Front bulkhead cross member for a vehicle and method of manufacturing the same

Abstract

A front cross beam of a vehicle includes a main pipe support made of steel, extending in a vehicle width direction and having an S-shaped cross section when cut in a vehicle length direction; side mounting supports joined to both end portions of the main pipe support; and a plastic sub support embedded in injection molding to surround the main pipe support and the side mounting supports.

Description

Technical Field

[0001] This invention relates to a front crossbeam of a vehicle and its manufacturing method. Background Technology

[0002] The front bulkhead crossbeam is one of the structural components inside the vehicle and is mainly located behind the dashboard. It is used to reinforce the body, provide a platform for various components such as airbag modules, HVAC systems and steering wheels to be installed, and reduce noise, vibration and harshness (NVH) transmitted to the vehicle interior.

[0003] The above description as background art is intended only to help understand the background of the present invention. The above does not imply that the present invention falls within the scope of prior art known to those skilled in the art. Summary of the Invention

[0004] Depending on the type of vehicle, the front bulkhead beam used may vary depending on factors such as the vehicle's width.

[0005] This invention provides a front bulkhead crossbeam for vehicles, whose core components are interchangeable regardless of vehicle type. This reduces costs and lightens the weight of the front bulkhead crossbeam while ensuring higher stiffness than conventional front bulkhead crossbeams, or at least maintaining the same level of stiffness.

[0006] The technical aspects sought in this invention are not limited to those described above. Other technical aspects not mentioned herein will be more clearly understood by those skilled in the art through the following description.

[0007] In view of the above, the front crossbeam of the vehicle according to the present invention includes: a main support bracket made of steel, configured to extend along the width direction of the vehicle and have an S-shaped cross section when cut along the length direction of the vehicle; side mounting brackets joined to both ends of the main support bracket; and a plastic sub-support bracket, which is embedded in injection molding to surround the main support bracket and the side mounting brackets.

[0008] The front crossbeam may also include a central support bracket that engages at one point or in part with the main support bracket. Sub-brackets may be injection molded to surround the main support bracket, side mounting brackets, and central support bracket.

[0009] The side mounting brackets and center support brackets can be made of steel and can be welded to the main support bracket.

[0010] The sub-support can be injection molded to include multiple horizontal and vertical ribs.

[0011] When each side mounting bracket is cut along the length of the vehicle, its cross-section can be S-shaped, and it can be joined to the main mounting bracket by welding at the part that contacts the main mounting bracket.

[0012] At a point (i.e., location or part) of the secondary support, a column mounting bracket may be engaged to partially surround that point. The column mounting bracket may include an upper bracket and a lower bracket. The upper and lower brackets may form a square closed cross-section.

[0013] The upper support of the column mounting bracket may include an inwardly recessed portion and an outwardly protruding portion.

[0014] The lower support of the column mounting bracket may include a bent portion formed by bending the end of an extension extending along the length of the vehicle; and a rib formed between the extension and the bent portion.

[0015] The main support may include inwardly recessed groove-shaped ribs that extend along the vertical direction of the main support.

[0016] The method for manufacturing a front crossbeam of a vehicle according to the present invention includes: a joining step of joining side mounting brackets to both ends of a main mounting bracket, the main mounting bracket being made of steel, extending along the width direction of the vehicle, and having an S-shaped cross-section when cut along the length direction of the vehicle; and an injection molding step of embedding injection-molded plastic sub-brackets to surround the main mounting bracket and the side mounting brackets.

[0017] During the joining step, the center support bracket can also be joined to one point or part of the main support bracket. During the injection molding step, an injection-molded sub-support bracket can be embedded to surround the main support bracket, side mounting brackets, and center support bracket.

[0018] The side mounting brackets and center support brackets can be made of steel and can be welded to the main support bracket.

[0019] In the injection molding process, the sub-support can be injection molded to include multiple horizontal and vertical ribs.

[0020] Following the injection molding step, the method may further include an assembly step, joining the column mounting bracket to partially surround a point or portion of the sub-bracket.

