JP7823937B2 - Collision reinforcement part and manufacturing method thereof - Google Patents

Description

The present invention relates to a crashworthiness component and a manufacturing method thereof, specifically to a crashworthiness component, such as a seat cross member, whose rigidity is reinforced for crashworthiness, and a manufacturing method thereof.

Roll stamping technology is a technology described in the following registered patents: Roll Stamping Apparatus (Registration No. 10-1417278), Roll Stamping Apparatus (Registration No. 10-1786260), and Roll Stamping Apparatus and Method (Registration No. 10-1917450).

The core of roll stamping technology is the use of roll forming equipment to produce parts with cross-sectional shapes that change along their length.

However, parts that change shape in the length direction cannot be manufactured using the standard roll forming method. Therefore, they are generally manufactured using press molding, which uses a mold. However, if the material is strong, forming large parts requires a very high press capacity, making it difficult to manufacture.

Therefore, roll stamping is a useful technology that can overcome these limitations. However, because roll stamping is basically a technology that uses a roll forming device, it is not easy to practically apply to very long parts that have changes in shape along their length. In other words, because the shape of the part along its length must be engraved around the stamping roll, the diameter of the stamping roll must be increased when the part is long. However, this increase in the diameter of the stamping roll directly leads to the problem of having to significantly increase the overall size of the roll forming device, making it difficult to practically apply in terms of installation space.

Korean Patent No. 10-1417278 Korean Patent No. 10-1786260 Korean Patent No. 10-1917450

The present invention was devised to solve the above-mentioned problems, and its purpose is to provide a crashworthiness component that can be manufactured using the roll stamping method without increasing the diameter of the stamping roll when manufacturing components from long material lengths, and a method for manufacturing the same.

To achieve the above objective, the impact reinforcement component of the present invention comprises a component body having side walls formed on both longitudinal sides and a top plate connecting the upper ends of the side walls on both sides, and end flanges bent and formed at both longitudinal ends of the component body. The component body is formed by continuous roll stamping, in which a stamping roll rotates and presses the material multiple times, and the component body includes a body portion having a bead formed on the top plate along the longitudinal direction, and a boundary portion where the body portion and end flanges are joined, which is integral with the body portion and end flanges and where the top plate is flat.

Here, the body portion may include a plurality of bead regions positioned spaced apart in the longitudinal direction, with the beads formed on the upper plate, and a middle no-bead region positioned between the plurality of bead regions and with the upper plate being flat.

In this case, the bead region may have multiple beads spaced apart from one another in the width direction of the upper plate.

Furthermore, the longitudinal length of the intermediate no-bead region may be equal to or greater than twice the combined longitudinal length of the boundary portion and end flange.

Meanwhile, another aspect of the present invention provides a method for manufacturing an impact reinforcement part, which includes a roll stamping step in which a stamping roll is rotated and pressed multiple times along the length of a material to continuously repeat roll stamping, and a flange forming step in which end flanges are formed by bending each of the end ends of the material, and in the roll stamping step, a plurality of bead regions and a middle no-bead region between the plurality of bead regions are formed in the material, and end no-bead regions are formed at each of the end ends.

Specifically, the roll stamping step includes an overall bending process in which the stamping roll is pressed and rotated against the material multiple times to bend the material to form both side walls and an upper plate; a first end no-bead process in which a flat upper plate is formed at one longitudinal end of the material to form the end no-bead region; a bead process in which a plurality of beads are formed on the upper plate of the material at intervals in the longitudinal direction to form the plurality of bead regions; a middle no-bead process in which a flat upper plate is formed between the plurality of beads to form the middle no-bead region; and a second end no-bead process in which a flat upper plate is formed at the other longitudinal end of the material to form the end no-bead region. The first end no-bead process, bead process, middle no-bead process, and second end no-bead process can be performed during the overall bending process, and the middle no-bead process can be performed during the bead process.

In this case, the longitudinal length of the middle no-bead region formed by the middle no-bead process may be equal to or greater than twice the longitudinal length of the end no-bead region formed by the first end no-bead process or the second end no-bead process.

