 130° C. to 150° C. and a pressure of 4 bar to 5 bar under conditions of 4 to 6 hours.

As an example, the thickness of the coating layer is 40 μm to 50 μm.

As an example, before forming the coating layer, one surface of the seatback frame is subjected to sanding.

Another aspect of the present application relates to a carbon exterior seatback frame.

As an example, the fiber reinforced plastic preform; A carbon fiber reinforced plastic skin layer formed on the continuous fiber reinforced plastic preform; And a coating layer formed on the carbon fiber reinforced plastic skin layer.

As an example, the thickness of the skin layer is 0.75 mm to 1 mm.

As an example, the thickness of the coating layer is 40 μm to 50 μm.

As an example, the preform is a first frame made of continuous fiber-reinforced thermoplastic and a second frame bonded to a localized region of the first frame, and made of Long Fiber-reinforced Thermoplastic. Includes a frame.

As an example, the first frame is a front frame, the second frame is a rib, the rib is coupled to the front frame, the rib includes a coupling end coupled to the front frame and a free end extending from the coupling end, , The width of the coupling end is larger than the width of the free end.

According to the exemplary embodiment of the present application, by providing a back cover-integrated seatback frame, it is possible to minimize the number of parts of the seatback frame, thereby simplifying the seatback manufacturing process.

According to an exemplary embodiment of the present application, a seatback frame with an integrated back cover may be provided, and particularly when applied to a first row seatback, a wider space may be provided to passengers seated in two rows.

According to the exemplary embodiment of the present application, a back cover-integrated seat back frame having excellent rigidity may be provided.

According to the exemplary embodiment of the present application, a back cover-integrated seatback frame having excellent appearance may be provided.

1 is a schematic diagram of a seatback frame according to an aspect of the present application.

2 is a flowchart of a method of manufacturing a seatback frame according to an aspect of the present application.

3 is a schematic diagram of a seatback frame according to an aspect of the present application.

4 is a schematic cross-sectional view of a seatback frame according to an aspect of the present application.

5 is a schematic diagram of a seatback frame according to an aspect of the present application.

The terms used in the present application are only used to describe specific embodiments, and are not intended to limit the present invention. Singular expressions include plural expressions unless the context clearly indicates otherwise. In the present application, terms such as "include" or "have" are intended to designate that features, elements, etc. described in the specification exist, but one or more other features or elements may not exist or be added. It doesn't mean none.

Unless otherwise defined, all terms used herein, including technical or scientific terms, have the same meaning as commonly understood by one of ordinary skill in the art to which the present invention belongs. Terms such as those defined in commonly used dictionaries should be interpreted as having a meaning consistent with the meaning in the context of the related technology, and should not be interpreted as an ideal or excessively formal meaning unless explicitly defined in this application. Does not.

Hereinafter, with reference to the accompanying drawings will be described in detail the carbon exterior seatback frame and the manufacturing method of the present application. However, the accompanying drawings are exemplary, and the scope of the carbon exterior seatback frame and the manufacturing method of the present application is not limited by the accompanying drawings.

In the present specification, the term "seatback frame" refers to a rigid structure provided inside a seat of a vehicle.

As shown in FIG. 1, the seatback frame 10 is a rigid structure provided inside a seat of a vehicle. However, the seatback frame of the present application is not limited to the structure shown in FIG. 1.

The present application is intended to provide a back cover-integrated seat back frame by combining the above-described seat back frame carbon material exterior skin layer. The specific manufacturing process will be described below.

2 is a flowchart illustrating a method of manufacturing a carbon exterior seatback frame according to an aspect of the present application.

As shown in Figure 2, (a) preparing a continuous fiber reinforced plastic (CFT) preform (S110), (b) laminating a skin layer of a carbon fiber reinforced plastic (CFRP) material on the preform (S120) , (c) heating and pressing the CFT preform on which the skin layer of the CFRP material is laminated in the autoclave to cure (S130), (d) insert-injecting the cured CFT preform to form a seatback frame (S140) And (e) forming a coating layer on one surface of the seatback frame (S140).

Hereinafter, for a detailed description, the present application will be described step by step.

S110: continuous fiber reinforced plastic ( CFT ) Preform Preparation stage

First, the manufacturing method of the present application prepares a continuous fiber-reinforced plastic (CFT) preform (S110).

In the present specification, the term "preform" means that a molding material is previously molded into a tablet for compression molding or transfer molding of a certain shape in order to shorten the molding time.

