Collision reinforcement part and manufacturing method thereof

Abstract

The impact reinforcement component according to the present invention includes a component body having side walls formed on both sides in the longitudinal direction, and an upper plate connecting upper ends of the side walls on both sides, and end flanges bent and formed on both ends in the longitudinal direction of the component body, the component body being formed by continuously repeating roll stamping in which a stamping roll rotates and presses a material multiple times, and the component body includes a body portion having a bead formed on the upper plate along the longitudinal direction, and a boundary portion which is integral with the body portion and the end flange and where the upper plate is flat as a joint portion between the body portion and the end flange.

Description

[Technical Field]

[0001] The present invention relates to a crash reinforcement part and a manufacturing method thereof, and more particularly to a crash reinforcement part whose rigidity is reinforced for collision resistance, such as a seat cross member, and a manufacturing method thereof. [Background technology]

[0002] The roll stamping technology is a technology described in the registered patents Roll Stamping Apparatus (Registration No. 10-1417278), Roll Stamping Apparatus (Registration No. 10-1786260), and Roll Stamping Apparatus and Method (Registration No. 10-1917450).

[0003] The essence of roll stamping technology is the production of parts with a cross-sectional shape that varies along the length using a roll forming device.

[0004] However, parts that change shape in the length direction cannot be manufactured using the usual roll forming method. Therefore, they are generally manufactured using press molding using a mold. However, if the material is strong, forming large parts requires a very high press capacity, making it difficult to manufacture.

[0005] Therefore, roll stamping is a useful technology that can overcome these limitations. However, because roll stamping is basically a technology that uses a roll forming apparatus, it is difficult to practically apply it to very long parts that have a change in shape in the longitudinal direction. That is, since the shape of the part in the longitudinal direction needs to be engraved around the stamping roll, the diameter of the stamping roll needs to be increased when the part is long. However, this increase in the diameter of the stamping roll directly leads to the problem of requiring a significantly larger roll forming apparatus overall, making it difficult to practically apply it in terms of installation space. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Korean Patent Registration No. 10-1417278 [Patent Document 2] Korean Patent Registration No. 10-1786260 [Patent Document 3] Korean Patent Registration No. 10-1917450 Summary of the Invention [Problem to be solved by the invention]

[0007] The present invention has been invented to solve the above-mentioned problems, and an object of the present invention is to provide a crashworthiness component that can be manufactured by a roll stamping method without increasing the diameter of the stamping roll when manufacturing a component from a long material, and a manufacturing method thereof. [Means for solving the problem]

[0008] To achieve the above object, an impact reinforcement component according to the present invention includes a component body having side walls formed on both longitudinal ends and a top plate connecting the upper ends of the side walls on both sides, and end flanges bent and formed on both longitudinal ends of the component body, the component body being formed by continuously repeating roll stamping in which a stamping roll rotates and presses a material multiple times, and the component body also includes a body portion having a bead formed on the top plate along the longitudinal direction, and a boundary portion where the body portion and the end flanges are joined and which is integral with the body portion and the end flanges and where the top plate is flat.

[0009] Here, the body portion may include a plurality of bead regions spaced apart from each other in the longitudinal direction, in which the beads are formed on an upper plate, and a middle no-bead region located between the plurality of bead regions and in which the upper plate is flat.

[0010] At this time, the bead region may include a plurality of beads spaced apart from one another in the width direction of the upper plate.

[0011] The length of the intermediate no-bead region in the longitudinal direction may be equal to or greater than twice the combined length of the boundary portion and the end flanges.

[0012] Meanwhile, according to another aspect of the present invention, there is provided a method for manufacturing an impact reinforcement part, including: a roll stamping step of continuously repeating roll stamping by rotating and pressing a stamping roll multiple times along the length direction of a material; and a flange forming step of bending each of both end portions of the material to form end flanges, wherein in the roll stamping step, a plurality of bead regions and intermediate no-bead regions between the plurality of bead regions are formed in the material, and end no-bead regions are formed at each of the both end portions.

[0013] Specifically, the roll stamping step includes an overall bending process in which the material is bent while pressing and rotating the stamping roll multiple times to form both side walls and an upper plate; a first end no-bead process in which a flat upper plate is formed at one end of the material in a longitudinal direction to form the end no-bead region; a bead process in which a plurality of beads are formed on the upper plate of the material at intervals in the longitudinal direction to form the plurality of bead regions; a middle no-bead process in which a flat upper plate is formed between the plurality of beads to form the middle no-bead region; and a second end no-bead process in which a flat upper plate is formed at the other end of the material in the longitudinal direction to form the end no-bead region. The first end no-bead process, bead process, middle no-bead process, and second end no-bead process may be performed in the overall bending process, and the middle no-bead process may be performed in the bead process.

