Pultrusion device for producing vehicle component having ribs

Abstract

The invention discloses a pultrusion apparatus for manufacturing a vehicle component having ribs. The interior of the vehicle component is divided into a plurality of regions by at least one rib, and the vehicle component is formed of a composite material having a constant thickness. A pultrusion apparatus includes a molding unit configured to mold a vehicle member by applying a fiber and a nonwoven fabric while impregnating the fiber with a resin. The molding unit includes: an upper mold forming a space; a lower die disposed below the upper die and coupled to the upper die; and a mandrel configured to be inserted into a gap formed between the upper mold and the lower mold, and one end of the mandrel is fastened to the upper mold.

Description

Technical Field

[0001] The present invention relates to a pultrusion device for manufacturing a vehicle component made of a composite material. Background Art

[0002] A vehicle body is usually made rigid by processing a metal sheet to form a curved cross-section or a closed cross-section.

[0003] As Figure 1 shown, a metal sheet is processed to manufacture a seat cross member 110, a center floor panel 121, a side beam outer member 122, and a center pillar 123, thereby constituting a vehicle body.

[0004] Recently, in order to reduce the weight of a vehicle, instead of a metal sheet, the application of a composite material using resin as a main material is increasing.

[0005] For example, the seat cross member 110 formed with a main body 111 (having a cross-section as Figure 2 shown) is formed using resin as a main material and is formed by a pultrusion process. Since it is difficult to obtain sufficient rigidity only with resin, the seat cross member 110 is manufactured by impregnating fibers with resin.

[0006] Similar to the seat cross member 110, various vehicle body components made of a composite material are manufactured by a vehicle body component forming device as Figure 3 and Figure 4 shown. The vehicle body component forming device includes an upper mold 131, a lower mold 132, and a mandrel 133. In a state where the mandrel 133 is inserted between the upper mold 131 and the lower mold 132, reinforcing fibers such as carbon fibers or glass fibers pass through a gap formed between the upper mold 131, the lower mold 132, and the mandrel 133, and at the same time, molten resin is injected, thereby impregnating the fibers with resin.

[0007] The fibers and the resin are integrally formed when passing through the upper mold 131, the lower mold 132, and the mandrel 133. Since the upper mold 131, the lower mold 132, and the mandrel 133 are arranged in the longitudinal direction of the vehicle body component forming device as Figure 4 shown, the fibers and the resin are supplied from one end of the vehicle body component forming device. The formed vehicle body component is pulled out from the other end, thereby manufacturing a vehicle body component having a constant cross-section.

[0008] As Figure 5 shown, a vehicle body component such as the seat cross member 110 has a plurality of ribs 112 formed therein to improve its strength. In other words, a plurality of ribs 112 are formed in the main body 111 constituting the seat cross member 110 to improve the rigidity of the seat cross member 110.

[0009] The seat cross member 110 is arranged in the width direction of the vehicle. Therefore, in the case of a side collision of the vehicle, the seat cross member 110 is configured to support the side portion of the vehicle to reduce the injury to the passengers inside the vehicle.

[0010] In particular, as the number of electric vehicles increases, in order to expand the cabin space and ensure the battery installation space, the battery is installed under the central floor panel 121.

[0011] However, there is a risk of battery explosion in the event of a collision. Therefore, the seat cross member 110 is used to support the collision load to prevent the battery from being damaged due to the collision.

[0012] When the seat cross member 110 has a cross section without ribs 112 formed thereon, the seat cross member 110 may be deformed in the case of a side collision, hitting the side portion of the battery, resulting in battery fire.

[0013] In order to form ribs 112 in the seat cross member 110, the mandrel 133 should be divided into different parts (see Figure 6 ). However, one end of the mandrel 133 is fixed to the outside of the upper die 131 and the lower die 132 in the form of a cantilever.

[0014] In addition, in order to prevent the resin-impregnated fibers from falling off, a non-woven fabric should be attached to the surface of the seat cross member 110. As Figure 7 shown, an outer upper non-woven fabric 114a, an outer lower non-woven fabric 114b, an inner upper non-woven fabric 114c, and an inner lower non-woven fabric 114d should be attached to the surface of the seat cross member 110.

[0015] Therefore, one end of the mandrel 133 is fixed at a position spaced apart from the upper die 131 and the lower die 132, and the fibers to be impregnated with resin and the non-woven fabric to be attached to the surface of the seat cross member 110 are placed in the space between the mandrel 133, the upper die 131, and the lower die 132.

[0016] Therefore, since one end of the mandrel 133 is fixed at a position spaced apart from the upper die 131 and the lower die 132, the mandrel 133 will inevitably sag due to its own weight.

[0017] As described above, due to the sagging at the other end of the mandrel 133, the thickness of the seat cross member 110 becomes uneven over its entire length. Summary of the Invention

[0018] One embodiment of the present invention aims to provide a pultrusion device for manufacturing a vehicle component having at least one rib, and the vehicle component can uniformly form a uniform cross-sectional thickness of the vehicle component constituting the vehicle body.