The impact reinforcement component of the present invention is formed by repeatedly and repeatedly rolling a stamping roll onto a material to form the component body. This results in a bead region being formed in the body of the component body, and a boundary region with a no-bead region extending from the body and connecting to the end flange in an integrated structure. This allows the bead region of the body to reinforce rigidity, while at the same time, the no-bead region at the boundary region allows for smooth and easy bending deformation of the end flange.

The method for manufacturing a crashworthiness component according to the present invention includes a roll stamping step in which a stamping roll is rotated and pressed multiple times along the length of the material, continuously repeating roll stamping. This allows the component to be constructed so that shape changes in the length direction are repeated periodically, making it possible to manufacture very long components without increasing the diameter of the stamping roll, and also has the advantage of easily forming the aforementioned boundary.

1 is a view showing a seat cross member according to the prior art; 1 is a view showing a collision reinforcement part according to the present invention; FIG. 3 is an enlarged view of A in FIG. 2. FIG. 3 is an enlarged view of B in FIG. 2; 1 is a flowchart showing a method for manufacturing an impact reinforcement component according to the present invention. 6 is a flowchart showing a roll stamping step in the method for manufacturing the impact reinforcement part of FIG. 5.

Hereinafter, preferred embodiments will be described in detail with reference to the accompanying drawings so that those skilled in the art to which the present invention pertains can easily implement the present invention. However, when describing preferred embodiments of the present invention in detail, if it is determined that a detailed description of related well-known functions or configurations may obscure the gist of the present invention, such detailed description will be omitted. Furthermore, parts having similar functions and operations will be given the same reference numerals throughout the drawings. Furthermore, in this specification, terms such as "top," "upper portion," "top surface," "bottom," "lower portion," "bottom surface," and "side surface" are used based on the drawings and may actually change depending on the direction in which components are arranged.

In addition, throughout the specification, when a part is said to be "connected" to another part, this includes not only "directly connected" but also "indirectly connected" through other components in between. Furthermore, unless otherwise specified, "comprising" a certain component does not mean excluding other components, but may further include other components.

Figure 1 shows a conventional seat cross member.

Referring to the drawings, the seat cross member 10 is configured at the bottom of the vehicle as a reinforcing part to prepare for a collision, i.e., a collision reinforcement part.

Such a seat cross member 10 is constructed as a single unit part with a hat-shaped cross section.

Such a sheet cross member 10 can be manufactured by roll forming because there is no change in cross-sectional shape along the length. In other words, flanges 11 can be created at both ends of the roll-formed part through post-processing, allowing them to be welded to the seal side 20.

However, a structure formed simply from side walls 10a on both sides and a flat top plate 10b reaches a limit where the reinforcement required to prepare for a collision is insufficient.

To overcome these limitations, although not shown in the drawings, a sheet cross member can be manufactured that includes a bead (a portion that is relatively raised upward compared to other portions) on the upper plate.

However, if beads are formed along the entire length of the upper plate, i.e., extending to both ends in the longitudinal direction, it becomes extremely difficult to create flanges that can be bent during the manufacturing process.

In other words, the end of the sheet cross member is not simply hat-shaped, but has a complex cross-sectional shape with a periphery that is bent (folded) multiple times by beads, making it extremely difficult to bend and deform the end to create a flange.

Therefore, in order to form a simple hat-shaped cross-sectional structure without a bead only at the end of the seat cross-member, the seat cross-member is composed of multiple unit parts rather than a single unit part. In other words, a seat cross-member can be made by connecting (joining by welding, etc.) a unit part with a structure with a bead and another unit part with a simple hat-shaped cross-sectional structure without a bead.

However, in the case of a simple hat-shaped cross-sectional structure like this, with no beads at the ends, it is easy to bend the ends and create a flange. However, when a seat cross member is made by joining multiple unit parts rather than as a single unit, the rigidity of the areas where the unit parts are connected (for example, welded areas) is relatively inferior to other areas, making it difficult to use as a collision reinforcement part.