[0014] In this case, the longitudinal length of the middle no-bead region formed by the middle no-bead process can be equal to or greater than twice the longitudinal length of the end no-bead region formed by the first end no-bead process or the second end no-bead process. [Effects of the Invention]

[0015] In the impact reinforcement part according to the present invention, the part body is formed by continuously repeating roll stamping, in which a stamping roll rotates and presses against a material multiple times, so that a bead region is formed in the body part of the part body, and a boundary part having a no-bead region extends from the body part and is configured as an integrated structure connecting to the end flange. This makes it possible to reinforce rigidity with the bead region of the body part, and at the same time, the no-bead region of the boundary part has the effect of making it smooth and easy to form bending deformation of the end flange.

[0016] The method for manufacturing an impact reinforcement component according to the present invention includes a roll stamping step in which a stamping roll is rotated and pressed multiple times along the length direction of a material to continuously repeat roll stamping. This allows the component to be constructed so that shape changes in the length direction are periodically repeated, making it possible to manufacture a very long component without increasing the diameter of the stamping roll, and also has the advantage of easily forming the above-mentioned boundary portion. [Brief explanation of the drawings]

[0017] [Figure 1] 1 is a view showing a seat cross member according to the prior art; [Figure 2] 1 is a view showing a collision reinforcement part according to the present invention; [Figure 3] FIG. 3 is an enlarged view of A in FIG. 2. [Figure 4] FIG. 3 is an enlarged view showing B in FIG. 2. [Figure 5] 1 is a flowchart showing a method for manufacturing an impact reinforcement component according to the present invention. [Figure 6]6 is a flowchart showing a roll stamping step in the method for manufacturing the impact reinforcement component of FIG. 5. DETAILED DESCRIPTION OF THE INVENTION

[0018] Hereinafter, preferred embodiments will be described in detail with reference to the accompanying drawings so that those skilled in the art can easily practice the present invention. However, in describing preferred embodiments of the present invention in detail, if it is determined that a detailed description of related well-known functions or configurations may obscure the gist of the present invention, such detailed description will be omitted. In addition, parts having similar functions and operations will be designated by the same reference numerals throughout the drawings. In addition, in this specification, terms such as "top," "upper," "upper surface," "bottom," "lower," "bottom surface," and "side" are used based on the drawings and may actually change depending on the direction in which components are arranged.

[0019] Throughout the specification, when a part is said to be "connected" to another part, this includes not only "directly connected" but also "indirectly connected" through other components therebetween. Furthermore, unless otherwise specified, "comprising" a certain component does not mean excluding other components, but may further include other components.

[0020] FIG. 1 is a diagram showing a seat cross member according to the prior art.

[0021] Referring to the drawings, a seat cross member 10 is configured in the lower part of a vehicle as a reinforcing part for preparing for a collision from the vehicle, that is, as a collision reinforcing part.

[0022] Such a seat cross member 10 is configured as a single unit part having a hat-shaped cross section.

[0023] Such a sheet cross member 10 can be manufactured by roll forming because there is no change in the cross-sectional shape along the length. That is, flanges 11 can be formed on both ends of the roll-formed part by post-processing, and then welded to the seal side 20.

[0024] However, a structure formed simply from both side walls 10a and a flat top plate 10b reaches a limit where the reinforcement against a collision becomes insufficient.

[0025] To overcome this limitation, a sheet cross member can be manufactured that includes a bead (a portion that is relatively raised upward compared to other portions) in the upper plate, although this is not shown in the drawings.

[0026] However, if beads are formed along the entire length of the upper plate, i.e., if the beads are formed all the way to both ends in the length direction, it becomes very difficult to create flanges that can be bent and deformed during the manufacturing process.

[0027] In other words, the end of the sheet cross member is not simply hat-shaped, but has a complex cross-sectional shape with a periphery that is bent (folded) multiple times by beads, making it extremely difficult to bend and deform the end to create a flange.