[0019] Other objects and advantages of the present invention can be understood from the following description and will become apparent with reference to the embodiments of the present invention. In addition, it will be apparent to those of ordinary skill in the art to which the present invention pertains that the objects and advantages of the present invention can be achieved by the claimed means and combinations thereof.

[0020] According to an embodiment of the present invention, a pultrusion device for manufacturing a vehicle member is provided. The pultrusion device includes a forming unit configured to form a vehicle member by impregnating fibers entering the forming unit with resin. The forming unit may include: an upper mold forming a first space; a lower mold disposed below the upper mold and having a second space corresponding to the first space of the upper mold; and a mandrel configured to be inserted into the first space and the second space between the upper mold and the lower mold, and one end of which is fastened to the upper mold.

[0021] The main body of the vehicle member may be formed by fibers and resin applied through gaps between the upper mold and the mandrel and between the lower mold and the mandrel, respectively. The mandrel is divided into sub-mandrels along the longitudinal direction of the mandrel. At least one rib of the vehicle member may be formed by fibers and resin provided by the first space and the second space between the upper mold and the lower mold and the space between the separated mandrels (such as sub-mandrels).

[0022] A mandrel mounting hole may be formed at one end of the upper mold, the first end of the mandrel is mounted in the mandrel mounting hole, and an assembly block mounted in the mandrel mounting hole may be fastened to the first end of the mandrel.

[0023] The front surface of the assembly block may be formed to slope downward. An upper fiber inlet for supplying fibers between the upper mold and the mandrel may be formed on the surface of the upper mold facing the front surface of the assembly block.

[0024] The front surface of the assembly block and the upper fiber inlet of the upper mold may be formed parallel to each other. A first gap may be formed between the front surface of the assembly block and the upper fiber inlet.

[0025] A lower fiber inlet may be formed at one end of the lower mold. The lower fiber inlet may be parallel to the bottom surface of the assembly block, a second gap may be formed between the lower fiber inlet and the bottom surface, and fibers may be supplied between the lower mold and the mandrel through the second gap.

[0026] An upper resin inlet for injecting resin into the interior of the upper mold may be formed to penetrate the upper mold at a predetermined distance from the assembly block. A lower resin inlet for injecting resin into the interior of the lower mold may be formed to penetrate the lower mold below the upper resin inlet.

[0027] The cross-sectional area of the portion of the mandrel where the upper resin inlet and the lower resin inlet intersect can be formed to be smaller than the cross-sectional areas of other portions of the mandrel. Each of the upper mold and the lower mold can be formed to have a thinner thickness at the portion where the upper resin inlet and the lower resin inlet are provided.

[0028] The fibers provided to the upper mold and the lower mold can include reinforcing fibers and non-woven fabrics. The reinforcing fibers are arranged within the vehicle member, and the non-woven fabrics are arranged on the surface of the vehicle member and configured to prevent the separation of the reinforcing fibers.

[0029] The upper reinforcing fibers formed as the upper portion of the vehicle member, and the outer upper non-woven fabric and the inner upper non-woven fabric surrounding the upper portion and the lower portion of the upper reinforcing fibers can be provided between the upper mold and the mandrel. The lower reinforcing fibers formed as the lower portion of the vehicle member and the ribs of the vehicle member, the lower side non-woven fabric surrounding the two side surfaces of the lower reinforcing fibers, the inner lower non-woven fabric surrounding the inside of the lower reinforcing fibers, and the outer lower non-woven fabric surrounding the lower portion of the lower reinforcing fibers can be provided between the lower mold and the mandrel.

[0030] The upper reinforcing fibers formed as the upper portion of the vehicle member, and the outer upper non-woven fabric and the inner upper non-woven fabric surrounding the upper portion and the lower portion of the upper reinforcing fibers can be provided between the upper mold and the mandrel. The lower reinforcing fibers formed as the lower portion of the vehicle member and the ribs of the vehicle member, the inner lower non-woven fabric surrounding the two side surfaces and the inside of the lower reinforcing fibers, and the outer lower non-woven fabric surrounding the lower portion of the lower reinforcing fibers can be provided between the lower mold and the mandrel.

[0031] The pultrusion forming apparatus can further include a plurality of pullers configured to convey the vehicle member discharged from the forming unit in the longitudinal direction of the vehicle member.

[0032] Each of the plurality of pullers can include a housing and a roller rotatably mounted within the housing. The roller is configured to convey the vehicle member by contacting the upper surface and the lower surface of the vehicle member passing through the inside of the housing.

[0033] Each puller can further include a conveying plate configured to support the upper surface and the lower surface of the vehicle member within the housing.

[0034] The plurality of pullers can be spaced apart in the direction in which the vehicle member is discharged.

[0035] One end of the forming unit can be connected to a fixing unit configured to guide and fix the positions of the fibers to be put into the upper mold and the lower mold.

