Roll bar of vehicle and method of manufacturing the same

Abstract

The present disclosure provides a vehicle roll bar and a manufacturing method thereof. The roll bar includes a front insulator connected to a powertrain; a rod bracket mounted to the front end of the rod bracket; a housing bracket disposed outside the rod bracket and secured to the vehicle body; a stopper rubber formed at the rear end of the rod bracket and disposed within the interior space defined by the housing bracket; and a rear insulator formed between the rod bracket and the housing bracket, wherein the rear insulator is secured to the outer surface of the rod bracket and the inner surface of the housing bracket. By simplifying the structure and employing an extrusion molding method, the roll bar enhances isolation performance against powertrain vibrations, improves durability, and reduces manufacturing costs.

Description

Technical Field

[0001] The present disclosure relates to a roll rod of a vehicle and a method for manufacturing the same. Background Art

[0002] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

[0003] Typically, a roll bar is one of the mounting elements used to support a vehicle's powertrain, connecting the powertrain to the vehicle body. The roll bar is interposed between the powertrain and the vehicle body to control the powertrain's roll motion and isolate vibrations.

[0004] Figure 7 is a diagram showing a conventional roll bar of a vehicle.

[0005] like Figure 7 As shown, a conventional roll bar includes a rod bracket 1 interposed between a powertrain and a vehicle body, and further includes a front insulator 2 and a rear insulator 3 provided at both side ends of the rod bracket 1. The front insulator 2 is connected to the powertrain, and the rear insulator 3 is supported between an end plate 5 and the rod bracket 1 by bolt members 4, and is connected to the vehicle body via a housing bracket 6.

[0006] However, it has been found that because the conventional roll bar is arranged so that the rear insulator 3 is assembled between the end plate 5 and the rod bracket 1 in a pre-compressed state, the conventional roll bar has high dynamic characteristics and therefore poor isolation performance.

[0007] To ensure rigidity, conventional roll bars typically use an extrusion process to manufacture the rod bracket 1 and housing bracket 6. However, due to their size, only two rod brackets 1 can be produced per set of dies, significantly reducing manufacturing costs. Furthermore, significant material loss due to scrap increases manufacturing costs. Furthermore, extrusion also reduces the durability of brackets 1 and 6 due to the numerous pores within the molded product.

[0008] Furthermore, since the conventional roll bar has a relatively complicated assembly structure, it is disadvantageous in terms of manufacturing cost and weight. Summary of the Invention

[0009] The present disclosure provides a roll bar for a vehicle and a method for manufacturing the same, which reduces manufacturing costs by simplifying the structure and applying an extrusion molding method, and enhances the isolation performance and durability of the vehicle from vibration of a powertrain.

[0010] In one form of the present disclosure, a roll bar for a vehicle includes: a front insulator connected to a powertrain; a rod bracket, the front insulator being mounted to a front end portion of the rod bracket; a housing bracket disposed outside the rod bracket, the housing bracket being fastened to a vehicle body; a stopper rubber formed at a rear end portion of the rod bracket, the stopper rubber being disposed in an interior space defined by the housing bracket; and a rear insulator formed between the rod bracket and the housing bracket, the rear insulator being fixed to an outer side surface of the rod bracket and an inner side surface of the housing bracket.

[0011] In one embodiment, the housing bracket may include a first housing disposed on the left side of the rod bracket while being spaced apart from the rod bracket by a predetermined interval; and a second housing disposed on the right side of the rod bracket while being spaced apart from the rod bracket by a predetermined interval. The rear insulator may include a first bridging rubber attached to the inner side surface of the first housing and the left side surface of the rod bracket; and a second bridging rubber attached to the inner side surface of the second housing and the right side surface of the rod bracket.

[0012] In another embodiment, the housing holder may further include: a third housing disposed behind the rod holder while being spaced a predetermined distance apart from the rod holder; a first wall formed on the inner side surface of the first housing and disposed behind the first bridging rubber; and a second wall formed on the inner side surface of the second housing and disposed behind the second bridging rubber. When the rod holder moves forward, the front surface of the stopper rubber may contact the first and second walls, and when the rod holder moves rearward, the rear surface of the stopper rubber may contact the third housing.

[0013] In another embodiment, the roll bar may further include a stopper bracket assembled to a rear end portion of the bar bracket, the stopper bracket being embedded in the stopper rubber. A left portion of the stopper bracket may protrude to the left side of the bar bracket and may be disposed behind the first wall, and a right portion of the stopper bracket may protrude to the right side of the bar bracket and may be disposed behind the second wall.

[0014] In yet another embodiment, the rod bracket may include a rear hole portion provided at a rear end portion of the rod bracket, and the stop bracket may include a coupling groove formed in a middle portion of the stop bracket. The stop bracket may be inserted into an internal space of the rear hole portion, and a rear end portion of the rear hole portion may be press-fitted into the coupling groove in the stop bracket.