[0028] Therefore, in order to form a simple hat-shaped cross-sectional structure without a bead only at the end of the seat cross-member, the seat cross-member is composed of multiple unit parts rather than one unit part. In other words, the seat cross-member can be made by connecting (joining by welding, etc.) a unit part having a structure with a bead and another unit part having a simple hat-shaped cross-sectional structure without a bead.

[0029] However, in the case of a simple hat-shaped cross-sectional structure like this, with no beads at the ends, it is easy to bend the ends and create a flange. However, when a seat cross member is made by joining multiple unit parts rather than as a single unit, the rigidity of the parts where the unit parts are connected (for example, welded parts) is relatively inferior to other parts, making it difficult to use as a collision reinforcement part.

[0030] FIG. 2 is a view showing a crashworthiness component according to the present invention, FIG. 3 is an enlarged view of A in FIG. 2, and FIG. 4 is an enlarged view of B in FIG.

[0031] Referring to the drawings, in order to solve the above-mentioned problems, the collision reinforcement component 1000 according to the present invention is configured with a boundary portion 120 having a simple cross-sectional structure without a bead (a portion that protrudes relatively upward compared to other portions) at the end, and such boundary portion 120 is configured as an integrated structure rather than a separate member from other portions.

[0032] Specifically, the present invention includes a component body 100 and an end flange 200 .

[0033] The component body 100 is formed by continuously repeating roll stamping, in which a stamping roll rotates and presses against a material multiple times.

[0034] The component body 100 manufactured by this method structurally has side walls S formed on both sides in the length direction, and an upper plate U connecting the upper ends of the side walls S on both sides.

[0035] The end flanges 200 are formed by bending each of both longitudinal end portions of the component body 100. As an example, such end flanges 200 are portions that are welded to other components such as seal sides.

[0036] Here, the component body 100 includes a body portion 110 and a boundary portion 120 .

[0037] The body portion 110 has a bead 111a formed on the upper plate U along the length direction.

[0038] Furthermore, the boundary portion 120 is a joint portion between the body portion 110 and the end flange 200 and is integral with the body portion 110 and the end flange 200 .

[0039] In this case, the upper plate U of the boundary portion 120 has a flat structure without a bead formed thereon. The boundary portion 120 is essentially a portion having a fairly short length, such as a boundary line between the body portion 110 and the end flange 200.

[0040] More specifically, the body portion 110 includes a bead region 111 and a middle no-bead region 112 .

[0041] The bead regions 111 are spaced apart from one another in the longitudinal direction, and beads 111a are formed on the upper plate U. That is, the bead regions 111 are formed long in the longitudinal direction, but are spaced apart from one another because there is a middle no-bead region 112 in the middle. For example, as shown in the drawing, two bead regions 111 may be spaced apart from one another.

[0042] The plurality of bead regions 111 spaced apart in the longitudinal direction are formed by roll stamping, as described in the part manufacturing method below. That is, a stamping roll rotates and compresses the material multiple times, thereby forming a plurality of beads 111a spaced apart in the longitudinal direction.

[0043] Furthermore, the bead region 111 may have a plurality of beads 111a spaced apart from one another in the width direction on the upper plate U. When a plurality of bead regions 111 are spaced apart from one another in the width direction in this manner, the rigidity of the collision reinforcement component 1000 is increased.

[0044] The intermediate no-bead region 112 is located between the plurality of bead regions 111, and the upper plate U has a flat structure.

[0045] As described above, the body portion 110 has bead regions 111 spaced apart from one another in the longitudinal direction, and the upper plate U forms a flat intermediate no-bead region 112 between the multiple bead regions 111, which are spaced apart from one another.

[0046] The stamping roll has an uneven structure for forming the bead 111a, and also has a flat portion for forming the boundary portion 120. If the size (diameter) of the stamping roll is appropriate taking into consideration various factors such as the side surface of the installation space, in order to manufacture a long collision reinforcement part 1000, a middle no-bead region 112 where the upper plate U is flat like the boundary portion 120 is formed by rotating and pressing it multiple times.

[0047] That is, by using the structure of the middle no-bead region 112, the impact reinforcement part 1000 of the present invention can be realized by a manufacturing method using multiple rotations of a stamping roll.

[0048] The boundary portions 120 are located at both ends of the component body 100 in the longitudinal direction, and are flat portions of the upper plate U, which are the same as the boundary line between the body portion 110 and the end flange 200, allowing the end flange 200 to be formed smoothly and easily during bending.