[0036] Another embodiment of a pultrusion device for manufacturing vehicle components is provided. The pultrusion device may include: a forming unit configured to form a vehicle component with ribs by applying reinforcing fibers and non-woven fabric and simultaneously impregnating the reinforcing fibers entering the forming unit with resin; a plurality of pullers configured to convey the vehicle component discharged from the forming unit in the longitudinal direction of the vehicle component; a guiding unit configured to guide the reinforcing fibers and non-woven fabric to be supplied to the forming unit; and a fixing unit configured to fix the guiding unit relative to the forming unit.

[0037] The guiding unit may include a plurality of guiding plates arranged at intervals in the longitudinal direction of the vehicle component, and through holes through which the reinforcing fibers and non-woven fabric pass.

[0038] The forming unit may include: an upper mold forming a first space; a lower mold arranged below the upper mold and having a second space corresponding to the first space of the upper mold; and a mandrel inserted into the first space and the second space between the upper mold and the lower mold, and one end of which is fastened to the upper mold.

[0039] The forming unit may further include: a mandrel mounting hole formed at one end of the upper mold, and the first end of the mandrel is mounted in the mandrel mounting hole; and an assembly block mounted in the mandrel mounting hole and fastened to the first end of the mandrel. Description of the Drawings

[0040] In the following specific description presented in conjunction with the accompanying drawings, the above and other objects, features, and advantages of the present invention should become more apparent:

[0041] Figure 1 is a perspective view showing the lower structure of a conventional vehicle.

[0042] Figure 2 is a cross-sectional view showing a seat crossmember according to the related art.

[0043] Figure 3 is a cross-sectional view showing a mold for forming a seat crossmember according to the related art.

[0044] Figure 4 is a side cross-sectional view showing a mold for forming a seat crossmember according to the related art.

[0045] Figure 5 is a cross-sectional view showing a seat crossmember with ribs formed according to the related art.

[0046] Figure 6 is a perspective view showing a mandrel for manufacturing a seat crossmember with ribs formed according to the related art.

[0047] Figure 7It is a cross-sectional view showing an example in which a non-woven fabric is disposed on the outer surface of a seat cross member according to the related art.

[0048] Figure 8 It is a perspective view showing a pultrusion device for manufacturing a vehicle member having ribs according to the present invention.

[0049] Figure 9 It is a perspective view showing a forming unit in a pultrusion device for manufacturing a vehicle member having ribs according to the present invention.

[0050] Figure 10 It is along Figure 8 The cross-sectional view obtained along line A-A.

[0051] Figure 11 It is along Figure 10 The cross-sectional view obtained along line C-C.

[0052] Figure 12 It is along Figure 8 The cross-sectional view obtained along line B-B.

[0053] Figure 13 It is a cross-sectional view showing an example in which a non-woven fabric is disposed in a pultrusion device for manufacturing a vehicle member having ribs according to the present invention.

[0054] Figure 14 It is a cross-sectional view showing another example in which a non-woven fabric is disposed in a pultrusion device for manufacturing a vehicle member having ribs according to the present invention.

[0055] Figure 15 It is a perspective view showing yet another example of a guiding unit for disposing a non-woven fabric in a pultrusion device for manufacturing a vehicle member having ribs according to the present invention. Detailed Description

[0056] The embodiments will be described in detail below with reference to the accompanying drawings.

[0057] The embodiments disclosed in this specification and the configurations depicted in the drawings are merely exemplary embodiments of the present invention and do not cover the entire scope of the present invention. Therefore, it should be understood that there may be various equivalent forms and variant forms when applying this specification.

[0058] To make the present invention clear, parts irrelevant to the description are omitted. In addition, throughout the specification, the same elements or equivalents are denoted by the same reference numerals.

[0059] In addition, the dimensions and thicknesses of each element are arbitrarily shown in the drawings, but the present invention is not necessarily limited thereto. Further, in the drawings, for clarity, the thicknesses of layers, films, plates, regions, etc. may be enlarged.

[0060] When components, devices, elements, etc. of the present invention are described as having a use or performing an operation, function, etc., the component, device, or element shall be regarded as "configured to" satisfy the use or perform the operation or function herein.

[0061] Hereinafter, a pultrusion device for manufacturing a vehicle member having ribs according to the present invention will be described in detail with reference to the accompanying drawings.

[0062] The pultrusion device 1 for manufacturing a vehicle member 10 according to the present invention may include a forming unit 30 configured to form the vehicle member 10 by impregnating fibers entering the forming unit 30 with resin. The forming unit 30 includes: an upper die 31 in which a space is formed; and a lower die 32 disposed below the upper die 32 and having a periphery fastened to the upper die 31. The forming unit 30 further includes a mandrel 33 inserted into the upper die 31 and the lower die 32 and having one end fastened to the upper die 32.

