Eco-friendly, ultra-lightweight cowl crossbar manufacturing apparatus and method for manufacturing cowl crossbar using same

Abstract

An eco-friendly, ultra-lightweight cowl crossbar manufacturing apparatus according to an embodiment of the present invention comprises a main hopper, a mixing extruder, a melting heater, a foaming injection die, and a cooling / hardening unit. The main hopper serves as an inlet for a base material, which is a polymer composite material, and a foaming agent for forming bubbles in the base material. The mixing extruder mixes and conveys the base material and the foaming agent. The melting heater is provided in the mixing extruder and melts materials. A cavity is formed between an action core and a reference die of the foaming injection die so as to correspond to the shape of a molded article, and the reference die includes an injection nozzle connected to the mixing extruder. The cooling / hardening unit cools the reference die and a core die. Also, the reference die includes a variable die that can be translated toward the action core.

Description

An eco-friendly, ultra-light cowl crossbar manufacturing device and a method for manufacturing a cowl crossbar using the same

[0001] The present invention relates to an eco-friendly, ultra-light cowl crossbar manufacturing device and a method for manufacturing a cowl crossbar using the same, and more specifically, to an apparatus and method for manufacturing a cowl crossbar that reduces weight and improves performance by using an eco-friendly composite material.

[0002] First, the present invention is related to a task performed as part of the national policy of the Republic of Korea (Task Unique Number: 1415185124 / Task Number: 20011130 / Ministry Name: Ministry of Trade, Industry and Energy (KR) / Task Management Agency Name: Korea Institute of Industrial Technology Planning and Evaluation / Research Project Name: Material and Component Technology Development / Research Project Name: Development of High-Strength, Low-Specific-Weight UHMWPP Composite Materials and Automotive Application Products with Excellent Impact Resistance and Friction Resistance / Contribution Rate: 100% / Host Agency: Deokyang Industry Co., Ltd. / Research Period: 2020.04.01~2024.12.31, 57 months).

[0003] The cowl crossbar is an important part that forms the frame of a car.

[0004] The cowl crossbar prevents the vehicle's body from bending and twisting, and serves to protect the passengers.

[0005] The cowl crossbar is mainly installed on the lower part of the vehicle's windshield, the rear end of the engine hood, or the front panel of the body, and various electrical components are mounted here.

[0006] Figures 1 to 3 illustrate a cowl crossbar according to the prior art (1). The prior art cowl crossbar usually uses a base frame (10, 12) made of metal.

[0007] Several metal bars are joined together to form a base frame (10, 12), and the base frame (10, 12) is fixed to the body frame. In addition, various electrical components are mounted on the base frame (10, 12).

[0008] The base frame (10, 12) may be connected to the body frame through auxiliary parts such as guide brackets (20, 22) or center brackets (24, 26), or may be combined with a cowl box (30, 32, 34). In addition, the structural stability between the guide brackets (20, 22) and / or center brackets (24, 26) was also increased by using supporters (40, 42).

[0009] Korean Patent No. 10-1691965 (hereinafter referred to as "Related Technology 1") discloses a "cowl crossmember." Related Technology 1 proposes an improved bracket structure that allows for more rigid connection of main pipes. While this improves the structural rigidity of the cowl crossmember, it still has a complex structure comprised of numerous components, as illustrated in Fig. 2. Furthermore, because the main components must be made of metal, it suffers from the disadvantage of being relatively heavy.

[0010] As shown in Fig. 3, a welding process was essential to firmly connect a bracket or cowl box (30, 32, 34) to a metal base frame (10, 12), and melting spots (W) formed at various locations of the product deteriorated the assembly quality.

[0011] Therefore, there was a need to propose a technology to solve these problems.

[0012] One object of the present invention is to solve the problem of the prior art in that the conventional cowl crossbar was made of metal and thus required a press forming process to create a shape for each part, and multiple welding processes were also required, making the manufacturing process complicated.