[0015] In yet another embodiment, the stopper rubber may include a rear contact portion formed on a rear surface portion of the stopper rubber, and may further include a first front contact portion and a second front contact portion formed on a front surface portion of the stopper rubber. The rear contact portion may be disposed behind the rod holder, the first front contact portion may be disposed behind a first wall on a left side of the rod holder, and the second front contact portion may be disposed behind a second wall on a right side of the rod holder.

[0016] In some aspects of the present disclosure, the first bridging rubber may include a first rod-engaging surface portion attached to the left surface of the rod bracket; and a first housing-engaging surface portion attached to the inner surface of the first housing. The first rod-engaging surface portion is disposed forward of the first housing-engaging surface portion and at a predetermined distance therefrom. The second bridging rubber may include a second rod-engaging surface portion attached to the right surface of the rod bracket; and a second housing-engaging surface portion attached to the inner surface of the second housing. The second rod-engaging surface portion is disposed forward of the second housing-engaging surface portion and at a predetermined distance therefrom.

[0017] In some forms of the present disclosure, the housing bracket may further include: a first body coupling portion protruding from an outer side surface of the first housing to be fastened to the vehicle body; and a second body coupling portion protruding from an outer side surface of the second housing to be fastened to the vehicle body.

[0018] In another aspect, the present disclosure provides a method for manufacturing a roll bar of a vehicle, the vehicle including a front insulator connected to a powertrain, the method comprising: a first step of forming a rod bracket by extrusion molding, the rod bracket including a front mounting portion formed at a front end portion of the rod bracket, the front insulator being mounted to the front mounting portion; a second step of forming a shell bracket by extrusion molding, the shell bracket including a body coupling portion for fastening to a body; a third step of arranging the shell bracket on an outer side of the rod bracket so that the rear end portion of the rod bracket is arranged in an inner space defined by the shell bracket; and a fourth step of forming a rear insulator between an outer side surface of the rod bracket and an inner side surface of the shell bracket, and forming a stopper rubber at the rear end portion of the rod bracket arranged in the inner space defined by the shell bracket.

[0019] In some forms of the present disclosure, the housing bracket may include a first housing, a second housing, and a third housing. In the third step, when the housing bracket is disposed outside the rod bracket, the first housing may be disposed on the left side of the rod bracket while being spaced apart from the rod bracket by a predetermined interval, the second housing may be disposed on the right side of the rod bracket while being spaced apart from the rod bracket by a predetermined interval, and the third housing may be disposed behind the rod bracket while being spaced apart from the rod bracket by a predetermined interval.

[0020] In some embodiments of the present disclosure, the rear insulator may include a first bridging rubber and a second bridging rubber. In a fourth step, when forming the rear insulator, the first bridging rubber may be attached to the inner surface of the first housing and the left surface of the rod bracket, and the second bridging rubber may be attached to the inner surface of the second housing and the right surface of the rod bracket.

[0021] In an exemplary form of the present disclosure, in the second step, when the case holder is formed, the first wall may be protrudingly formed on the inner side surface of the first case, and the second wall may be protrudingly formed on the inner side surface of the second case.

[0022] In yet another embodiment, in the fourth step, when the stopper rubber is formed, the rear surface of the stopper rubber may be spaced a predetermined distance from the third housing, and the front surface of the stopper rubber may be spaced a predetermined distance from the first wall and the second wall. The stopper rubber may be formed simultaneously with the formation of the rear insulator.

[0023] In an exemplary embodiment of the present disclosure, the method may further include: forming a stop bracket by extrusion molding; and coupling the stop bracket to a rear end portion of the rod bracket before the third step. When the housing bracket is disposed outside the rod bracket in the third step, a left portion of the stop bracket may be disposed behind the first wall while being spaced apart from the first wall by a predetermined distance, and a right portion of the stop bracket may be disposed behind the second wall while being spaced apart from the second wall by a predetermined distance.

[0024] In an exemplary embodiment of the present disclosure, a rear hole portion may be formed at the rear end portion of the rod bracket, and a coupling groove may be formed in the middle portion of the stop bracket. The stop bracket is inserted into the interior space of the rear hole portion, and then the rear end portion of the rear hole portion is press-fitted into the coupling groove in the stop bracket, thereby coupling the stop bracket and the rear hole portion.

[0025] In an exemplary form of the present disclosure, in the fourth step, when the stopper rubber is formed, a rear contact portion may be formed on the rear surface of the stopper rubber. The rear contact portion may be provided behind the rod bracket and may be spaced apart from the third housing by a predetermined interval.

[0026] In an exemplary embodiment of the present disclosure, in the fourth step, when the stopper rubber is formed, a first front contact portion and a second front contact portion may be formed on the front surface portion of the stopper rubber. The first front contact portion may be provided behind the first wall on the left side of the rod holder while being spaced apart from the first wall on the left side of the rod holder by a predetermined interval, and the second front contact portion may be provided behind the second wall on the right side of the rod holder while being spaced apart from the second wall on the right side of the rod holder by a predetermined interval.