[0063] The forming unit 30 can manufacture the vehicle member 10, such as a seat cross member, by impregnating fibers entering the forming unit 30 with resin. Figures 8 to 14 A seat cross member is shown as an example of the vehicle member 10. The fibers passing through the forming unit 30 include reinforcing fibers and non-woven fabric. The reinforcing fibers are arranged inside the vehicle member 10 to enhance rigidity, and the non-woven fabric is used to surround the reinforcing fibers and thus arranged on the surface of the vehicle member 10 to prevent the separation of the reinforcing fibers. The reinforcing fibers include carbon fibers, glass fibers, etc., and thus have the effect that the vehicle member 10 formed in the forming unit 30 is made of a composite material such as carbon fiber reinforced plastic (CFRP) or glass fiber reinforced plastic (GFRP). The non-woven fabric may be glass fiber. In the present invention, at least one rib 12 can be applied to the inside of the main body 11 in the vehicle member 10 to enhance rigidity while dividing the internal space of the main body 11. Thus, instead of using expensive carbon fibers as the reinforcing fibers, only glass fibers can be used. Therefore, the required rigidity of the vehicle member 10 can be achieved and the cost can be reduced.

[0064] The forming unit 30 includes: an upper die 31 in which a space is formed; a lower die 32 disposed below the upper die 31 and having a periphery fastened to the upper die 31; and a mandrel 33 which is divided into a plurality of sub-mandrels, for example, three sub-mandrels 33-1, 33-2, and 33-3, along the longitudinal direction of the mandrel 33, as Figure 11As shown, each of the multiple sub-mandrels 33-1, 33-2, and 33-3 is inserted into the space between the upper die 31 and the lower die 32. Each end of the multiple sub-mandrels 33-1, 33-2, and 33-3 is fastened to the upper die 31. For the purpose of simplifying the description of the forming unit 30, the multiple sub-mandrels 33-1, 33-2, and 33-3 are hereinafter referred to as the mandrel 33.

[0065] The upper die 31 and the lower die 32 are correspondingly coupled to each other. Spaces S1 and S2 corresponding to the vehicle member 10 can be formed therein.

[0066] The mandrel 33 can be disposed at such spaces S1 and S2 between the upper die 31 and the lower die 32 to form the vehicle member 10.

[0067] The upper die 31 has a groove (not shown) formed in the lower part thereof in the longitudinal direction to form a protruding portion of the vehicle member 10.

[0068] Reference Figure 9 , a mandrel mounting hole 31a for fastening the mandrel 33 can be formed at one end of the upper die 31. In other words, the mandrel mounting hole 31a can be formed at the end side where the reinforcing fiber and the resin are supplied. By removing a part from one end of the upper die 31, the mandrel mounting hole 31a can be formed as a concave shape from one end of the upper die 31 toward the other end.

[0069] In the upper die 31, an upper fiber inlet 31b can be formed on one side of the mandrel mounting hole 31a. In the mandrel mounting hole 31a, the front surface of the vehicle member 10 in the forming direction (from the lower left part to the upper right part in Figure 8 and Figure 9 ) can be formed as an inclined surface, and the front surface becomes the upper fiber inlet 31b.

[0070] An upper resin inlet 31c for injecting resin into the space between the upper die 31 and the lower die 32 can be formed in the upper die 31. The upper resin inlet 31c can be formed at a certain interval from the upper fiber inlet 31b. As Figure 10 shown, the upper resin inlet 31c can be located in front of the upper fiber inlet 31b in the forming direction. In other words, the reinforcing fiber and the non-woven fabric supplied through the upper fiber inlet 31b can pass through the upper fiber inlet 31b and then through the upper resin inlet 31c.

[0071] The lower die 32 can be fastened to the lower part of the upper die 31. When the reinforcing fiber and the resin flow into the space formed between the lower die 32 and the upper die 31, the reinforcing fiber can be impregnated with the resin, thereby manufacturing the vehicle member 10 made of a composite material.

[0072] One end of the lower mold 32 can serve as a lower fiber inlet 32a for introducing reinforcing fibers and non-woven fabric.

[0073] A lower resin inlet 32b for injecting resin into the space between the upper mold 31 and the lower mold 32 can also be formed in the lower mold 32. When the upper mold 31 and the lower mold 32 are assembled, the lower resin inlet 32b can be formed directly below the upper resin inlet 31c.

[0074] One end of the mandrel 33 can be fastened to one end of the upper mold 31, and the remaining part can be inserted between the upper mold 31 and the lower mold 32. The remaining part of the mandrel 33 except the end fastened to the upper mold 31 can form a gap G together with the upper mold 31 and the lower mold 32, and the vehicle component 10 can be manufactured by the resin flowing through the gap G.

[0075] The main body 11 of the vehicle component 10 can be formed by the resin flowing in the gap G between the mandrel 33 and the upper mold 31 and the resin flowing in the gap G between the mandrel 33 and the lower mold 32.

[0076] The mandrel 33 can be formed in a separated form to form at least one rib 12 within the vehicle component 10.

[0077] Since the length of the mandrel 33 is formed shorter than the lengths of the upper mold 31 and the lower mold 32, the other end of the mandrel 33 can be located within the upper mold 31 or the lower mold 32.