[0013] Another object of the present invention is to solve the problem of conventional cowl crossbars, which were relatively heavy and bulky due to the use of heavy metal to ensure durability.

[0014] Another task of the present invention is to solve the problems of the prior art in which the number of parts is large and the assembly is complex, resulting in various design restrictions.

[0015] The tasks of the present invention are not limited to those mentioned above, and other tasks or purposes not mentioned can be understood through the following description.

[0016] According to one embodiment of the present invention, a device for manufacturing an eco-friendly, ultra-light cowl crossbar includes a main hopper, a mixing extruder, a melting heater, a foaming injection mold, and a cooling and curing device. The main hopper is an inlet into which a polymer composite base material and a foaming agent that forms foam in the base material are introduced. The mixing and extruding device transports the base material and the foaming agent introduced into the main hopper in a predetermined direction and mixes them. The melting heater is provided in the mixing extruder to heat and melt the material to be extruded. The foaming injection mold includes a master mold and an action core. A cavity, which is a space corresponding to the outer shape of a molded part, is formed between the master mold and the action core, and the master mold is connected to the mixing extruder and includes an injection nozzle, which is an inlet through which the molten material is injected into the cavity. The cooling and curing device cools the master mold and the core mold. In addition, the master mold includes a variable mold that forms at least a portion of the cavity and is translated in the direction of the action core.

[0017] Alternatively, in a device for manufacturing an eco-friendly, ultra-light cowl crossbar according to one embodiment of the present invention, the foam injection mold is moved back and forth in a straight line so that the action core approaches or moves away from the reference mold.

[0018] And, in a device for manufacturing an eco-friendly, ultra-light cowl crossbar according to one embodiment of the present invention, a variable mold protrudes forward in conjunction with the movement of an action core to maintain the shape of the cavity, and returns toward a reference mold to control the volume of the cavity.

[0019] Alternatively, in a device for manufacturing an eco-friendly, ultra-light cowl crossbar according to one embodiment of the present invention, the variable mold moves toward the reference mold when the pressure inside the cavity is higher than a predetermined value.

[0020] A method for manufacturing an eco-friendly, ultra-light cowl crossbar according to one embodiment of the present invention includes an injection step of injecting a base material, which is a polymer composite material, and a foaming agent that forms foam in the base material into a main hopper at a predetermined ratio, a mixing step of heating and mixing the base material and the foaming agent, a conveying step of extruding the mixed material in a predetermined direction, an injection step of injecting the mixed material into a foam injection mold, a primary curing step of cooling the mixed material filled in a cavity within the foam injection mold, a core back step of moving an action core of the foam injection mold to increase the volume of the cavity, a secondary curing step of additionally injecting the mixed material into the cavity and cooling it, and an extraction step of taking out a molded part from the foam injection mold.

[0021] And, in a method for manufacturing an eco-friendly ultra-light cowl crossbar according to one embodiment of the present invention, the core back step includes an action core moving step in which the action core moves a predetermined distance in a direction away from a reference mold.

[0022] Alternatively, in a method for manufacturing an eco-friendly ultra-light cowl crossbar according to one embodiment of the present invention, the core back step includes a cavity moving step in which the action core and the variable mold move a predetermined distance away from the reference mold, a pressurizing step in which additional mixed material is injected into the cavity, and a cavity expansion step in which the variable mold returns toward the reference mold when the pressure inside the cavity is higher than a predetermined value.

[0023] According to the present invention, by providing a technology capable of producing a cowl crossbar of complex shape in one piece, there is an effect of significantly reducing the time, manpower, and cost required for the process.

[0024] According to the present invention, environmental pollution can be prevented by manufacturing parts using eco-friendly composite materials.

[0025] According to the present invention, by producing an integrated cowl crossbar using an eco-friendly composite material through an injection molding process, the degree of freedom in design is increased, and thereby a more efficient structure can be applied to an actual product.