[0021] According to the front crossbeam and its manufacturing method disclosed in this article, the overall weight of the front crossbeam can be reduced, and the core components used in manufacturing the front crossbeam can be standardized regardless of the vehicle model, thereby reducing the manufacturing cost of the front crossbeam.

[0022] The beneficial effects achievable by this invention are not limited to those described above. Those skilled in the art will gain a clearer understanding of other effects not mentioned herein through the following description. Attached Figure Description

[0023] The above and other aspects, features and advantages of the present invention will become more apparent from the following detailed description taken in conjunction with the accompanying drawings, in which:

[0024] Figure 1 The front bulkhead beam of a vehicle according to an embodiment of the present invention is shown;

[0025] Figure 2 Showing the composition Figure 1 The core component of the front crossbeam;

[0026] Figure 3 It is shown Figure 2 A view of the cross section taken along line AA of the front beam;

[0027] Figure 4 It is shown Figure 1 A view of the cross section taken along line BB of the front crossbeam;

[0028] Figure 5 This is a view showing the joint between the main support and the side mounting bracket of the front crossbeam according to an embodiment of the present invention;

[0029] Figure 6 This is a view showing the column mounting bracket of the front crossbeam according to an embodiment of the present invention;

[0030] Figure 7 It is a cross-sectional view of the main support in the width direction, in which vertical ribs are formed on the main support by the flow of plastic resin;

[0031] Figure 8 This is a cross-sectional view along the length of the main support, showing the ribs formed on the main support to enhance the fixing force of the vertical ribs; and

[0032] Figure 9 This is a flowchart illustrating a method for manufacturing the front crossbeam of a vehicle according to the present invention. Detailed Implementation

[0033] In describing the embodiments described herein, details of known functions or constructions incorporated herein may obscure the subject matter of the embodiments, so such descriptions are omitted. Furthermore, it should be understood that the accompanying drawings are for illustrative purposes only. The inventive concept and embodiments are not limited to the drawings and include all modifications, equivalents, or substitutions falling within the spirit and scope of the invention. The following description is not intended to limit the invention to the described forms or a particular field. It should be understood that various substitutions, modifications, and alterations can be made to the invention, whether explicit or implicit. Those skilled in the art will understand that the content of the invention can be changed in form and detail.

[0034] The technical concept of the present invention will be described with reference to specific embodiments. However, as will be understood by those skilled in the art, various aspects disclosed herein may be modified or otherwise implemented without departing from the spirit and scope of the invention. Therefore, the following description should be considered illustrative and intended to teach those skilled in the art how to make and use the various embodiments. It should be understood that the forms of the invention shown and described herein are exemplary embodiments. Equivalent elements, materials, processes, or steps may replace the elements, materials, processes, or steps illustrated and described in the present invention. Expressions used in the present invention, such as “comprising,” “including,” “incorporated,” “consisting of,” “having,” or “is,” and variations thereof, should be interpreted in a non-exclusive manner, that is, allowing the inclusion of items, components, or elements not expressly listed. Furthermore, references to the singular should be interpreted to include the plural as well.

[0035] Furthermore, the various embodiments disclosed herein should be considered exemplary and illustrative, and should not be construed as limiting the scope of the invention. All expressions relating to engagement (such as attachment, fastening, joining, and connection) are used only to aid in understanding the invention and are not intended to limit the location, orientation, or use of any component or method disclosed herein. Therefore, expressions relating to engagement should be interpreted broadly. Moreover, these expressions relating to engagement do not imply that two or more elements are directly connected to each other. Furthermore, all numerical terms, such as “first,” “second,” “third,” “primary,” “secondary,” “main,” or any other general term or numerical expression, should be understood only as identifiers used to aid in understanding the various components, embodiments, modifications, or variations of the invention, and do not imply any limitation on any component, embodiment, modification, variation, or their order or priority. In other words, these terms can be used to describe various components, but should not be construed as limiting the components to these terms. These terms are only used to distinguish one component from another.