[0027] In an exemplary form of the present disclosure, in the second step, when the shell bracket is formed by extrusion molding, a first body connection portion can be protrudingly formed on the outer side surface of the first shell to be fastened to the body, and a second body connection portion can be protrudingly formed on the outer side surface of the second shell to be fastened to the body.

[0028] In another form, the method may further include mounting a front insulator to the front mounting portion.

[0029] Other aspects and exemplary forms of the disclosure are discussed below.

[0030] It is understood that the term "vehicle" or "vehicular" or other similar terms used herein generally include motor vehicles, such as passenger cars including sport utility vehicles (SUVs), buses, trucks, various commercial vehicles, watercraft including various boats and ships, aircraft, etc., and include hybrid vehicles, electric vehicles, plug-in hybrid vehicles, hydrogen-powered vehicles and other alternative fuel (e.g., fuels derived from resources other than petroleum) vehicles. As referred to herein, a hybrid vehicle is a vehicle that has two or more power sources, for example, a gasoline and electric dual-power vehicle.

[0031] The above and other features of the present disclosure are discussed below.

[0032] Further areas of applicability will become apparent from the description provided herein.It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] In order that the present disclosure may be better understood, various forms of the present disclosure, given by way of example, will now be described with reference to the accompanying drawings, in which:

[0034] Figure 1 is a perspective view of a roll bar in one form of the present disclosure;

[0035] Figure 2 is a plan view of a roll bar in one form of the present disclosure;

[0036] Figure 3 It is along Figure 2 A cross-sectional view taken along line AA in FIG.

[0037] Figure 4 It is along Figure 2 A cross-sectional view taken along line BB in FIG.

[0038] Figure 5A and Figure 5B is a diagram showing an operating state of a roll bar in one form of the present disclosure;

[0039] Figures 6A to 6C is a diagram illustrating a manufacturing process of a roll bar in one form of the present disclosure; and

[0040] Figure 7 is a diagram showing a conventional roll bar of a vehicle.

[0041] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. DETAILED DESCRIPTION

[0042] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

[0043] Hereinafter, reference will now be made in detail to exemplary forms of the present disclosure, examples of which are illustrated in the accompanying drawings.

[0044] It should be understood that the drawings are not necessarily drawn to scale, presenting a somewhat simplified representation of various features illustrating the basic principles of the present disclosure. The specific design features of the present disclosure disclosed herein, including, for example, specific dimensions, orientations, positions, and shapes will be determined in part by the specific intended application and use environment.

[0045] A vehicle roll bar according to one embodiment of the present disclosure is used in conjunction with an engine mount installed between the engine and the vehicle body, and a transmission mount installed between the transmission and the vehicle body, to support the powertrain. The roll bar is connected between the powertrain and the vehicle body and is used to control the roll motion of the powertrain and isolate vibration noise.

[0046] like Figure 1 and Figure 2 As shown, the roll bar may include a bar bracket 10 , a housing bracket 20 , a rear insulator 30 , a stopper rubber 40 , and a front insulator 50 .

[0047] The rod bracket 10 is connected between the powertrain and the vehicle body in a manner arranged in the front-to-rear direction of the vehicle. A front insulator 50 coupled to the powertrain may be mounted to the front end of the rod bracket 10, a stopper rubber 40 may be provided at the rear end of the rod bracket 10, and a rear insulator 30 may be provided in the middle portion of the rod bracket 10.

[0048] In one embodiment, the rod bracket 10 may include a front mounting portion 11, a rear mounting portion 12, a front aperture portion 13, and a rear aperture portion 14 arranged in a row in the front-to-rear direction of the vehicle. The front mounting portion 11 may be formed into a cylindrical structure, and the front insulator 50 may be press-fitted to the inner side of the front mounting portion 11. The rear mounting portion 12 may be formed into a structure having a rectangular cross-section, and the rear insulator 30 may be engaged with and mounted on the outer side surface of the rear mounting portion 12. Each of the front aperture portion 13 and the rear aperture portion 14 may be formed into a rectangular cylindrical structure. The front aperture portion 13 may be disposed between the front mounting portion 11 and the rear mounting portion 12 and formed integrally therewith. The rear aperture portion 14 may be disposed at the rear end of the rear mounting portion 12 and formed integrally therewith.

[0049] The rod bracket 10 may be disposed between the powertrain and the vehicle body and may move in the front-rear direction of the vehicle according to the movement of the powertrain.

[0050] Alternatively, the rod bracket 10 can be formed using an extrusion molding method. To this end, the rod bracket 10 can have a simple structure that allows for extrusion molding. In one embodiment, the rod bracket 10 can be formed to have a uniform cross-section relative to the left and right directions of the vehicle. In other words, when forming the rod bracket 10, in order to push and remove the molded rod bracket 10 from the mold, the rod bracket 10 can be formed to maintain a constant cross-section in the removal direction. In other words, the cross-section of the rod bracket 10 can remain constant in the direction of removal from the mold. The advantages of the extrusion molding method used to form the rod bracket 10 are that the structure of the molded product is dense, ensuring high strength, and the molding process is simple, making it very economical compared to general casting methods.