[0078] An assembly block 33a can be provided to fasten one end of the mandrel 33 to the upper mold 31. The assembly block 33a can be first fastened to the mandrel 33, and then the assembly block 33a can be fastened to the mandrel mounting hole 31a, so that the mandrel 33 can be fastened to the upper mold 31.

[0079] Compared with the related art where one end of the mandrel is located outside the upper mold and the lower mold, since one end of the mandrel 33 is fastened to one end of the upper mold 31 and the lower mold 32, the stability can be improved.

[0080] The reinforcing fibers and non-woven fabric required to form the vehicle component 10 are introduced into the assembly block 33a through a gap G1 formed between the front surface of the assembly block 33a and the upper fiber inlet 31b. The front surface of the assembly block 33a can be formed to slope downward in the molding direction, the upper fiber inlet 31b can be formed parallel to the front surface of the assembly block 33a, and the gap G1 can be formed between the upper fiber inlet 31b and the front surface. Thus, the reinforcing fibers and non-woven fabric are introduced through the gap G1. Since the front surface of the assembly block 33a is formed to slope downward, the fibers (i.e., the reinforcing fibers and non-woven fabric) can easily move between the upper mold 31 and the mandrel 33.

[0081] The reinforcing fibers injected through the gap G1 between the front surface of the assembly block 33a and the upper fiber inlet 31b can be used to reinforce the upper part of the vehicle member 10. The non-woven fabric introduced through the gap G1 can surround the surface of the upper part of the vehicle member 10 and can prevent the separation of the reinforcing fibers.

[0082] Another gap G2 can be formed between the bottom surface of the assembly block 33a and the lower fiber inlet 32a, and the reinforcing fibers and the non-woven fabric are introduced through the gap G2. The bottom surface of the assembly block 33a and the lower fiber inlet 32a can be formed to be parallel to each other, and the reinforcing fibers introduced through the gap G2 formed between the bottom surface of the assembly block 33a and the lower fiber inlet 32a can be used to enhance the strength of the lower part of the vehicle member 10. In addition, the non-woven fabric introduced through the gap G2 can surround the surface of the lower part of the vehicle member 10 and can prevent the separation of the reinforcing fibers from the lower part of the vehicle member 10.

[0083] In the part of the mandrel 33 where the upper resin inlet 31c and the lower resin inlet 32b are located, the cross-sectional area of the mandrel 33 can be formed to be smaller than that of other parts. Refer to Figure 10 , the part of the mandrel 33 where the upper resin inlet 31c and the lower resin inlet 32b are located can have a height lower than that of other parts, and the upper die 31 and the lower die 32 are each shown as having a thinner thickness.

[0084] Therefore, the space S1 between the upper die 31 and the mandrel 33 in the part where the upper resin inlet 31c is formed can be larger than the space in other parts. In addition, even in the part where the lower resin inlet 32b is formed, the space S2 between the lower die 32 and the mandrel 33 can also be formed to be larger than the space in other parts, thereby facilitating the impregnation of the reinforcing fibers with resin in the spaces S1 and S2. In other words, since there is more resin in the spaces S1 and S2 compared to other parts, the impregnation of the reinforcing fibers with resin can be promoted.

[0085] When the upper die 31 and the lower die 32 are assembled together, or when the upper die 31 or the lower die 32 is manufactured in a separated state, the fastening block 34 can be used to fasten the upper die 32 and the lower die 31 together. Refer to Figure 9 , an example is shown in which the separable upper die 31 and lower die 32 can be integrally fastened to each other using the fastening block 34, and the upper die 31 and the lower die 32 can be integrally fastened to each other.

[0086] As Figure 9 shown, in order to fasten the lower die 32 to the separated upper die 31, the fastening block 34 can be arranged outside the lower die 32 and the upper die 31, and can be fastened to the upper die 31 and the lower die 32 by fastening bolts, so that the upper die 31 and the lower die 32 are combined into a whole.

[0087] The puller 50 can convey the vehicle member 10 that has been formed and taken out from the forming unit 30. The puller 50 can convey the vehicle member 10 in the longitudinal direction of the vehicle member 10.

[0088] Reference Figure 12 , the puller 50 can include: a housing 51; a conveying plate 52 for supporting the upper and lower surfaces of the vehicle member 10 within the housing 51; and rollers 53 rotatably mounted within the housing 51 and configured to convey the vehicle member 10 by contacting the upper and lower surfaces of the vehicle member 10.

[0089] A space can be formed within the housing 51 through which the vehicle member 10 discharged from the forming unit 30 can pass.

[0090] The conveying plate 52 can be mounted within the housing 51 and can support the upper and lower surfaces of the vehicle member 10 passing through the puller 50. The conveying plate 52 can support the upper and lower surfaces of the vehicle member 10 within the housing 51.

