Integrated hyper-extruded rear cross member and manufacturing method thereof

Abstract

The present invention relates to an integral hyper-extruded rear cross member and a method for manufacturing the same, and more specifically, to an integral hyper-extruded rear cross member of a vehicle in which a pair of side members are symmetrically attached to both sides of a front member and a rear member so as to prevent twisting or bending in the front, rear, or left and right directions of the vehicle, wherein the front member, the side members, and the rear member are integrally formed by aluminum extrusion molding.

Description

Technology Field

[0001] The present invention relates to an integral hyper-extruded rear cross member and a method for manufacturing the same. Background Technology

[0002] Generally, in passenger vehicles, cross members are installed at the front and rear wheel positions along the vehicle's width to support many suspension components and withstand lateral loads transmitted to the vehicle body, by installing them at the points where the suspension load is concentrated. Depending on the installation location, cross members are classified into front cross members and rear cross members.

[0003] The front cross member or rear cross member has its upper part connected to the vehicle body and its lower part connected to the suspension, and functions to prevent twisting or bending of the vehicle in the front, rear, or left and right directions.

[0004] In the rear cross member, an assist arm and a lower arm are connected by an eccentric cam bolt to allow adjustment of the toe angle and camber angle in order to improve the straightness and drivability of the vehicle wheels. By rotating the cam bolt guided by the cam guide, the toe angle and camber angle can be adjusted.

[0005] A representative example is the rear cross member for a vehicle disclosed in Korean Patent Publication No. (A) 10-2020-0132472 (2020.11.25.), which is configured to include: a cam bolt seating portion in which a cam bolt insertion hole portion into which a cam bolt portion is inserted is formed; a base portion connected to the cam bolt seating portion and having a crack prevention hole portion formed therein to prevent cracking; and a pair of cam bolt support portions that protrude outward from the base portion and are positioned on both sides of the cam bolt seating portion to support the sides of the cam bolt portion.

[0006] Another example is the rear cross member for an automobile disclosed in Korean Patent Publication No. (A) 10-2017-0037191 (April 4, 2007). The rear cross member for an automobile comprises a cast member made of aluminum to which suspension parts are connected, and an extruded member connecting the cast member. The rear cross member is characterized by having a metal connector installed between the cast member and the extruded member to join them.

[0007] In the case of the aforementioned conventional technologies, products provided by pressing and welding steel plates or casting aluminum were difficult to manufacture and had problems such as increasing vehicle weight and reducing fuel efficiency due to their weight. Consequently, the industry required a rear cross member with a novel configuration to solve these weight problems.

[0008] Figure 1a shows a photograph of a conventional steel boxing type rear cross member, and Figure 1b shows a photograph of a steel pipe type rear cross member.

[0009] As shown in Fig. 1a, steel upper / lower boxing types and various arm mounting brackets are applied separately, and as shown in Fig. 1b, it can be seen that steel pipe rods and various arm brackets are applied separately. In the case of the existing steel type, a pipe rod type is applied to reduce weight and increase corrosion resistance.

[0010] FIG. 2a shows a photograph of a member to which conventional aluminum gigacasting is applied, and FIG. 2b shows a rear cross member to which conventional aluminum die casting and extrusion are applied.

[0011] As shown in FIGS. 2a and 2b, an integrated gigacasting is being applied using aluminum material to reduce weight compared to steel (Tesla), and since die-casting facilities are limited in Korea, only the side members are die-cast and the center part is made of extruded material.

[0012] FIG. 3 shows an exploded perspective view of a conventional steel upper / lower box type rear cross member. As shown in FIG. 3, CO2 welding is applied after thin sheet forming of the upper / lower box type steel parts, the body mounting corrosion pipe is applied as a separate part, and a separate bracket is applied for connecting various arms.

[0013] Therefore, due to the characteristics of the part, excessive material thickness is applied to individual components to ensure durability, leading to problems such as reduced quality of individual component forming, excessive weight compared to aluminum, increased heat input during CO2 welding due to excessive material thickness (increased bead width, reduced rust prevention performance, increased weight, etc.), and reduced quality caused by thermal deformation during boxing-type CO2 welding. Prior art literature

[0014] Republic of Korea Published Patent No. 10-2020-0132472 Republic of Korea Published Patent No. 10-2017-0037191 The problem to be solved

[0015] Accordingly, the present invention has been devised to solve the aforementioned conventional problems, and according to an embodiment of the present invention, the corrosion resistance is improved by applying an aluminum material, the number of parts is reduced and welding is not required by applying an aluminum extrusion integral type, weight reduction is increased by applying an aluminum extrusion integral type, the strap can be reused after processing, and the freedom of movement of various arm fastening points can be increased by changing the processing part.