[0051] The housing bracket 20 is positioned outside the rod bracket 10 and secured to the vehicle body. It surrounds the middle and rear portions of the rod bracket 10, outside the rear insulator 30 and the stopper rubber 40. Specifically, the housing bracket 20 may be formed into a rectangular ring structure with one open side. In other words, the housing bracket 20 may be formed into a U-shaped rectangular ring structure.

[0052] Reference Figure 1 and Figure 2 The housing bracket 20 may include a first housing 21, a second housing 22, and a third housing 23. The first housing 21 may be formed into a panel structure having a predetermined size. The first housing 21 may be disposed on the left side of the rod bracket 10 while being spaced apart from the rod bracket 10 by a predetermined interval. The second housing 22 may be formed into a panel structure having a predetermined size. The second housing 22 may be disposed on the right side of the rod bracket 10 while being spaced apart from the rod bracket 10 by a predetermined interval. The first housing 21 and the second housing 22 may be disposed parallel to each other.

[0053] The third housing 23 may be formed into a panel structure having a predetermined size. The third housing 23 may be disposed between the first housing 21 and the second housing 22 and may be integrally formed therewith. The third housing 23 may be disposed behind the rod holder 10 while being spaced a predetermined distance apart from the rod holder 10. The distance between the inner surface of the first housing 21 and the left surface of the rod holder 10 may be equal to the distance between the inner surface of the second housing 22 and the right surface of the rod holder 10.

[0054] Furthermore, the housing bracket 20 may include a first wall 24 formed on the inner surface of the first housing 21 and a second wall 25 formed on the inner surface of the second housing 22. The first wall 24 may be formed to protrude perpendicularly from the inner surface of the first housing 21. The second wall 25 may be formed to protrude perpendicularly from the inner surface of the second housing 22. The first wall 24 and the second wall 25 may be arranged parallel to the third housing 23. Alternatively, the first wall 24 and the second wall 25 may be arranged in a straight line. The rear aperture portion 14 of the rod bracket 10 may be disposed between the first wall 24 and the second wall 25. A predetermined gap may be provided between the first wall 24 and the rear aperture portion 14. A predetermined gap may be provided between the second wall 25 and the rear aperture portion 14.

[0055] In addition, the housing bracket 20 may include a first vehicle body coupling portion 26 formed on the outer side surface of the first housing 21 and a second vehicle body coupling portion 27 formed on the outer side surface of the second housing 22. The first vehicle body coupling portion 26 may be formed to protrude perpendicularly from the outer side surface of the first housing 21. The second vehicle body coupling portion 27 may be formed to protrude perpendicularly from the outer side surface of the second housing 22. The first vehicle body coupling portion 26 and the second vehicle body coupling portion 27 may be arranged parallel to the third housing 23. Alternatively, the first vehicle body coupling portion 26 and the second vehicle body coupling portion 27 may be arranged in a straight line.

[0056] The housing bracket 20 can be formed by extrusion. To this end, the housing bracket 20 can have a simple structure suitable for extrusion molding. In one embodiment, the housing bracket 20 can be formed to have a uniform cross-section relative to the left and right sides of the vehicle. In other words, when the housing bracket 20 is formed by extrusion molding, the housing bracket 20 can be formed to maintain a constant cross-section in the direction of removal in order to eject and remove the molded housing bracket 20.

[0057] Reference Figure 1 and Figure 2 The rear insulator 30 may be disposed between the rod bracket 10 and the housing bracket 20. The rear insulator 30 may be formed by a vulcanization molding method. When the rear insulator 30 is formed, the rear insulator 30 may be joined and fixed to the outer surface of the rod bracket 10 and the inner surface of the housing bracket 20.

[0058] In another form, the rear insulator 30 may include a first bridging rubber 31 and a second bridging rubber 32. The first bridging rubber 31 may be provided between the first housing 21 and the rod bracket 10 and may be attached to the inner side surface of the first housing 21 and the left surface of the rod bracket 10. The second bridging rubber 32 may be provided between the second housing 22 and the rod bracket 10 and may be attached to the inner side surface of the second housing 22 and the right surface of the rod bracket 10. In this case, one end portion of the first bridging rubber 31 (i.e., the first rod engaging surface portion) may be engaged to the left surface of the rear mounting portion 12 of the rod bracket 10, and one end portion of the second bridging rubber 32 (i.e., the second rod engaging surface portion) may be engaged to the right surface of the rear mounting portion 12.

[0059] The first bridging rubber 31 may be provided with a first lever engaging surface portion 31a on its right side and a first housing engaging surface portion 31b on its left side. When forming the first bridging rubber 31, the first lever engaging surface portion 31a may be attached and fixed to the left surface of the lever bracket 10. When forming the first bridging rubber 31, the first housing engaging surface portion 31b may be attached and fixed to the inner side surface of the first housing 21.