[0026] According to the present invention, by using an eco-friendly composite material, the number of parts and the mass per unit volume are significantly reduced.

[0027] The effects of the present invention are not limited to those mentioned above, and other effects not mentioned will be clearly understood by those skilled in the art from the description below.

[0028] Figures 1 to 3 are perspective views showing a cowl crossbar manufactured according to conventional technology.

[0029] FIGS. 4 and 5 are front and rear perspective views showing a cowl crossbar manufactured using an ultra-light cowl crossbar manufacturing device according to one embodiment of the present invention.

[0030] Figure 6 is a schematic diagram briefly showing a manufacturing device for an ultra-light cowl crossbar according to one embodiment of the present invention.

[0031] FIG. 7 and FIG. 8 are partial cross-sectional views illustrating the structure and operating state of an injection mold in a device for manufacturing an ultra-light cowl crossbar according to one embodiment of the present invention.

[0032] Figure 9 is a partial cross-sectional view of a cowl crossbar manufactured using an ultra-light cowl crossbar manufacturing device according to one embodiment of the present invention.

[0033] Figure 10 is a flowchart showing a method for manufacturing a cowl crossbar using a device for manufacturing an ultra-light cowl crossbar formed as an integral body according to one embodiment of the present invention.

[0034] Hereinafter, embodiments disclosed in this specification will be described in detail with reference to the attached drawings. Identical or similar components are assigned identical or similar drawing reference numerals, and redundant descriptions may be omitted.

[0035] When a component is said to be "connected" or "connected" to another component, it means that the component may be directly connected or connected to the other component, or that there may be other components in between. Conversely, when a component is said to be "directly connected" or "directly connected," it means that there are no other components in between.

[0036] In this specification, the terms “include” or “have” indicate the presence of features, steps, operations, components, parts or combinations thereof described in the specification, but do not exclude any of them.

[0037] The first direction (X), second direction (Y), and third direction (Z) described in this specification represent each dimension and directionality on a three-dimensional coordinate system used to express a three-dimensional shape. Therefore, the first direction (X), second direction (Y), and third direction (Z) each mean directions determined in mutually orthogonal dimensions.

[0038] The present invention discloses a cowl crossbar (100) made of an eco-friendly composite material for a vehicle, a manufacturing device for manufacturing the same, and a manufacturing method for manufacturing the same.

[0039] The cowl crossbar (100) is a component installed at the boundary between the engine compartment and the interior of a vehicle. The cowl crossbar (100) serves as a load-bearing bar that secures the steering system to the vehicle body. It also connects the vehicle frame across the left and right sides, preventing the body from twisting or leaning. Various electrical components can be installed on the cowl crossbar (100).

[0040] A manufacturing device and a manufacturing method according to one embodiment of the present invention are each proposed to manufacture an integral cowl crossbar (100) made of an eco-friendly composite material through injection molding.

[0041]

[0042] Describes the manufacturing device for an eco-friendly, ultra-light cowl crossbar.

[0043] FIG. 4 and FIG. 5 are front perspective views and rear perspective views showing a cowl crossbar (100) manufactured using a manufacturing device for an ultra-light cowl crossbar (100) according to one embodiment of the present invention.

[0044] As shown in FIGS. 4 and 5, a manufacturing device according to one embodiment of the present invention is a device for manufacturing a cowl crossbar (100) formed as an integral body.

[0045] A plurality of bolt (B) joints that can be connected to the body with bolts (B) can be formed in the cowl crossbar (100).

[0046] In addition, the cowl crossbar (100) made of an eco-friendly composite material can be elastically deformed within a limited range, and at least a portion of it can be formed into a form that is forcibly fitted by external force when combined with a vehicle body or electrical components.