[0036] The terms "module" and "unit" used for components in the following description are given or used interchangeably for convenience in writing the specification only, and do not have different meanings or functions in themselves. When the components, devices, units, modules, elements, apparatuses, etc. of the present invention are described as having a certain purpose or performing a certain operation or function, the component, device, unit, module, element, or apparatus shall be regarded herein as "constructed to" satisfy that purpose or perform that operation or function.

[0037] When an element is described as being "connected" or "combined" with any other element, it should be understood that not only can the element be directly connected or combined with other elements, but other elements may also exist in between. Conversely, when an element is described as being "directly connected" or "directly combined" with any other element, it should be understood that no other elements exist in between.

[0038] Any number or type of components in any construction described herein may be included within the scope of this invention. These components may include any combination of the features described herein and may be arranged in various constructions described herein. Concepts relating to the structure and arrangement of the components of this invention, as well as their use and operation, may be applied to any number of embodiments and specific examples of any combination discussed herein. Embodiments including various arrangements of features will be described below with reference to the accompanying drawings.

[0039] In the following description, the various embodiments described herein will be illustrated in detail with reference to the accompanying drawings. Throughout the specification and drawings, the same or similar elements are given the same or similar reference numerals, and therefore repeated descriptions thereof are omitted.

[0040] Figure 1 The front crossbeam of a vehicle according to an embodiment of the present invention is shown. Figure 2 This shows the core components that make up the front bulkhead crossbeam of the vehicle. (See reference) Figure 1 and Figure 2 The front crossbeam of the vehicle according to the present invention is constructed as follows.

[0041] First, a main support bracket 100 made of steel is prepared. The main support bracket 100 extends along the width direction of the vehicle or is configured to extend along the width direction of the vehicle, and its cross-section is S-shaped when cut or viewed along the length direction of the vehicle. The main support bracket 100 can extend along the width direction of the vehicle to ensure rigidity in that direction. Furthermore, as... Figure 3 As shown, the main support bracket 100 includes an S-shaped cross-section. As described below, because the main support bracket 100 has an S-shaped cross-section, and the plastic resin forming the sub-support 500 fills the hollow space of the S-shaped cross-section, the front and rear portions of the main support bracket 100 are reinforced. Therefore, rigidity in the vehicle's longitudinal direction is also ensured.

[0042] As described above, the main support 100 can be made of steel and corresponds to the core component that ensures the rigidity of the front crossbeam. The main support 100 can be manufactured by extrusion to have an S-shaped cross-section.

[0043] The side mounting brackets 300 are attached to both ends of the main support bracket 100. The side mounting brackets 300 are located at both ends of the main support bracket 100. When the front bulkhead crossbeam is manufactured, the front bulkhead crossbeam can be fixed to the vehicle body via the side mounting brackets 300.

[0044] The side mounting bracket 300 can be made of the same steel as the main mounting bracket 100. (Refer to...) Figure 5 The side mounting bracket 300 also has an S-shaped cross section when cut along the length of the vehicle, and can be joined to the main bracket 100 by welding at the part that contacts the main bracket 100.

[0045] By manufacturing the side mounting bracket 300 separately in this way and attaching it to the main mounting bracket 100, the main mounting bracket 100 can be universally applicable. In other words, specifications such as vehicle width can vary depending on the vehicle model. Therefore, although the side mounting bracket 300 used to mount the front crossbeam to the vehicle body is manufactured differently for various vehicle models, the main mounting bracket 100, as a core component providing the rigidity of the front crossbeam, can be universally applicable. As a result, the manufacturing cost of the front crossbeam can be reduced.

[0046] Furthermore, by standardizing the main support 100 and manufacturing the side mounting brackets 300 separately, the S-shaped cross-section structure of the main support 100 can be made as long as possible. This allows for increased rigidity of the main support 100 and improved formability and productivity.

[0047] After the side mounting bracket 300 is joined to the main mounting bracket 100, an injection-molded plastic sub-bracket 500 can be inserted to surround the main mounting bracket 100 and the side mounting bracket 300. In other words, the assembly of the main mounting bracket 100 and the side mounting bracket 300 can be embedded in a mold, and plastic resin can be injected to mold the remaining sub-bracket 500. Since the main mounting bracket 100 is as... Figure 3 The design features an S-shaped cross-section, thus maximizing the contact area between the injected plastic resin and the main support 100. This increases the physical bonding strength between the sub-support 500 and the main support 100. Furthermore, the embedded injection molding method surrounding the main support 100 allows for complete integration of the sub-support 500 and the main support 100. This simplifies the assembly process and extends the durability and service life of the component.