[0060] The second bridging rubber 32 may be provided with a second lever engaging surface portion 32a on its left side and a second housing engaging surface portion 32b on its right side. When forming the second bridging rubber 32, the second lever engaging surface portion 32a may be attached and fixed to the right surface of the lever bracket 10. When forming the second bridging rubber 32, the second housing engaging surface portion 32b may be attached and fixed to the inner side surface of the second housing 22.

[0061] In this case, the first lever engagement surface portion 31a can be positioned forward of the first housing engagement surface portion 31b and at a predetermined distance therefrom, and the second lever engagement surface portion 32a can be positioned forward of the second housing engagement surface portion 32b and at a predetermined distance therefrom. In other words, the first and second bridge rubbers 31 and 32 can be positioned so as to be inclined at a predetermined angle relative to the forward and backward movement direction of the lever holder 10. This enhances the durability of the first and second bridge rubbers 31 and 32 against powertrain vibrations.

[0062] Meanwhile, the stopper rubber 40 may be provided at the rear end portion of the rod bracket 10. In this case, the stopper rubber 40 may be formed by a vulcanization molding method and may be provided in the internal space defined by the housing bracket 20. In order to enhance the stopping performance and durability of the stopper rubber 40, a stopper bracket 16 (see FIG. 1 ) may be provided inside the stopper rubber 40. Figure 3 and Figure 4 ). The stopper bracket 16 can be used as a frame for the stopper rubber 40.

[0063] Reference Figures 3 to 6C Before forming the stopper rubber 40, the stopper bracket 16 may be assembled to the rear end portion of the rod bracket 10. The stopper bracket 16 may have a coupling groove 16a formed in its middle portion, into which the rear end portion of the rear hole portion 14 may be inserted and coupled in a press-fit manner. For example, the stopper bracket 16 inserted into the interior space of the rear hole portion 14 may be pressed toward the rear end portion of the rear hole portion 14 and coupled thereto.

[0064] When the stopper rubber 40 is formed at the rear end portion of the rod bracket 10 , the stopper bracket 16 is covered by the stopper rubber 40 . That is, the stopper bracket 16 may be built into the stopper rubber 40 .

[0065] To prevent the stopper bracket 16 from separating from the rod bracket 10, the stopper rubber 40 may be provided with a rear contact portion 43 on its rear surface. Furthermore, to reduce the weight of the stopper rubber 40, the stopper rubber 40 may be provided with a first front contact portion 41 and a second front contact portion 42 on its front surface. Specifically, the front surface of the stopper rubber 40 may be formed such that the portion between the first front contact portion 41 and the second front contact portion 42 is relatively recessed. In other words, the middle portion of the front surface of the stopper rubber 40 may be relatively recessed.

[0066] The first and second front contact portions 41 and 42 may be formed to protrude forward of the stopper rubber 40, and the rear contact portion 43 may be formed to protrude rearward of the stopper rubber 40. The rear contact portion 43 may be provided on neither the left rear side nor the right rear side of the stopper bracket 16.

[0067] In one form, the first front contact portion 41 may be provided on the left side of the rod holder 10, the second front contact portion 42 may be provided on the right side of the rod holder 10, and the rear contact portion 43 may be provided behind the rod holder 10 and in a straight line with the rod holder 10. In this case, the first front contact portion 41 may be provided behind the first wall 24 while being spaced apart from the first wall 24 by a predetermined interval, the second front contact portion 42 may be provided behind the second wall 25 while being spaced apart from the second wall 25 by a predetermined interval, and the rear contact portion 43 may be provided in front of the third housing 23 while being spaced apart from the third housing 23 by a predetermined interval.

[0068] Therefore, if Figure 5A and Figure 5BAs shown, when the rod bracket 10 moves toward the front of the vehicle due to the movement of the powertrain, the first front contact portion 41 and the second front contact portion 42 respectively contact the first wall 24 and the second wall 25, and when the rod bracket 10 moves toward the rear of the vehicle due to the movement of the powertrain, the rear contact portion 43 contacts the third housing 23. Therefore, excessive deformation of the rear insulator 30 can be prevented, and the movement of the rod bracket 10 can be restricted.

[0069] When the stopper rubber 40 collides with the first and second walls 24 and 25, most of the collision load is applied to the first and second front contact portions 41 and 42. Consequently, the left and right portions of the stopper bracket 16 located behind the first and second front contact portions 41 and 42 are pressed rearward. Consequently, the coupling force between the rod bracket 10 and the stopper bracket 16 can be increased.

[0070] Reference Figure 2 and Figure 3 , the left and right portions of the stopper bracket 16 protrude to the left and right sides of the rod bracket 10, respectively, inside the stopper rubber 40. That is, the left portion of the stopper bracket 16 can be disposed behind the first wall 24, and the right portion of the stopper bracket 16 can be disposed behind the second wall 25.

[0071] When stopper rubber 40 collides with third housing 23, most of the collision load is applied to rear contact portion 43. Consequently, most of the collision load is applied to the rear end portion of rod holder 10 located in front of rear contact portion 43, while almost no collision load is applied to the left or right portions of stopper bracket 16. Consequently, stopper bracket 16 is prevented from being pressed in a direction separating from the rear end portion of rod holder 10. Furthermore, rod holder 10 is pressed toward stopper bracket 16, thereby increasing the coupling force between rod holder 10 and stopper bracket 16.