As an example, the CFT preform of the present application is bonded to a first frame made of continuous fiber-reinforced thermoplastic and a localized region of the first frame, and is made of long fiber-reinforced thermoplastic. And a second frame made of.

As used herein, the term "continuous fiber-reinforced plastic" refers to a thermoplastic continuous fiber-reinforced composite material.

In general, continuous fiber-reinforced plastics contain reinforcing fibers such as glass fiber or carbon fiber in a continuous phase in plastics with relatively weak mechanical strength, and such continuous fiber-reinforced plastics have a length of 1 mm or less. Short Fiber-reinforced Thermoplastics or Long Fiber-reinforced Thermoplastics (LFT) or Glass Mat-reinforced Thermoplastics (GMT) of 5 to 50 mm in length. In comparison, the mechanical strength, stiffness and impact performance are very good.

In addition, the continuous fiber-reinforced plastic has excellent flexibility and can be woven in one or both directions, and the continuous fiber-reinforced plastic structure woven through it can be applied to products requiring various mechanical performances.

The continuous fiber-reinforced plastic as described above is typically manufactured by a pultrusion method or a mixed spinning (Commingle) or hot pressing method.

In addition, the thermoplastic resin may include at least one selected from the group consisting of polypropylene resin, polyethylene resin, polyamide resin, polyester resin, polyphenylene sulfide resin, and combinations thereof.

In the present specification, the term "long fiber reinforced plastic" refers to a thermoplastic long fiber composite material. And the thermoplastic resin may include at least one selected from the group consisting of polypropylene resin, polyethylene resin, polyamide resin, polyester resin, polyphenylene sulfide resin, and combinations thereof.

Through this, while securing the rigidity and strength required for the seatback frame, there is an advantage that it is possible to reduce the weight and weight.

It is preferable that the shape of one side of the preform has the shape of the seatback frame intended by the present application.

In addition, in an example, the CFT preform may be subjected to sanding after masking.

The sanding process and the apparatus for carrying out the same are particularly limited, as long as they are applicable in the technical field to which the present application belongs. Through this, it is possible to improve the bonding force by making one surface of the preform bonded to the skin layer to be described later rough.

S120: Skin layer Lamination step

In the manufacturing method of the present application, a skin layer made of a carbon fiber reinforced plastic (CFRP) material is laminated on the preform (S120).

First, after performing a lay-up of the skin layer, the process of laminating the skin layer may be finished.

As an example, a carbon fiber reinforced plastic is manufactured by pouring a resin for making plastic into carbon fiber and molding it at a constant temperature. Depending on the type of resin used, it can be divided into thermosetting carbon fiber reinforced plastics that cannot be reused once hardened and thermoplastic carbon fiber reinforced plastics that can be reused by applying heat again after use.

In order to pour resin into the carbon fiber and mold it into a desired product shape, the fiber must be made into a fabric. Conventionally, the carbon fiber (thread) itself can be woven into a cloth shape, and the carbon fiber (thread) is thinly stretched. The resin can be evenly distributed by making it into a tape and weaving it.

Carbon fiber reinforced plastic is 1/4 lighter than iron, but has 10 times stronger strength and 7 times stronger elastic modulus, has excellent durability, impact resistance, abrasion resistance, heat resistance, etc., and does not rust, so when applied to the applicant's seatback, the above-described effect is achieved. Can be given to.

As an example, the carbon fiber reinforced plastic material is laminated in 3 to 4 layers. In order to improve the appropriate strength and appearance, it is preferable to laminate in 3 to 4 layers. However, in consideration of weight and cost, it is more preferable to laminate in three layers.

As an example, the carbon fiber reinforced plastic material is laminated to a thickness of 0.75 mm to 1 mm. For example, if the thickness of one layer of carbon fiber reinforced plastic material is 0.25 mm, the thickness of three layers of carbon fiber reinforced plastic material is 0.75 mm. In addition, in consideration of weight and cost, it is more preferable to laminate to a thickness of 0.75 mm.

On one side of the carbon fiber reinforced plastic material, since the carbon fiber reinforced plastic material contains an epoxy resin, it exhibits sticky adhesiveness, so that the shape intended for the present application should be well maintained. This is because it is necessary not to damage the carbon shape (orthogonal pattern) on the surface of the carbon fiber reinforced plastic material.

S130: curing step using an autoclave

In addition, in the manufacturing method of the present application, the CFT preform in which the skin layer of the CFRP material is stacked is heated and pressurized in an autoclave to cure (S130).

As used herein, the term "autoclave" refers to a container capable of reacting at high temperature and high pressure.