[0091] The rollers 53 can be mounted within the housing 51. The rollers 53 can transmit a driving force to the vehicle member 10 to move the vehicle member 10 in the direction in which the puller 50 is arranged. In one embodiment, a plurality of rollers 53 can be mounted at multiple points and rotated by a drive motor (not shown). The rollers 53 can also contact the upper and lower surfaces of the vehicle member 10. When the rollers 53 are driven by the drive motor, the rollers 53 can convey the vehicle member 10.

[0092] In another embodiment, a plurality of pullers 50 can be mounted in the longitudinal direction of the vehicle member 10. Figure 8 An example of arranging three pullers 50 is shown.

[0093] The conveying speed of the vehicle member 10 within the puller 50 can be synchronized with the speed at which the vehicle member 10 is taken out from the forming unit 30. For example, when the vehicle member 10 is taken out from the forming unit 30 at a speed of 0.3 meters per minute (m / min), each puller 50 can also move the vehicle member 10 at the same speed of 0.3 m / min.

[0094] In Figure 8 , one end of the forming unit 30 can be connected to a fixing unit 40 for fixing a guiding unit 60 configured to guide the positions of the reinforcing fiber and non-woven fabric to be supplied. A reel (not shown) wound with the reinforcing fiber and non-woven fabric can be installed in the fixing unit 40, and the reinforcing fiber and non-woven fabric can be unwound from the reel and supplied to the forming unit 30.

[0095] Figure 13Shows an example of the arrangement of reinforcing fibers and non-woven fabrics placed in the upper fiber inlet 31b and the lower fiber inlet 32a.

[0096] As described above, at least one rib can be formed. In one embodiment, a plurality of ribs 12 can be formed within the vehicle member 10. The reinforcing fibers and the non-woven fabrics can each be divided into an upper portion and a lower portion, and can be placed between the upper mold 31 and the lower mold 32.

[0097] For example, in order to form the upper end of the vehicle member 10, the upper reinforcing fibers 13U can be arranged. The upper portion and the lower portion of the upper reinforcing fibers 13U can be surrounded by the outer upper non-woven fabric 14a and the inner upper non-woven fabric 14b.

[0098] In addition, in order to form the lower end and the ribs 12 of the vehicle member 10, the lower reinforcing fibers 13L can be arranged. The lower portion of the lower reinforcing fibers 13L can be surrounded by the outer lower non-woven fabric 14e. The two side surfaces of the lower reinforcing fibers 13L can be surrounded by the lower side non-woven fabric 14c, and the portion of the lower reinforcing fibers 13L to be formed into the ribs 12 can be surrounded by the inner lower non-woven fabric 14d.

[0099] In Figure 13 the part shown as cross-section U can be placed into the upper mold 31 through the upper fiber inlet 31b, and the part shown as cross-section L can be placed into the lower mold 32 through the lower fiber inlet 32a.

[0100] Figure 15 Shows an example of the guiding unit 60, in which the non-woven fabrics 14a, 14b, 14c, 14d, and 14e are arranged on the upper reinforcing fibers 13U and the lower reinforcing fibers 13L.

[0101] In the guiding unit 60, a plurality of guiding plates 61, 62, 63, and 64 can be arranged at intervals, and through holes for the upper reinforcing fibers 13U, the lower reinforcing fibers 13L, and the non-woven fabrics 14a, 14b, 14c, 14d, and 14e to pass through can be formed in the guiding plates 61, 62, 63, and 64.

[0102] Each of the non-woven fabrics 14a, 14b, 14c, 14d, and 14e can pass through the plurality of guiding plates 61, 62, 63, and 64, and can be guided in a form that surrounds the upper reinforcing fibers 13U and the lower reinforcing fibers 13L in the cross-sectional shape. In addition, each of the non-woven fabrics 14a, 14b, 14c, 14d, and 14e can pass through each of the guiding plates 61, 62, 63, and 64, and can be sequentially guided to be close to the final cross-sectional shape.

[0103] The upper reinforcing fibers 13U and the lower reinforcing fibers 13L may be disposed between the nonwoven fabrics 14a, 14b, 14c, 14d, and 14e and conveyed. In addition, the nonwoven fabrics 14a, 14b, 14c, 14d, and 14e may be arranged to be adjacent to the upper reinforcing fibers 13U and the lower reinforcing fibers 13L when passing through the guide plates 61, 62, 63, and 64.

[0104] Reference Figure 15 , a configuration in which the first guide plate 61 to the fourth guide plate 64 are arranged at intervals from each other within the guide unit 60 is shown.

[0105] Through holes for the upper reinforcing fibers 13U, the lower reinforcing fibers 13L, and the nonwoven fabrics 14a, 14b, 14c, 14d, and 14e to pass through may be formed in each of the guide plates 61, 62, 63, and 64. In Figure 15 it, a through hole 61a for the upper reinforcing fibers 13U to pass through may be formed in the first guide plate 61, and through holes 62a and 62b for the upper reinforcing fibers 13U and the lower reinforcing fibers 13L to pass through may be shown only in the second guide plate 62. However, through holes for the upper reinforcing fibers 13U, the lower reinforcing fibers 13L, and the nonwoven fabrics 14a, 14b, 14c, 14d, and 14e to pass through may be formed in each of the guide plates 61, 62, 63, and 64.