[0072] Although not shown in the drawings, in another form, the first front contact portion 41 and the second front contact portion 42 may be omitted from the front surface portion of the stopper rubber 40, and the rear contact portion 43 may be omitted from the rear surface portion of the stopper rubber 40. In the case where the front contact portions 41 and 42 and the rear contact portion 43 are omitted, the rear surface portion of the stopper rubber 40 can be provided to be spaced apart from the third housing 23 by a predetermined interval, and the front surface portion of the stopper rubber 40 can be provided to be spaced apart from the first wall 24 and the second wall 25 by a predetermined interval.

[0073] Similar to the rod bracket 10 and the housing bracket 20, the stop bracket 16 can also be formed by extrusion. To this end, the stop bracket 16 can have a simple structure suitable for extrusion molding. In one embodiment, the stop bracket 16 can be formed to maintain a constant cross-section relative to the left and right directions of the vehicle. In other words, when the stop bracket 16 is formed by extrusion molding, the stop bracket 16 can be formed to maintain a constant cross-section in the direction of removal in order to eject and remove the molded stop bracket 16 from the mold.

[0074] In this case, the lever holder 10 , the housing holder 20 and the locking holder 16 can be produced using aluminum by an extrusion method.

[0075] The roll bar configured as described above can be manufactured as follows. Figure 6A The steps of forming and assembling the rod bracket 10 and the stop bracket 16 are shown. Figure 6B The steps of forming and processing the housing bracket 20 are shown. Figure 6C The steps of forming the rear insulator 30 and the stopper rubber 40 after the housing bracket 20 is disposed outside the rod bracket 10 are shown. Figure 6C The step of assembling the front insulator 50 is also shown.

[0076] The manufacturing process of the roll bar may include a first step of forming the rod bracket 10 by extrusion molding, a second step of forming the housing bracket 20 by extrusion molding, a third step of disposing the housing bracket 20 outside the rod bracket 10, and a fourth step of forming the rear insulator 30 and the stopper rubber 40.

[0077] Reference Figure 6A , the extrusion molding of the stopper bracket 16 can be performed after the extrusion molding of the rod bracket 10. In order to enhance the stopping performance and durability of the stopper rubber 40, the stopper bracket 16 can be assembled to the rear end portion of the rod bracket 10 before molding the stopper rubber 40. In this case, the rear end portion of the rod bracket 10 can be press-fitted and fixed in the coupling groove 16a in the stopper bracket 16.

[0078] Reference Figure 6B After the extrusion molding of the housing bracket 20 is performed, holes may be formed in the first vehicle body coupling portion 26 and the second vehicle body coupling portion 27 of the housing bracket 20. These holes may be used when the housing bracket 20 is bolted to the vehicle body.

[0079] Reference Figure 6CWhen the housing bracket 20 is disposed outside the rod bracket 10, the housing bracket 20 may surround the rod bracket 10 except for the front mounting portion 11 of the rod bracket 10. That is, when the housing bracket 20 is disposed outside the rod bracket 10, the housing bracket 20 surrounds the middle portion and the rear portion of the rod bracket 10. Specifically, the first housing 21 may be disposed on the left side of the rod bracket 10 while being spaced apart from the rod bracket 10 by a predetermined interval, the second housing 22 may be disposed on the right side of the rod bracket 10 while being spaced apart from the rod bracket 10 by a predetermined interval, and the third housing 23 may be disposed behind the rod bracket 10 while being spaced apart from the rod bracket 10 by a predetermined interval. The stop bracket 16 may be disposed in a space surrounded by the first wall 24, the second wall 25, and the third housing 23 (i.e., an internal space defined by the housing bracket 20). In this case, the left portion of the stopping bracket 16 may be disposed behind the first wall 24 while being spaced apart from the first wall 24 by a predetermined interval, and the right portion of the stopping bracket 16 may be disposed behind the second wall 25 while being spaced apart from the second wall 25 by a predetermined interval.

[0080] As described above, after the housing bracket 20 is disposed outside the rod bracket 10, the rear insulator 30 is formed between the outer surface of the rod bracket 10 and the inner surface of the housing bracket 20, and the stopper rubber 40 is formed at the rear end of the rod bracket 10 and the outer surface of the stopper bracket 16. The rear insulator 30 and the stopper rubber 40 can be formed by a vulcanization molding method. In this case, the rear insulator 30 and the stopper rubber 40 can be formed simultaneously.

[0081] Simultaneously with the molding of the rear insulator 30, the rear insulator 30 can be attached and fixed to the rod bracket 10 and the housing bracket 20. Simultaneously with the molding of the stopper rubber 40, the stopper rubber 40 can be bonded and fixed to the rear end portion of the rod bracket 10 and the outer surface of the stopper bracket 16. Therefore, the roll bar does not require a separate assembly process other than the step of mounting the stopper bracket 16 to the rear end portion of the rod bracket 10.