[0048] Therefore, the main support bracket 100, the side mounting bracket 300, and the auxiliary support bracket 500 can form the front crossbeam of the vehicle, thereby helping to improve the rigidity of the vehicle.

[0049] The sub-support 500 can also be injection molded to include multiple horizontal ribs 11 and multiple vertical ribs 12. In one example, one horizontal rib may be provided. The sub-support 500 is designed and molded to include multiple horizontal ribs 11 and vertical ribs 12 to enhance structural strength and improve resistance to external impacts. The sub-support 500 is manufactured by an embedded injection molding process in a manner that surrounds the main support 100.

[0050] Multiple transverse ribs 11 formed on the sub-support 500 effectively disperse the load applied in the horizontal direction. Vertical ribs 12 support the force applied in the vertical direction. The various ribs improve the overall stiffness and stability.

[0051] Alternatively, the center support bracket 400 can be engaged to a point (i.e., location or part) of the main support bracket 100, which is located approximately at or near the center between the two ends of the front bulkhead crossbeam. The center support bracket 400 serves to provide additional support and connection at the central portion of the front bulkhead crossbeam and to ensure the stability of the vehicle's internal structure and the proper arrangement of various components.

[0052] The center support bracket 400 reinforces the central portion of the front bulkhead crossbeam to help maintain its overall shape stably and prevent bending or deformation. Furthermore, it effectively disperses vibrations and loads generated during vehicle operation.

[0053] Similar to the main support bracket 100 and the side mounting bracket 300, the center support bracket 400 may be made of steel and may be welded to the main support bracket 100. Furthermore, when the front crossbeam is manufactured to include the center support bracket 400, the secondary support bracket 500 may also be formed to surround the center support bracket 400.

[0054] At a point (i.e., part, location, or portion) of the sub-support 500, a column mounting bracket 700 is engaged to partially surround that point or engagement portion of the sub-support 500. The column mounting bracket 700 includes an upper bracket 710 and a lower bracket 730. The upper bracket 710 and the lower bracket 730 may form a square closed cross-section.

[0055] Reference Figure 1 and Figure 6 The pillar mount 700 is assembled to the front crossbeam of the vehicle to provide space for accommodating the vehicle's steering column. The pillar mount 700 also includes structures configured to suppress the transmission of noise and vibration along the vertical direction of the vehicle.

[0056] The column mounting bracket 700 is manufactured to include an upper bracket 710 and a lower bracket 730. The upper bracket 710 and the lower bracket 730 can be integrally formed, forming a trapezoidal closed cross surface. This suppresses the transmission of noise and vibration along the vertical direction of the vehicle.

[0057] Furthermore, the upper support 710 includes an inwardly recessed portion 711 and an outwardly protruding portion 712. By providing a bend in the shape of the upper support 710 through the recess 711 and the protruding portion 712, the section modulus can be increased. This suppresses the transmission of noise and vibration to the driver.

[0058] The lower bracket 730 includes a bent portion 732 formed by bending the end of an extension 731 that extends along the length of the vehicle. A rib 733 may be formed between the extension 731 and the bent portion 732 to enhance the rigidity of the column mounting bracket 700 itself.

[0059] Reference Figure 7 and Figure 8A groove-shaped rib 900 is formed inwardly recessed within the main support 100. The rib 900 can be formed along the vertical direction of the main support 100. When plastic resin is injected into the main support 100, as... Figure 7 As shown, plastic resin flows along the surface of the main pipe support, forming vertical ribs in the process. In this case, the formed ribs impregnate the metal ribs and cure. The ribs partially engage with the ribs, thus firmly fixing the vertical ribs formed on the main pipe support to it. This ensures excellent bond strength even without the use of additional fastening devices such as adhesives or bolts.