Figure 2 is a drawing showing a crashworthiness component according to the present invention, Figure 3 is an enlarged view of A in Figure 2, and Figure 4 is an enlarged view of B in Figure 2.

Referring to the drawings, in order to solve the above-mentioned problems, the impact reinforcement component 1000 according to the present invention is configured with a boundary portion 120 having a simple cross-sectional structure without a bead (a portion that protrudes relatively upward compared to other portions) at the end, and this boundary portion 120 is configured as an integrated structure rather than a separate member from other portions.

Specifically, the present invention includes a component body 100 and an end flange 200.

The component body 100 is formed by continuously repeating roll stamping, in which a stamping roll rotates and presses against the material multiple times.

The component body 100 manufactured using this method structurally has side walls S formed on both sides in the longitudinal direction, and an upper plate U connecting the upper ends of the side walls S on both sides.

The end flanges 200 are formed by bending each of the longitudinal ends of the component body 100. For example, such end flanges 200 are the parts that are welded to other components, such as seal sides.

Here, the component body 100 includes a body portion 110 and a boundary portion 120.

The body portion 110 has a bead 111a formed along the length of the upper plate U.

Furthermore, the boundary portion 120 is a joint between the body portion 110 and the end flange 200 and is integral with the body portion 110 and the end flange 200.

In this case, the upper plate U of the boundary portion 120 has a flat structure with no bead formed. This boundary portion 120 is essentially a portion with a fairly short length, and is like a boundary line between the body portion 110 and the end flange 200.

More specifically, the body portion 110 includes a bead region 111 and a middle no-bead region 112.

The bead regions 111 are spaced apart in the longitudinal direction, with beads 111a formed on the upper plate U. That is, the bead regions 111 are formed long in the longitudinal direction, but because there is a middle no-bead region 112 in the middle, multiple bead regions 111 are spaced apart. For example, as shown in the drawing, two bead regions 111 can be spaced apart.

These multiple bead regions 111, spaced apart in the longitudinal direction, are formed by roll stamping, as described in the part manufacturing method below. That is, the stamping roll rotates and compresses the material multiple times, forming multiple beads 111a spaced apart in the longitudinal direction.

Furthermore, the bead region 111 may have multiple beads 111a arranged spaced apart from one another in the width direction on the upper plate U. When multiple bead regions 111 are arranged spaced apart in the width direction in this manner, the rigidity of the collision reinforcement component 1000 is increased.

In addition, the intermediate no-bead region 112 is located between multiple bead regions 111, and the upper plate U has a flat structure.

As described above, the body portion 110 has bead regions 111 spaced apart from one another in the longitudinal direction, and the upper plate U forms a flat, intermediate no-bead region 112 between the multiple spaced bead regions 111.

The stamping roll has an uneven structure for forming the bead 111a, as well as a flat portion for forming the boundary portion 120. However, if the stamping roll is of an appropriate size (diameter) taking into account various factors such as the installation space side, in order to manufacture a long collision reinforcement part 1000, multiple rotations and compression are required to form a middle no-bead region 112 where the upper plate U is flat, like the boundary portion 120.

In other words, due to the structure of the above-mentioned middle no-bead region 112, the impact reinforcement part 1000 of the present invention can be realized by a manufacturing method using multiple rotations of a stamping roll.

The boundary portions 120 are located at both longitudinal ends of the component body 100, and are flat portions of the upper plate U that coincide with the boundary line between the body portion 110 and the end flange 200, allowing the end flange 200 to be formed smoothly and easily during bending.

The end flange 200 extends integrally from the boundary portion 120 before being bent. However, because the boundary portion 120 has a simple hat-shaped cross-sectional structure without a bead, bending deformation of the end flange 200 can be performed smoothly and easily.

In this way, by using a manufacturing method that uses multiple rotations of the stamping roll, the present invention creates a structure in which the longitudinal length of the middle no-bead region 112 is equal to or greater than twice the combined longitudinal length of the boundary region 120 and the end flange 200.