[0016] Meanwhile, the technical problems to be solved by the present invention are not limited to those mentioned above, and other technical problems not mentioned will be clearly understood by those skilled in the art to which the present invention belongs from the description below. means of solving the problem

[0017] The objective of the present invention can be achieved as an integral hyper-extruded rear cross member, wherein a pair of side members are symmetrically connected to both sides of a front member and a rear member so as to prevent twisting or bending in the front, rear, or left and right directions of the vehicle, and wherein the front member, the side member, and the rear member are integrally formed by aluminum extrusion molding.

[0018] And the above extrusion direction is the height direction of the rear cross member, and the front member, the side member, and the rear member may be characterized in that the reinforcing bulkhead is integrally formed when extruded as a single unit.

[0019] In addition, the rear cross member extrusion base material, in which the front member, the side member, and the rear member are integrally provided through aluminum extrusion, may be manufactured, and then the processed part may be removed through shearing and hole processing.

[0020] In addition, the body mounting can be integrally provided at both ends of the rear member and the front member through processing after integral extrusion, without combining the arm member and the mounting bracket member.

[0021] In addition, the lower arm fastening part is integrally provided on the rear member through processing after integral extrusion without combining the arm separate part and the mounting bracket separate part, and the arm fastening part and the step bar fastening part are integrally provided on the side member and the front member. Effects of the invention

[0022] According to the integral hyper-extrusion rear cross member according to an embodiment of the present invention, corrosion resistance is improved by applying aluminum material, the number of parts is reduced and welding is not required by applying an aluminum extrusion integral type, weight reduction is increased by applying an aluminum extrusion integral type, the strap can be reused after processing, and the freedom of movement of various arm fastening points can be increased by changing the processing part.

[0023] Meanwhile, the effects obtainable from the present invention are not limited to those mentioned above, and other unmentioned effects will be clearly understood by those skilled in the art to which the present invention belongs from the description below. Brief explanation of the drawing

[0024] The following drawings attached to this specification illustrate preferred embodiments of the present invention and serve to further enhance understanding of the technical concept of the present invention together with the detailed description of the invention; therefore, the present invention should not be interpreted as being limited only to the matters described in such drawings. FIG. 1a is a photograph of a conventional steel boxing type rear cross member, Fig. 1b is a photo of a steel pipe type rear cross member, FIG. 2a is a photograph of a member to which conventional aluminum gigacasting is applied, FIG. 2b shows a rear cross member to which conventional aluminum die casting and extrusion are applied, FIG. 3 is an exploded perspective view of a conventional steel upper / lower box type rear cross member, FIG. 4a is a perspective view of an integrated hyper-extruded rear cross member according to an embodiment of the present invention, FIG. 4b is a plan view of an integrated hyper-extruded rear cross member according to an embodiment of the present invention, FIG. 4c is a bottom view of an integrated hyper-extruded rear cross member according to an embodiment of the present invention, FIG. 4d is a side view of an integrated hyper-extruded rear cross member according to an embodiment of the present invention, FIG. 4e is a front view of an integrated hyper-extruded rear cross member according to an embodiment of the present invention, FIG. 5a is a partial upper perspective view of an integrated hyper-extruded rear cross member according to an embodiment of the present invention, FIG. 5b is a partial lower perspective view of an integrated hyper-extruded rear cross member according to an embodiment of the present invention, FIG. 6 is an extruded rear cross member base material according to an embodiment of the present invention, FIG. 7a shows a processed portion of an integrated hyper-extruded rear cross member base material according to an embodiment of the present invention, FIG. 7b shows a perspective view of an integrated hyper-extruded rear cross member and a processed part (strap) according to an embodiment of the present invention. Specific details for implementing the invention

[0025] The above objects, other objects, features, and advantages of the present invention will be easily understood through the following preferred embodiments associated with the accompanying drawings. However, the present invention is not limited to the embodiments described herein and may be embodied in other forms. Rather, the embodiments introduced herein are provided to ensure that the disclosed content is thorough and complete and to ensure that the spirit of the invention is sufficiently conveyed to a person skilled in the art.