[0106] The upper reinforcing fibers 13U may enter the inside of the guide unit 60 through the through hole formed in the first guide plate 61, and may pass through the second guide plate 62, the third guide plate 63, and the fourth guide plate 64 in the form of passing through the through holes formed in the second guide plate 62, the third guide plate 63, and the fourth guide plate 64. The lower reinforcing fibers 13L may also pass through the first guide plate 61, and then may sequentially pass through the second guide plate 62, the third guide plate 63, and the fourth guide plate 64. Similarly, the nonwoven fabrics 14a, 14b, 14c, 14d, and 14e may also pass through the first guide plate 61, and then pass through the second guide plate 62 to the fourth guide plate 64. The nonwoven fabrics 14a, 14b, 14c, 14d, and 14e may surround the upper reinforcing fibers 13U and the lower reinforcing fibers 13L, and thus a predetermined cross section may be gradually formed along the direction from the first guide plate 61 toward the fourth guide plate 64. Therefore, the cross section of the nonwoven fabrics 14a, 14b, 14c, 14d, and 14e may pass through the first guide plate 61 in a flat state, but the cross section may be gradually deformed when passing through the second guide plate 62 and the third guide plate 63. In addition, the cross section may be processed into a final shape having a cross section when passing through the fourth guide plate 64.

[0107] The reinforcing fibers and the nonwoven fabric can be impregnated with the resin injected through the upper resin inlet 31c and the lower resin inlet 32b while the reinforcing fibers and the nonwoven fabric move between the upper mold 31 and the mandrel 33 and between the lower mold 32 and the mandrel 33. Since the liquid resin can penetrate the reinforcing fibers and the nonwoven fabric, the reinforcing fibers can be impregnated with the resin even when the reinforcing fibers are surrounded by the nonwoven fabric.

[0108] When passing through the upper mold 31 and the lower mold, the curing operation of the resin impregnated between the reinforcing fibers can be carried out by applying heat and pressure so as to complete the manufacture of the vehicle member 10.

[0109] The puller 50 installed beside the molding unit 30 can pull out and convey the vehicle member 10 passing through the molding unit 30.

[0110] The resin can be supplied to the upper mold 31 and the lower mold 32 while the reinforcing fibers and the nonwoven fabric are supplied through one end of the molding unit 30. Heat and pressure are applied to the upper mold 31 and the lower mold 32. Thus, the vehicle member 10, such as a seat cross member, can be finally obtained.

[0111] Figure 14 Another example of the arrangement of the reinforcing fibers and the nonwoven fabric put into the upper fiber inlet 31b and the lower fiber inlet 32a is shown.

[0112] In this example, as in the above example, in the upper part of the vehicle member 10, in order to form the upper end in the vehicle member 10, the upper reinforcing fibers 13U can be arranged, and the upper part and the lower part of the upper reinforcing fibers 13U can be surrounded by the outer upper nonwoven fabric 14a and the inner upper nonwoven fabric 14b.

[0113] In addition, in order to form the lower end and the rib 12 in the vehicle member 10, the lower reinforcing fibers 13L can be arranged, and the lower part of the lower reinforcing fibers 13L can be surrounded by the outer lower nonwoven fabric 14e. However, the upper part of the lower reinforcing fibers 13L can be integrally surrounded by the inner lower nonwoven fabric 14d, including the side surface of the lower reinforcing fibers 13L and the upper end of the rib 12.

[0114] According to the pultrusion device 1 for manufacturing the vehicle member 10 having at least one rib 12 of the present invention with the above configuration, one end of the mandrel 33 can be fixed to the upper mold 31 and the lower mold 32, so that the mandrel 33 can be prevented from sagging in the upper mold 31 and the lower mold 32.

[0115] Since the sagging of the mandrel 33 is prevented, the gap G between the mandrel 33, the upper mold 31 and the lower mold 32 becomes uniform, so that the thickness of the manufactured vehicle member 10 can be uniform over its entire length.

[0116] Although the present invention has been described with reference to the accompanying drawings, it will be apparent to those of ordinary skill in the art that various changes and modifications can be made without departing from the spirit and scope of the present invention and without being limited to the embodiments disclosed herein. Therefore, it should be noted that such changes or modifications fall within the scope of the claims of the present invention, and the scope of the present invention should be construed based on the appended claims.

Claims

1. A pultrusion device for manufacturing a vehicle component, the pultrusion device comprising: a molding unit configured to mold a vehicle component having at least one rib by impregnating fibers entering the molding unit with a resin, Wherein, the molding unit comprises: an upper mold forming a first space; a lower mold disposed below the upper mold and forming a second space corresponding to the first space; and A mandrel has one end fastened to the upper die, and the mandrel is configured to be inserted into the first space and the second space between the upper die and the lower die.