[0082] The rear insulator 30 may include a first bridging rubber 31 and a second bridging rubber 32. Figure 6C When forming the bridging rubbers 31 and 32, the first bridging rubber 31 may be attached to the inner side surface of the first housing 21 and the left surface of the rear mounting portion 12 of the rod bracket 10, and the second bridging rubber 32 may be attached to the inner side surface of the second housing 22 and the right surface of the rear mounting portion 12 of the rod bracket 10. In addition, when forming the stopper rubber 40, the rear surface portion of the stopper rubber 40 may be provided at a predetermined interval from the third housing 23, and the front surface portion of the stopper rubber 40 may be provided at a predetermined interval from the first wall 24 and the second wall 25.

[0083] When the stopper rubber 40 is formed, the rear contact portion 43 may be formed on the rear surface portion of the stopper rubber 40 and may be disposed behind the rod bracket 10, and the first front contact portion 41 and the second front contact portion 42 may be formed on the front surface portion of the stopper rubber 40. The first front contact portion 41 may be disposed behind the first wall 24 on the left side of the rod bracket 10, and the second front contact portion 42 may be disposed behind the second wall 25 on the right side of the rod bracket 10.

[0084] In addition, the front insulator 50 may be mounted in an internal space in the front mounting portion 11 formed at the front end portion of the rod bracket 10 in a press-fitting manner.

[0085] As apparent from the above description, according to the roll bar configured and manufactured as described above, rear insulator 30 absorbs vibrations when the powertrain undergoes small displacement movements, and when the powertrain undergoes large displacement movements, rear insulator 30 absorbs vibrations while stopper rubber 40 restricts the fore-and-aft movement of rod bracket 10. Furthermore, stopper rubber 40 restricts deformation of rear insulator 30 when the powertrain undergoes large displacement movements. Therefore, the roll bar can maintain its isolation performance against powertrain movement and durability.

[0086] In addition, since the brackets 10, 16 and 20 constituting the roll bar are formed by an extrusion molding method, the manufacturing cost of the roll bar can be reduced. In addition, since the roll bar has a simple assembly structure, it is advantageous in terms of cost and weight.

[0087] Above, the present disclosure is described in detail with reference to the exemplary forms of the present disclosure. However, it will be understood by those skilled in the art that these forms can be changed without departing from the principles and ideas of the present disclosure.

Claims

1. A roll bar for a vehicle, comprising: front insulator, connected to the powertrain; a rod bracket, the front insulator being mounted to a front end portion of the rod bracket; a housing bracket, disposed on an outer side of the rod bracket, the housing bracket being fastened to the vehicle body; a stopper rubber formed at a rear end portion of the rod bracket, the stopper rubber being disposed in an internal space defined by the housing bracket; as well as a rear insulator formed between the rod bracket and the housing bracket, the rear insulator being fixed to the outer side surface of the rod bracket and the inner side surface of the housing bracket, Wherein, the housing bracket includes: a first housing provided on the left side of the rod bracket while being spaced apart from the rod bracket by a predetermined interval; and a second housing disposed on the right side of the rod bracket while being spaced apart from the rod bracket by a predetermined interval; Wherein, the rear insulator comprises: a first bridging rubber attached to an inner side surface of the first housing and a left surface of the rod bracket; and a second bridging rubber attached to the inner side surface of the second housing and the right surface of the rod bracket, and Wherein, the housing support further comprises: a third housing disposed behind the rod bracket while being spaced apart from the rod bracket by a predetermined interval; a first wall formed on an inner side surface of the first housing and disposed behind the first bridging rubber; and The second wall is formed on the inner side surface of the second housing and is disposed behind the second bridging rubber.

2. The roll bar according to claim 1, wherein: When the rod holder moves forward, the front surface portion of the stopper rubber contacts the first and second walls of the housing holder, and when the rod holder moves rearward, the rear surface portion of the stopper rubber contacts the third housing of the housing holder.

3. The roll bar according to claim 2, further comprising: A stop bracket is assembled to the rear end of the rod bracket, and the stop bracket is built into the stop rubber. The left portion of the stop bracket protrudes to the left side of the rod bracket and is disposed behind the first wall, and the right portion of the stop bracket protrudes to the right side of the rod bracket and is disposed behind the second wall.

4. The roll bar according to claim 3, wherein: The rod bracket includes a rear hole portion provided at a rear end portion of the rod bracket, The stopping bracket includes a coupling groove formed at a middle portion of the stopping bracket, and The stop bracket is inserted into the inner space in the rear hole portion, and a rear end portion of the rear hole portion is press-fitted into the coupling groove in the stop bracket.

5. The roll bar according to claim 3, wherein: The stop rubber comprises: a rear contact portion formed on a rear surface portion of the stopper rubber; and A first front contact portion and a second front contact portion are formed on the front surface portion of the stopper rubber, and The rear contact portion is disposed behind the rod bracket, the first front contact portion is disposed behind the first wall on the left side of the rod bracket, and the second front contact portion is disposed behind the second wall on the right side of the rod bracket.