[0060] A method for manufacturing a front crossbeam of a vehicle according to the present invention is also provided. The method includes a joining step (S100) of joining side mounting brackets to both ends of a main mounting bracket, the main mounting bracket being made of steel, extending along the width direction of the vehicle, and having an S-shaped cross-section when cut or viewed along the length direction of the vehicle. The method may further include an injection molding step (S200) of embedding an injection-molded plastic sub-bracket to surround the main mounting bracket and the side mounting brackets.

[0061] In the joining step (S100), the center support bracket may also be joined to a point (i.e., location or part) of the main support bracket. In the injection molding step (S200), an injection-molded sub-support bracket may be embedded to surround the main support bracket, the side mounting bracket, and the center support bracket.

[0062] The side mounting brackets and center support brackets are made of steel and can be welded to the main support bracket.

[0063] In the injection molding step (S200), the sub-support can be injection molded to include multiple horizontal ribs and vertical ribs.

[0064] After the injection molding step (S200), the method may further include an assembly step (S300) in which the column mounting bracket is joined to surround a point or part of the sub-bracket.

[0065] Although the technical concept of the invention has been illustrated and explained in conjunction with specific embodiments, those skilled in the art will understand that various improvements and modifications can be made to the invention without departing from the technical concept of the invention as defined in the appended claims.

Claims

1. A front bulkhead crossbeam for a vehicle, the front bulkhead crossbeam comprising: The main support bracket, made of steel, is constructed to extend along the width of the vehicle and has an S-shaped cross-section along the length of the vehicle. Side mounting brackets are attached to both ends of the main support bracket; as well as A plastic sub-bracket surrounds the main bracket and the side mounting bracket.

2. The front crossbeam according to claim 1, further comprising: The central support bracket is connected to the main support bracket. The secondary bracket surrounds the main bracket, the side mounting bracket, and the central support bracket.

3. The front crossbeam according to claim 2, wherein, The side mounting bracket and the center support bracket are made of steel and are each welded to the main support bracket.

4. The front crossbeam according to claim 1, wherein, The sub-support includes multiple vertical ribs and one or more horizontal ribs.

5. The front crossbeam according to claim 1, wherein, Each of the side mounting brackets has an S-shaped cross-section along the length of the vehicle and is welded to the main support bracket at the portion that contacts the main support bracket.

6. The front crossbeam according to claim 1, further comprising: A column mounting bracket engages with the sub-bracket at a joint to partially surround the joint. The column mounting bracket includes an upper bracket and a lower bracket, which together form a square closed cross section.

7. The front crossbeam according to claim 6, wherein, The upper support of the column mounting bracket includes an inwardly recessed portion and an outwardly protruding portion.

8. The front crossbeam according to claim 6, wherein: The lower support of the column mounting bracket includes: a bent portion, which bends at the end of an extension extending along the length direction of the vehicle; and A rib is provided between the extension and the bend.

9. The front crossbeam according to claim 1, wherein, The main support includes inwardly recessed groove-shaped ribs that extend along the vertical direction of the main support.

10. A method for manufacturing a front bulkhead crossbeam of a vehicle, the method comprising the following steps: The side mounting brackets are joined to both ends of the main support bracket, which is made of steel and is configured to extend along the width of the vehicle and have an S-shaped cross-section along the length of the vehicle. as well as An embedded injection-molded plastic sub-support is used to surround the main support and the side mounting bracket.

11. The method of claim 10, further comprising the step of: Connect the central support bracket to the main support bracket; as well as The sub-support is embedded in the injection mold to surround the main support, the side mounting bracket, and the center support bracket.

12. The method according to claim 11, wherein: The side mounting bracket and the central support bracket are made of steel; and The side mounting bracket and the center support bracket are joined to the main support bracket by welding.

13. The method according to claim 10, wherein, The sub-support is injection molded to include multiple vertical ribs and one or more horizontal ribs.

14. The method of claim 10, further comprising the step of: Following the embedding injection molding step, a connecting post mounting bracket is attached to partially surround a portion of the sub-bracket.

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