2. The pultrusion device for manufacturing a vehicle component according to claim 1, wherein: The body of the vehicle component is formed by fibers and resin provided through gaps between an upper mold and a mandrel and between a lower mold and a mandrel, respectively; Dividing the mandrel into sub-mandrels along the longitudinal direction of the mandrel; The at least one rib of the vehicle component is formed of fiber and resin provided through the first and second spaces between the upper and lower dies and the space between the sub-mandrels.

3. The pultrusion device for manufacturing a vehicle component according to claim 1, wherein: A mandrel mounting hole is formed at one end of the upper die, and the first end of the mandrel is mounted in the mandrel mounting hole; An assembly block mounted in the mandrel mounting hole is fastened to the first end of the mandrel.

4. The pultrusion device for manufacturing a vehicle component according to claim 3, wherein: The front surface of the assembly block is inclined downward; An upper fiber inlet for supplying fibers between the upper mold and the mandrel is formed on a surface of the upper mold facing the front surface of the assembly block.

5. The pultrusion device for manufacturing a vehicle component according to claim 4, wherein: The front surface of the assembly block and the upper fiber inlet of the upper mold are parallel to each other; A first gap is formed between the front surface of the assembly block and the upper fiber inlet.

6. The pultrusion device for manufacturing a vehicle component according to claim 3, wherein: A lower fiber inlet is formed at one end of the lower mold; the lower fiber inlet is parallel to the bottom surface of the assembly block; a second gap formed between the lower fiber inlet and the bottom surface of the assembly block; Fibers are provided between the lower mold and the mandrel through the second gap.

7. The pultrusion device for manufacturing a vehicle component according to claim 3, wherein: an upper resin inlet for injecting resin into the interior of the upper mold, arranged to penetrate the upper mold at a predetermined distance from the assembly block; A lower resin inlet for injecting resin into the interior of the lower mold is disposed through the lower mold below the upper resin inlet.

8. The pultrusion device for manufacturing a vehicle component according to claim 7, wherein: The cross-sectional area of ​​a portion of the mandrel at the intersection of the upper resin inlet and the lower resin inlet is smaller than the cross-sectional area of ​​other portions of the mandrel; Each of the upper mold and the lower mold is formed to have a thinner thickness at a portion where an upper resin inlet and a lower resin inlet are provided, respectively.

9. The pultrusion device for manufacturing a vehicle component according to claim 7, wherein: The fibers provided to the upper mold and the lower mold include: reinforcing fibers disposed within the vehicle component; and A nonwoven fabric is disposed on a surface of the vehicle component and is configured to prevent the reinforcing fibers from being separated.

10. The pultrusion device for manufacturing a vehicle component according to claim 9, wherein: providing an upper reinforcing fiber molded into an upper portion of the vehicle member and an outer upper nonwoven fabric and an inner upper nonwoven fabric surrounding an upper portion and a lower portion of the upper reinforcing fiber between the upper mold and the mandrel; A lower reinforcing fiber molded into a lower portion of the vehicle component and at least one rib of the vehicle component, a lower non-woven fabric surrounding both side surfaces of the lower reinforcing fiber, an inner lower non-woven fabric surrounding the inside of the lower reinforcing fiber, and an outer lower non-woven fabric surrounding the lower portion of the lower reinforcing fiber are provided between the lower mold and the mandrel.

11. The pultrusion device for manufacturing a vehicle component according to claim 9, wherein: providing an upper reinforcing fiber molded into an upper portion of the vehicle member and an outer upper nonwoven fabric and an inner upper nonwoven fabric surrounding an upper portion and a lower portion of the upper reinforcing fiber between the upper mold and the mandrel; A lower reinforcing fiber molded into a lower portion of the vehicle component and at least one rib of the vehicle component, an inner lower nonwoven fabric surrounding both side surfaces of the lower reinforcing fiber and an inner portion of the lower reinforcing fiber, and an outer lower nonwoven fabric surrounding a lower portion of the lower reinforcing fiber are provided between the lower mold and the mandrel.

12. The pultrusion device for manufacturing a vehicle component according to claim 1, further comprising: A plurality of pullers are configured to convey the vehicle components discharged from the molding unit in a longitudinal direction of the vehicle components.

13. The pultrusion device for manufacturing a vehicle component according to claim 12, wherein: Each of the plurality of pullers comprises: a housing; and Rollers are rotatably mounted in the housing and are configured to convey the vehicle component by contacting the upper and lower surfaces of the vehicle component passing through the interior of the housing.

14. The pultrusion device for manufacturing a vehicle component according to claim 13, wherein: Each puller further includes a conveying plate configured to support an upper surface and a lower surface of the vehicle component within the housing.

15. The pultrusion apparatus for manufacturing a vehicle component according to claim 12, wherein: The plurality of pullers are arranged at intervals in a direction in which the vehicle component is ejected.

16. The pultrusion apparatus for manufacturing a vehicle component according to claim 1, wherein: One end of the molding unit is connected to a fixing unit configured to guide and fix positions of fibers to be provided into the upper and lower dies.

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