6. The roll bar according to claim 1, wherein: The first bridging rubber comprises: a first rod engaging surface portion attached to a left surface of the rod bracket; and a first housing engaging surface portion attached to an inner side surface of the first housing, The first lever engagement surface portion is disposed in front of and at a predetermined distance from the first housing engagement surface portion, and The second bridging rubber comprises: a second rod engaging surface portion attached to a right surface of the rod bracket; and a second shell engaging surface portion attached to an inner side surface of the second shell, The second lever engagement surface portion is disposed forward of the second housing engagement surface portion at a predetermined distance therefrom.

7. The roll bar according to claim 1, wherein: The housing support further comprises: a first vehicle body coupling portion protruding from an outer side surface of the first housing to be fastened to the vehicle body; and A second vehicle body coupling portion protrudes from an outer side surface of the second housing to be fastened to the vehicle body.

8. A method for manufacturing a roll bar for a vehicle, the roll bar comprising a front insulator connected to a powertrain, the method comprising: forming a rod bracket by extrusion molding, the rod bracket including a front mounting portion formed at a front end portion of the rod bracket, the front insulator being mounted to the front mounting portion; forming a housing bracket by extrusion, the housing bracket including a vehicle body coupling portion for fastening to a vehicle body; disposing the housing bracket outside the rod bracket so that a rear end portion of the rod bracket is disposed within an interior space defined by the housing bracket; as well as forming a rear insulator between an outer side surface of the rod bracket and an inner side surface of the housing bracket, wherein the rear insulator includes a first bridging rubber and a second bridging rubber, and a stopper rubber is formed at a rear end portion of the rod bracket disposed in the inner space defined by the housing bracket, wherein the housing bracket includes a first housing, a second housing, and a third housing, wherein, when the housing bracket is disposed outside the rod bracket, the first housing is disposed on the left side of the rod bracket while being spaced apart from the rod bracket by a predetermined interval, the second housing is disposed on the right side of the rod bracket while being spaced apart from the rod bracket by a predetermined interval, and the third housing is disposed behind the rod bracket while being spaced apart from the rod bracket by a predetermined interval, wherein, when forming the rear insulator, the first bridging rubber is attached to the inner side surface of the first housing and the left surface of the rod bracket, and the second bridging rubber is attached to the inner side surface of the second housing and the right surface of the rod bracket, When the housing bracket is formed by extrusion molding, a first wall is protrudingly formed on the inner side surface of the first housing, and a second wall is protrudingly formed on the inner side surface of the second housing. wherein, when the stopper rubber is formed, a rear surface portion of the stopper rubber is spaced apart from the third housing by a predetermined interval, and a front surface portion of the stopper rubber is spaced apart from the first wall and the second wall by a predetermined interval, and The first wall is arranged behind the first bridging rubber, and the second wall is arranged behind the second bridging rubber.

9. The method according to claim 8, wherein When the stopper rubber is molded, a rear contact portion is formed on a rear surface portion of the stopper rubber, and the rear contact portion is provided behind the lever bracket and spaced apart from the third housing by a predetermined interval.

10. The method according to claim 8, wherein When the stopper rubber is formed, a first front contact portion and a second front contact portion are formed on the front surface portion of the stopper rubber, and the first front contact portion is provided behind the first wall on the left side of the rod bracket while being spaced apart from the first wall on the left side of the rod bracket by a predetermined interval, and the second front contact portion is provided behind the second wall on the right side of the rod bracket while being spaced apart from the second wall on the right side of the rod bracket by a predetermined interval.

11. The method according to claim 8, further comprising: forming the stop bracket by extrusion; as well as Before arranging the housing bracket outside the rod bracket, coupling the stop bracket to the rear end of the rod bracket, When the housing bracket is arranged outside the rod bracket, the left portion of the stopping bracket is arranged behind the first wall and is separated from the first wall by a predetermined interval, and the right portion of the stopping bracket is arranged behind the second wall and is separated from the second wall by a predetermined interval.

12. The method according to claim 11, wherein A rear hole portion is formed at the rear end portion of the rod bracket, A coupling groove is formed in the middle portion of the stop bracket, and The stop bracket is inserted into the inner space in the rear hole portion, and then a rear end portion of the rear hole portion is press-fitted into the coupling groove in the stop bracket, thereby coupling the stop bracket and the rear hole portion.

13. The method according to claim 8, wherein When the rear insulator is formed, the stopper rubber is formed at the same time.

14. The method according to claim 8, wherein When the housing bracket is formed by extrusion molding, a first vehicle body coupling portion is protrudingly formed on an outer side surface of a first housing of the housing bracket for fastening to the vehicle body, and a second vehicle body coupling portion is protrudingly formed on an outer side surface of a second housing of the housing bracket for fastening to the vehicle body.

15. The method according to claim 8, further comprising: The front insulator is mounted to the front mounting portion.

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