When manufacturing multiple impact reinforcement components 1000 of a set length using a long material, the material is roll-stamped into multiple impact reinforcement components 1000 and then cut and separated. Therefore, the length of the middle no-bead region 112 must be twice the combined length of the boundary portion 120, which is the flat end no-bead region 121 of the upper plate U, and the end flange 200. However, since some loss may occur during cutting, a requirement of more than twice the length may be adopted to ensure the formation of sufficient end flange 200.

Figure 5 is a flowchart showing a method for manufacturing an impact reinforcement part according to the present invention, and Figure 6 is a flowchart showing the roll stamping step in the method for manufacturing the impact reinforcement part of Figure 5.

Based on Figures 2 to 4 and referring to Figures 5 and 6, the method for manufacturing an impact reinforcement part according to the present invention includes a roll stamping step S100 and a flange forming step S200.

The roll stamping step S100 is a step in which the stamping roll is rotated and pressed multiple times along the length of the material, thereby continuously repeating roll stamping.

Flange forming step S200 is a step that is carried out after roll stamping step S100, and is a step in which both ends of the material are bent to form end flanges 200.

When manufacturing a collision reinforcement part such as a sheet cross member using a longitudinally elongated material, the product is completed through the roll stamping step S100 and the flange forming step S200.

Here, in the roll stamping step S100, a plurality of bead regions 111 and a middle no-bead region 112 between the plurality of bead regions 111 are formed in the material, and end no-bead regions 121 are formed at each of the two end portions.

Specifically, the roll stamping step S100 includes a full bending process S110, a first end no-bead process S120, a bead process S130, a middle portion no-bead process S130, and a second end no-bead process S150.

In the overall bending process S110, the material is bent while the stamping roll is pressed and rotated multiple times to form both side walls S and the upper plate U.

In addition, in the first end no-bead process S120, a flat upper plate U is formed at one end of the material in the longitudinal direction to form an end no-bead region 121.

Then, in the beading process S130, multiple beads 111a are formed on the upper plate U of the material, spaced apart from one another in the longitudinal direction, to form multiple bead regions 111.

In addition, in the above-mentioned middle no-bead process S130, a flat upper plate U is formed between the multiple beads 111a to form the middle no-bead region 112.

In addition, in the second end no-bead process S150, a flat upper plate U is formed at the other end of the material in the longitudinal direction to form the end no-bead region 121.

At this time, the first end no-bead process S120, bead process S130, middle portion no-bead process S130, and second end portion no-bead process S150 are performed during the entire bending process S110, and the middle portion no-bead process S130 is performed during the bead process S130.

That is, as the stamping roll rotates and compresses the material multiple times to form both side walls S and an upper plate U on the material, the first end no-bead process S120, bead process S130, and second end no-bead process S150 are performed sequentially, and during this time, the middle portion no-bead process S130 is performed during the bead process S130. That is, as the stamping roll rotates and compresses the material multiple times, the first end no-bead process S120, bead process S130, middle portion no-bead process S130, and second end no-bead process S150 are performed.

Then, in the flange forming step S200, after the roll stamping step S100, the end no-bead region 121, which has a flat upper surface, is bent to form the end flange 200.

On the other hand, the longitudinal length of the middle no-bead region 112 can be equal to or greater than twice the longitudinal length of the end no-bead region 121.

When manufacturing multiple impact reinforcement parts 1000 having a set length using a long material, the material is roll stamped in the roll stamping step S100 and then cut and separated to form multiple impact reinforcement parts 1000. Therefore, the length of the middle no-bead region 112 must be twice the length of the end no-bead region 121 where the upper plate U is flat. However, since some of the material may be lost during cutting, a condition of more than twice the length may be adopted to ensure the formation of a sufficient end flange 200.