In one example, the steps of heating and pressing in an autoclave specifically include: laminating a CFT preform in which a skin layer of a CFRP material is stacked on a prepared mold; Packing the mold in a vacuum bag; Curing the mold packed in a vacuum bag by heating and pressing in an autoclave; And removing the CFT preform from the mold.

Through this, the preform and the skin layer are cured and properly bonded.

Here, the type of the mold and the method of forming the mold are not particularly limited. However, since the shape in the mold affects the shape of the skin to be described later, it should be designed to meet the intention of the present application. In addition, since the skin is adhered to one surface of the seatback frame, it is preferable that the mold has a shape corresponding to the one surface of the seatback frame.

Before entering the autoclave, a mold in which a carbon fiber reinforced plastic material is laminated must be made in a vacuum state. However, the vacuum bag may be any, and is not particularly limited as long as it is a means for autoclaving used in the art.

It is also possible to provide a vacuum state by using a cover. As shown in Figure 6, it is also possible to provide a cover through which the user can directly provide a vacuum state.

Autoclave molding is a method of pressure molding, which is a kind of bag molding. After laminating the sheet-like lamination molding material to the required thickness using either a hard male or a shape, cover it with an elastic flexible bag or sheet made of rubber or other material on it, and cover the whole It is a method of hardening plastic materials by inserting in the autoclave and heating by blowing steam or by injecting compressed air to pressurize.

As a result, volatile components generated from the resin in the product are removed, and since the gap between each layer of the prepreg disappears, bonding can be completed completely, and excellent mechanical properties can be provided. In addition, since the applied pressure is not large, it is easy to manufacture a mold, making it easy to manufacture complex shapes.

This application can be applied to any device as long as it is an apparatus capable of performing an autoclave process.

In addition, in one example, the autoclave is driven at a temperature of 130° C. to 150° C. and a pressure of 4 bar to 5 bar under conditions of 4 to 6 hours. Here, it is more preferable to perform the autoclave process for 5 hours. Through this, the carbon fiber reinforced plastic is properly cured, as intended by the present application.

After removing the packing from the mold, the CFT preform is removed, and at this time, the CFT preform may be removed by the user.

S140: Insert injection step

Further, in the manufacturing method of the present application, a seatback frame is formed by insert-injecting the cured CFT preform (S140).

Insert injection refers to the technique of injecting an insert member such as a nut for assembly in the inserted state when injection molding a synthetic resin product through an injection molding machine. The insert member for assembly is inserted in a stable and accurate position. It is an injection molding technique that provides a product with a beautiful appearance because it is easy to assemble with other parts by injection, the assembly state is solid, and the insert member for assembly is not exposed to the outside.

The insert injection method is not particularly limited, and any method applicable in the technical field to which the present application belongs may be applied to the present application.

S150: coating layer forming step

And, the manufacturing method of the present application forms a coating layer on one surface of the seatback frame (S150).

The carbon fiber reinforced plastic skin layer may be sanded and a coating layer may be formed.

As an example, the coating layer has a gloss and skin layer protection effect. It is preferable that the thickness of the coating layer is 40 μm to 50 μm.

In addition, the coating agent is not particularly limited, and may be a coating agent for automobile painting generally used in the technical field to which the present application belongs. In addition, the coating method is also not particularly limited, and may be a coating method for automobile painting generally used in the technical field to which the present application belongs.

Since the coating layer is formed, the appearance of the integrated seatback frame may have a gloss. However, it is also possible to form a coating layer to which various gloss is not applied.

Another aspect of the present application relates to an external skin adhesive seatback frame.

3 and 4 are a schematic view and a cross-sectional schematic view of an external skin adhesive seatback frame according to an aspect of the present application. However, in FIG. 3, except for the coating layer 30, only the preform 10 and the carbon fiber reinforced plastic skin layer 20 of the seatback frame are shown.

3 and 4, the preform 10 of the seatback frame; A carbon fiber reinforced plastic skin layer 20 formed on the preform; And a coating layer 30 formed on the carbon fiber reinforced plastic skin layer.

A portion overlapping with the content described in the above-described manufacturing method of the seatback frame is not specifically described, and is replaced by the above description.

The integrated seatback frame of the present application includes a preform 10 of the seatback frame sequentially; A carbon fiber reinforced plastic skin layer 20 formed on the preform; And a coating layer 30 formed on the carbon fiber reinforced plastic skin layer. However, it is not limited to such a structure, and a technology applicable in the technical field to which the present application belongs is applied, so that a layer suitable for a function may be additionally inserted between the above-described layers.