[0049] The end flange 200 has a structure in which it extends integrally from the boundary portion 120 before being bent, but since the boundary portion 120 has a simple hat-shaped cross-sectional structure without a bead, bending deformation of the end flange 200 can be performed smoothly and easily.

[0050] In this way, by adopting a manufacturing method using multiple rotating stamping rolls, the present invention forms a structure in which the longitudinal length of the middle no-bead region 112 is equal to or greater than twice the combined longitudinal length of the boundary portion 120 and the end flange 200.

[0051] When using a long material to manufacture a plurality of collision reinforcement parts 1000 having a set length, the material is roll-stamped to form a plurality of collision reinforcement parts 1000, and then cut and separated. Therefore, the length of the middle no-bead region 112 must be twice the combined length of the boundary portion 120, which is the flat end no-bead region 121 of the upper plate U, and the end flange 200. However, since some of the length may be lost during cutting, a condition of more than twice the combined length may be adopted in order to form a sufficient end flange 200.

[0052] FIG. 5 is a flowchart showing a method for manufacturing an impact reinforcement part according to the present invention, and FIG. 6 is a flowchart showing a roll stamping step in the method for manufacturing an impact reinforcement part of FIG.

[0053] 2 to 4 and with reference to FIGS. 5 and 6, the method for manufacturing an impact reinforcement component according to the present invention includes a roll stamping step S100 and a flange forming step S200.

[0054] The roll stamping step S100 is a step of continuously repeating roll stamping by rotating and pressing the stamping roll multiple times along the length direction of the material.

[0055] The flange forming step S200 is a step performed after the roll stamping step S100, in which both ends of the material are bent to form end flanges 200.

[0056] When manufacturing a collision reinforcement part such as a sheet cross member using a longitudinally long material, the product is completed through the roll stamping step S100 and the flange forming step S200.

[0057] Here, in the roll stamping step S100, a plurality of bead regions 111 and a middle no-bead region 112 between the plurality of bead regions 111 are formed in the material, and end no-bead regions 121 are formed at both ends.

[0058] Specifically, the roll stamping step S100 includes a full bending step S110, a first end no-bead step S120, a bead step S130, a middle portion no-bead step S130, and a second end no-bead step S150.

[0059] In the overall bending step S110, the material is bent while pressing and rotating the stamping rolls multiple times to form both side walls S and the upper plate U.

[0060] In the first end no-bead step S120, a flat upper plate U is formed on one end of the material in the length direction to form an end no-bead region 121.

[0061] In the beading process S130, a plurality of beads 111a are formed on the upper plate U of the material at intervals in the length direction to form a plurality of bead regions 111.

[0062] In the no-bead intermediate section step S130, a flat upper plate U is formed between the plurality of beads 111a to form the no-bead intermediate section 112.

[0063] In the second end no-bead process S150, a flat upper plate U is formed on the other end of the material in the length direction to form an end no-bead region 121.

[0064] At this time, the first end no-bead step S120, the bead step S130, the middle portion no-bead step S130, and the second end no-bead step S150 are performed during the entire bending step S110, and the middle portion no-bead step S130 is performed during the bead step S130.

[0065] That is, in the process of forming both side walls S and an upper plate U on the material while the stamping roll rotates and compresses the material multiple times, the first end no-bead process S120, the bead process S130, and the second end no-bead process S150 are performed sequentially, and at this time, the middle portion no-bead process S130 is performed during the bead process S130. That is, in the process of forming the material while the stamping roll rotates and compresses the material multiple times, the first end no-bead process S120, the bead process S130, the middle portion no-bead process S130, and the second end no-bead process S150 are performed.

[0066] In the flange forming step S200, the end flange 200 is formed by bending the end no-bead region 121 having a flat upper surface after the roll stamping step S100.

[0067] Meanwhile, the length of the middle no-bead region 112 in the longitudinal direction may be equal to or greater than twice the length of the end no-bead region 121 in the longitudinal direction.

[0068] When manufacturing a plurality of collision reinforcement components 1000 having a set length using a long material, the material is roll stamped in the roll stamping step S100 and then cut and separated to form a plurality of collision reinforcement components 1000. Therefore, the length of the middle no-bead region 112 must be twice the length of the end no-bead region 121 where the upper plate U is flat. However, since some of the no-bead region 121 may be lost during cutting, a condition of more than twice the length may be adopted in consideration of forming a sufficient end flange 200.