[0026] In this specification, when a component is described as being on another component, it means that it may be formed directly on the other component or that a third component may be interposed between them. Also, in the drawings, the thicknesses of the components are exaggerated for the effective description of the technical content.

[0027] The embodiments described herein will be explained with reference to cross-sectional and / or plan views, which are exemplary illustrations of the invention. In the drawings, the thicknesses of films and regions are exaggerated for effective explanation of the technical content. Accordingly, the shapes of the exemplary drawings may be modified by manufacturing techniques and / or tolerances, etc. Accordingly, the embodiments of the invention are not limited to the specific shapes depicted but include variations in shape produced according to the manufacturing process. For example, a region depicted as a right angle may be rounded or have a certain curvature. Accordingly, the regions illustrated in the drawings have properties, and the shapes of the regions illustrated in the drawings are intended to illustrate specific shapes of the regions of the device and are not intended to limit the scope of the invention. Although terms such as first, second, etc., have been used to describe various components in the various embodiments of this specification, these components should not be limited by such terms. These terms are used merely to distinguish one component from another. The embodiments described and illustrated herein also include their complementary embodiments.

[0028] The terms used herein are for describing the embodiments and are not intended to limit the invention. In this specification, the singular form includes the plural form unless specifically stated otherwise in the text. As used herein, 'comprises' and / or 'comprising' do not exclude the presence or addition of one or more other components to the mentioned components.

[0029] In describing the specific embodiments below, various specific details have been included to explain the invention more specifically and to aid understanding. However, a reader with sufficient knowledge in the art to understand the invention will recognize that it can be used without these various specific details. In some cases, it is noted in advance that commonly known aspects that are not significantly related to the invention have been omitted to prevent unnecessary confusion in describing the invention.

[0031] Hereinafter, the configuration of an integrated hyper-extruded rear cross member according to an embodiment of the present invention and the method of manufacturing the same will be described.

[0032] FIG. 4a shows a perspective view of an integrated hyper-extruded rear cross member according to an embodiment of the present invention. FIG. 4b shows a plan view of an integrated hyper-extruded rear cross member according to an embodiment of the present invention.

[0033] FIG. 4c illustrates a bottom view of an integrated hyper-extruded rear cross member according to an embodiment of the present invention. FIG. 4d illustrates a side view of an integrated hyper-extruded rear cross member according to an embodiment of the present invention. FIG. 4e illustrates a front view of an integrated hyper-extruded rear cross member according to an embodiment of the present invention.

[0035] The present invention is a rear cross member of a vehicle in which a pair of side members are symmetrically connected to both sides of a front member and a rear member so as to prevent twisting or bending in the front, rear, or left and right directions of the vehicle, and as shown in FIGS. 4a to 4e, the integral hyper-extruded rear cross member (100) according to an embodiment of the present invention is formed such that the front member (10), side member (30), and rear member (20) are all integrally extruded through aluminum integral hyper-extrusion.

[0036] This extrusion direction is the height direction of the rear cross member.

[0037] In addition, as shown in FIGS. 4a to 4c, a reinforcing bulkhead (3) is provided inside the front member (10), side member (30), and rear member (20) that are integrally connected, and it can be seen that this reinforcing bulkhead (30) is not welded or fastened separately after extrusion, but is formed integrally during extrusion molding.

[0039] FIG. 5a shows a partial upper perspective view of an integrated hyper-extruded rear cross member according to an embodiment of the present invention.

[0040] And FIG. 5b shows a partial lower perspective view of an integrated hyper-extruded rear cross member according to an embodiment of the present invention.

[0041] In the integral hyper-extruded rear cross member (100) according to an embodiment of the present invention, body mountings (11, 21) are integrally provided at each end of the rear member (20) and the front member (10) through processing after integral extrusion, without joining separate arms or separate mounting brackets by welding, etc.

[0042] In addition, the integrated hyper-extruded rear cross member (100) according to an embodiment of the present invention is formed such that, without joining separate arms or separate mounting brackets by welding or the like, a lower arm fastening part (22) is integrally provided on the rear member (20) through processing after integrated extrusion, and various arm fastening parts and step bar fastening parts (32) are integrally provided on the side member (30) and the front member (10).