As a result, the impact reinforcement part 1000 according to the present invention is formed by repeatedly performing roll stamping, in which a stamping roll rotates and compresses a material multiple times, to form the part body 100. As a result, a bead region 111 is formed in the body portion 110 of the part body 100, and a boundary portion 120 having a no-bead region extends from the body portion 110 and connects to the end flange 200 in an integrated structure. This allows the bead region 111 of the body portion 110 to reinforce rigidity, while at the same time, the no-bead region of the boundary portion 120 allows the end flange 200 to smoothly and easily undergo bending deformation.

The method for manufacturing an impact reinforcement part according to the present invention includes a roll stamping step S100 in which the stamping roll is rotated and pressed multiple times along the length of the material, thereby continuously repeating roll stamping. This allows the part to be constructed so that the shape changes in the length direction are repeated periodically, making it possible to manufacture very long parts without increasing the diameter of the stamping roll, and also easily form the boundary portion 120 described above.

Although the present invention has been described above with reference to the accompanying drawings, those skilled in the art will understand that the present invention may be embodied in other specific forms without changing the technical concept or essential features of the present invention. Therefore, the above-described embodiments should be understood to be illustrative in all respects and not limiting.

REFERENCE SIGNS LIST 100 Component body 110 Body part 111 Bead region 111a Bead 112 Middle no-bead region 120 Boundary part 121 End no-bead region 200 End flange 1000 Collision reinforcement part S Side wall U Upper plate S100 Roll stamping step S110 Overall bending step S120 First end no-bead step S130 Bead step S140 Middle bead step S150 Second end no-bead step S200 Flange forming step

Claims (5)

A component for forming a plurality of crash reinforcement components,
a component body having side walls formed on both sides in the length direction and an upper plate connecting the upper ends of the side walls on both sides;
end flanges formed by bending at both ends of the component body in the longitudinal direction,
The component body is formed by continuous repetition of roll stamping, in which a stamping roll rotates and presses against a blank multiple times;
The component body is
a body portion having a plurality of beads formed on an upper plate along a length direction;
A joint portion between the body portion and the end flange includes a boundary portion that is integral with the body portion and the end flange and has a flat upper plate;
The body portion is
a bead region in which a plurality of beads are formed on the upper plate, the bead region being spaced apart from one another in the longitudinal direction;
an intermediate no-bead region located between the plurality of bead regions and having a flat upper plate;
The intermediate no-bead region is configured to allow the formation of the plurality of crash reinforcement components . The component according to claim 1 , wherein the bead region comprises a plurality of beads arranged on the upper plate at intervals in the width direction. The component of claim 1 , wherein the longitudinal length of the intermediate no-bead region is equal to or greater than twice the combined longitudinal length of the border and end flanges. A roll stamping step in which the stamping roll is rotated and pressed multiple times along the length direction of the material to continuously repeat roll stamping;
and forming end flanges by bending each of the opposite ends of the blank,
In the roll stamping step,
forming a plurality of bead regions and a middle no-bead region between the plurality of bead regions in the material, and forming end no-bead regions at both ends;
The roll stamping step includes:
a full-bending process in which the stamping roll is pressed and rotated against the material multiple times to bend the material to form side walls and an upper plate;
a first end no-bead process for forming a flat upper plate on one end of the material in the longitudinal direction to form the end no-bead region;
a beading process for forming a plurality of beads spaced apart from one another in a longitudinal direction on the upper plate of the material to form a plurality of the bead regions;
a middle no-bead process for forming a flat upper plate between a plurality of the beads to form the middle no-bead region;
a second end no-bead process for forming a flat upper plate on the other end of the material in the longitudinal direction to form the end no-bead region;
the first end no-bead process, the bead process, the middle portion no-bead process, and the second end no-bead process are performed in the process of the entire bending process, the middle portion no-bead process is performed in the process of the bead process, and the middle portion no-bead process is performed in the process of the bead process,
A method for manufacturing a collision reinforcement component configured to form a plurality of collision reinforcement components by cutting the middle no-bead region. The method for manufacturing an impact reinforcement component described in claim 4, wherein the longitudinal length of the intermediate no-bead region formed by the intermediate no-bead process is equal to or greater than twice the longitudinal length of the end no-bead region formed by the first end no-bead process or the second end no-bead process.