[0069] As a result, the impact reinforcement part 1000 according to the present invention is formed by continuously repeating roll stamping, in which a stamping roll rotates and presses a material multiple times, to form the part body 100. As a result, a bead region 111 is formed in the body part 110 of the part body 100, and a boundary part 120 having a no-bead region extends from the body part 110 and connects to the end flange 200, forming an integrated structure. This allows the bead region 111 of the body part 110 to reinforce rigidity, and at the same time, the no-bead region of the boundary part 120 makes it smooth and easy to form bending deformation in the end flange 200.

[0070] Furthermore, the method for manufacturing an impact reinforcement part according to the present invention includes a roll stamping step S100 in which a stamping roll is rotated and pressed multiple times along the length direction of a material, thereby continuously repeating roll stamping. This allows the part to be constructed so that shape changes in the length direction are periodically repeated, making it possible to manufacture a very long part without increasing the diameter of the stamping roll, and also easily form the boundary portion 120 described above.

[0071] Although the embodiments of the present invention have been described above with reference to the accompanying drawings, those skilled in the art will understand that the present invention may be embodied in other specific forms without changing the technical spirit or essential features of the present invention. Therefore, it should be understood that the above-described embodiments are illustrative in all respects and are not limiting. [Explanation of symbols]

[0072] 100 part body 110 body part 111 bead area 111a bead 112 Middle no-bead area 120 Boundary area 121 End no-bead area 200 End flange 1000 Collision reinforcement parts S side wall U Upper plate S100 Roll stamping stage S110 Overall bending process S120 First end no-bead process S130 Bead process S140 Middle bead process S150 No-bead process for second end S200 Flange forming stage

Claims

1. A component for forming a plurality of collision reinforcement components, a component body having side walls formed on both sides in the length direction and an upper plate connecting the upper ends of the side walls on both sides; end flanges formed by bending at both ends of the component body in the longitudinal direction; Including, The component body is formed by continuous repetition of roll stamping, in which a stamping roll rotates and presses against a blank multiple times; The component body is a body portion having a plurality of beads formed on an upper plate along a length direction; The joint between the body and the end flange is integral with the body and the end flange, and the upper plate is a flat boundary portion. Including, The body portion is a bead region in which a plurality of beads are formed on the upper plate, the bead region being spaced apart from one another in the longitudinal direction; a middle no-bead region located between the plurality of bead regions and having a flat upper plate; Including, The intermediate no-bead region is configured to allow the formation of the plurality of crash reinforcement components.

2. The component according to claim 1 , wherein the bead region comprises a plurality of beads arranged on the upper plate at intervals in the width direction.

3. The component of claim 1 , wherein the longitudinal length of the intermediate no-bead region is equal to or greater than twice the combined longitudinal length of the border and end flanges.

4. A roll stamping step in which the stamping roll is rotated and pressed multiple times along the length direction of the material to continuously repeat roll stamping; a flange forming step of bending both ends of the material to form end flanges; Including, In the roll stamping step, forming a plurality of bead regions and a middle no-bead region between the plurality of bead regions in the material, and forming end no-bead regions at both ends; The roll stamping step includes: a full-bending process in which the stamping roll is pressed and rotated against the material multiple times to bend the material to form side walls and an upper plate; a first end no-bead process for forming a flat upper plate on one end of the material in the longitudinal direction to form the end no-bead region; a beading process for forming a plurality of beads spaced apart from one another in a longitudinal direction on the upper plate of the material to form a plurality of the bead regions; a middle no-bead process for forming a flat upper plate between a plurality of the beads to form the middle no-bead region; a second end no-bead process in which a flat upper plate is formed on the other end of the material in the longitudinal direction to form the end no-bead region; Including, the first end no-bead process, the bead process, the middle portion no-bead process, and the second end no-bead process are performed in the process of the entire bending process, the middle portion no-bead process is performed in the process of the bead process, and the middle portion no-bead process is performed in the process of the bead process, A method for manufacturing a collision reinforcement component configured to form a plurality of collision reinforcement components by cutting the middle no-bead region.

5. 5. The method for manufacturing an impact reinforcement component according to claim 4, wherein a length in a longitudinal direction of the intermediate no-bead region formed by the intermediate no-bead process is equal to or greater than twice the length in the longitudinal direction of the end no-bead region formed by the first end no-bead process or the second end no-bead process.

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