As an example, the thickness of the skin layer is 0.75 mm to 1 mm. As an example, the thickness of the coating layer is 40 μm to 50 μm.

The preform is a first frame made of continuous fiber-reinforced thermoplastic and bonded or attached to a localized area of the first frame, and a second frame made of long fiber-reinforced thermoplastic. Include.

5 is a schematic diagram of a seatback frame according to an embodiment of the present application. As shown in Figure 5, specifically, the first frame 100 is a front frame, the second frame 200 is a rib, the rib is coupled or attached to the front frame, the rib is coupled to the front frame It includes a coupling end (attached end) 210 and a free end 230 extending from the coupling end, and the width of the coupling end is greater than the width of the free end. It can be three times or more, for example. Therefore, since the coupling portion is relatively wide, it can be stably coupled.

Through the seatback frame having such a structure, it is possible to provide a seatback frame having an excellent appearance. In addition, through the seatback frame having such a structure, it is possible to provide a seatback frame having excellent strength.

Although the above has been described with reference to the preferred embodiments of the present application, those skilled in the art will be able to variously modify and change the present application without departing from the spirit and scope of the present invention described in the following claims. You will understand that you can.

[Explanation of code]

10: Preform of the seatback frame

20: carbon fiber reinforced plastic skin layer

30: coating layer

40: first frame

100: first frame

200: second frame

210: coupling end

220: free end

Claims

Preparing a continuous fiber reinforced thermoplastic (CFT) preform;

Laminating a skin layer of carbon fiber reinforced plastic (CFRP) material on the preform;

Curing the CFT preform on which the skin layer of the CFRP material is stacked by heating and pressing in an autoclave;

Insert-injecting the cured CFT preform to form a seatback frame; And

A method of manufacturing a carbon exterior seatback frame comprising the step of forming a coating layer on one surface of the seatback frame.
The method of claim 1,

The CFT preform is a method of manufacturing a carbon exterior seatback frame which is a preform subjected to sanding.
The method of claim 1,

The CFT preform is a first frame made of continuous fiber-reinforced thermoplastic and

A method of manufacturing a carbon exterior seatback frame comprising a second frame bonded to the localized region of the first frame and made of Long Fiber-reinforced Thermoplastic.
The method of claim 1,

The method of manufacturing a carbon exterior seatback frame in which the skin layer of the CFRP material is laminated in 3 to 4 layers.
The method of claim 1,

The method of manufacturing a carbon exterior seatback frame in which the skin layer of the CFRP material is laminated to a thickness of 0.75 mm to 1 mm.
The method of claim 1,

The steps of heating and pressurizing in the autoclave include:

Laminating the CFT preform in which the skin layer of the CFRP material is stacked on a prepared mold;

Packing the mold with a vacuum bag;

Curing the mold packed in the vacuum bag by heating and pressing the mold in an autoclave; And

A method of manufacturing a carbon exterior seatback frame comprising the step of removing the CFT preform from the mold.
The method of claim 1,

The autoclave is a method of manufacturing a carbon exterior seatback frame that is driven under conditions of 4 to 6 hours at a temperature of 130°C to 150°C and a pressure of 4 bar to 5 bar.
The method of claim 1,

The thickness of the coating layer is 40 ㎛ to 50 ㎛ method of manufacturing a carbon exterior seatback frame.
The method of claim 1,

Before forming the coating layer, a method of manufacturing a carbon exterior seatback frame in which one surface of the seatback frame is subjected to sanding.
Continuous fiber reinforced plastic preforms;

A carbon fiber reinforced plastic skin layer formed on the continuous fiber reinforced plastic preform; And

A carbon exterior seatback frame comprising a coating layer formed on the carbon fiber reinforced plastic skin layer.
The method of claim 10,

The thickness of the skin layer is 0.75 mm to 1 mm carbon exterior seatback frame.
The method of claim 10,

The thickness of the coating layer is 40 ㎛ to 50 ㎛ carbon exterior seatback frame.
The method of claim 10,

The preform is a first frame made of continuous fiber-reinforced thermoplastic and

A carbon exterior seatback frame that is bonded to the local region of the first frame and includes a second frame made of Long Fiber-reinforced Thermoplastic.
The method of claim 13,

The first frame is a front frame, the second frame is a rib, the rib is coupled to the front frame,

The rib includes a coupling end coupled to the front frame and a free end extending from the coupling end,

A carbon exterior seatback frame in which the width of the coupling end is larger than the width of the free end.