[0044] More specifically, as shown in FIG. 5a, it can be seen that a front body mounting part (11) and an assist arm connecting part (12) are integrally provided at both ends of the front member (10), and a rear body mounting part (21) is integrally provided at both ends of the rear member (20). It can also be seen that an upper arm connecting part (31) is integrally connected to one side of the side member (3).

[0045] And as shown in FIG. 5b, it can be seen that a step bar fastening part is integrally provided on one side of the bottom surface of the side member, an assist arm fastening part (31) is integrally provided on one side of the bottom surface of the front member (10), and a lower arm fastening part (22) is integrally provided on one side of the bottom surface of the rear member (20).

[0047] FIG. 6 illustrates an extruded rear cross member base material according to an embodiment of the present invention. As shown in FIG. 6, first, an extruded rear cross member base material (1) in which a rear member, a side member, a front member, and a body mounting part are integrated is manufactured and molded through integral hyper extrusion.

[0048] FIG. 7a illustrates a processed portion of an integrated hyper-extruded rear cross member base material according to an embodiment of the present invention. FIG. 7b illustrates a perspective view of an integrated hyper-extruded rear cross member and a processed portion (strap) according to an embodiment of the present invention.

[0049] As shown in FIG. 6, after manufacturing a rear cross member extrusion base material (10) in which a front member, a side member, and a rear member are integrally provided through aluminum integral hyper extrusion, the processed part (2, strap)) is removed through shear processing and hole processing to produce an integral hyper extrusion rear cross member (100) according to an embodiment of the present invention.

[0050] Therefore, the entire rear cross member can be manufactured as a single piece through integrated hyper extrusion and post-processing without the need to manufacture various mounting brackets and arms as separate parts and weld them. Also, the removed processed part (2, strap) is easy to reuse.

[0052] In addition, the apparatus and method described above are not limited to the configurations and methods of the embodiments described above; rather, all or part of each embodiment may be selectively combined to allow for various modifications to be made. Explanation of the symbols

[0053] 1: Rear cross member extruded base material 2: Processed part (strap) 3: Reinforced bulkhead 10: Front Member 11: Front member body mounting 12: Assist arm connection part 20: Rear member 21: Rear member body mounting 22: Lower arm connection part 30: Side member 31: Upper arm connection part 32: Step bar connection part 100: Integrated Hyper Extrusion Rear Cross Member

Claims

Claim 1 A rear cross member of a vehicle having a pair of side members symmetrically attached to both sides of a front member and a rear member so that the upper part is connected to the vehicle body to prevent twisting or bending in the front, rear, or left and right directions of the vehicle, wherein the front member, the side member, and the rear member are integrally extruded from aluminum, the extrusion direction is the height direction of the rear cross member, and reinforcing bulkheads are integrally formed during extrusion of the front member, the side member, and the rear member, and after manufacturing a rear cross member extrusion base material in which the front member, side member, and rear member are integrally provided through aluminum integral hyper extrusion, the processed parts are removed through shearing and hole machining to produce an integral hyper-extruded rear cross member, thereby enabling the entire rear cross member to be manufactured as a single unit through integral hyper extrusion and post-processing without the need for welding, the removed processed parts are easy to reuse, and the rear member and the front member are formed through integral extrusion post-processing without attaching separate parts for arms or mounting brackets. An integrated hyper-extruded rear cross member characterized by having body mountings integrally provided at both ends, without combining separate arm parts and mounting brackets, having a lower arm fastening part integrally provided on the rear member through processing after integral extrusion, having an arm fastening part and a step bar fastening part integrally provided on the side member and the front member, having a front body mounting part and an assist arm fastening part integrally provided on both ends of the front member, having a rear body mounting part integrally provided on both ends of the rear member, having an upper arm fastening part integrally connected to one side of the side member, having a step bar fastening part integrally provided on one side of the bottom surface of the side member, having an assist arm fastening part integrally provided on one side of the bottom surface of the front member, and having a lower arm fastening part integrally provided on one side of the bottom surface of the rear member. Claim 2 delete Claim 3 delete Claim 4 delete Claim 5 delete

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