[0047] The cowl crossbar (100) includes an exposed surface (110), which is a surface exposed to the outside, and a reinforced surface (120), which is a portion that is not exposed when attached to the vehicle body. A separate process may be further performed on the exposed surface (110) to improve aesthetics. A plurality of reinforcing walls may be formed on the reinforced surface (120) to improve the structural rigidity and durability of the cowl crossbar (100).

[0048] Figure 6 is a schematic diagram briefly showing a manufacturing device for an ultra-light cowl crossbar (100) according to one embodiment of the present invention.

[0049] As illustrated in FIG. 6, a manufacturing device for an ultra-light cowl crossbar (100) according to one embodiment of the present invention includes a main hopper (200), a mixing extruder (300), a melting heater, a foaming injection mold (400), and a cooling curing machine.

[0050] The main hopper (200) is an inlet into which a base material (S1) and a foaming agent (S2) are introduced. The base material (S1) may be a polyolefin (PO) resin composition, which is an organic compound having multiple double bonds and is a polymer composite material. This is merely exemplary and does not limit the components of the base material (S1) introduced into the manufacturing device according to the present invention.

[0051] The parent material (S1) may be a thermoplastic polyolefin (TPO) resin composition.

[0052] The base material (S1) may be a resin composition composed of an isotactic polypropylene resin, an atactic polypropylene resin, an inorganic filler, and a rubber, as disclosed in Korean Patent No. 10-1720714, ‘Method for manufacturing automotive interior materials using polyolefin resin composition and automotive interior materials manufactured thereby.’

[0053] The isotactic polypropylene resin may be composed of at least one selected from the group consisting of homo-polypropylene (Homo-PP), a random copolymer in which a comonomer selected from the group consisting of propylene, ethylene, butylene, and octene is neutralized, and a block copolymer in which ethylene-propylene rubber is blended with polypropylene.

[0054] The atactic polypropylene resin may have an Mw of 100,000 to 2 million g / mol, and more specifically, may be limited to 200,000 to 1.5 million g / mol.

[0055] Inorganic fillers are added to reinforce rigidity. The manufacturing device according to one embodiment of the present invention does not limit the components of the inorganic filler. However, for example, the inorganic filler may be at least one selected from among talc, calcium carbonate, calcium sulfate, magnesium oxide, calcium stearate, willastonite, mica, silica, calcium silicate, nanoclay, whiskers, glass fiber, carbon fiber, graphite, graphene, and carbon.

[0056] A manufacturing device according to one embodiment of the present invention does not limit the components of the rubber.

[0057] Additionally, the parent material (S1) may contain one or more additives such as an antioxidant, a UV stabilizer, a flame retardant, a colorant, a plasticizer, a heat stabilizer, and a slip agent.

[0058] The parent material (S1) is fed into the main hopper (200) in a crushed state. In addition, the crushed powdered parent material (S1) is composed only of particles smaller than a certain size.

[0059] The foaming agent (S2) may be composed of thermally expandable microcapsules.

[0060] The main hopper (200) includes an inlet facing upward, and the body connected to the inlet may be formed to have a passage that becomes narrower toward the bottom or to have a series of paths.

[0061] Additionally, multiple inlets can be formed in the main hopper (200), and the base material (S1) and the foaming agent (S2) can be separately introduced.

[0062] The main hopper (200) guides the base material (S1) and the foaming agent (S2) to the mixing extruder (300).

[0063] The main hopper (200) may include a mixing ratio controller. The mixing ratio controller controls the weight ratio of the base material (S1) and the foaming agent (S2) fed to the mixing extruder (300). In a manufacturing device according to one embodiment of the present invention, the main hopper (200) feeds a mixed material composed of 95 to 97 wt% of the base material (S1) and 3 to 5 wt% of the foaming agent (S2) into the mixing extruder (300).

[0064] The mixing extruder (300) includes a conveying pipe (310) having a passage formed therein and a conveying screw (320) provided inside the conveying pipe (310) to mix the mixed material and convey it in one direction.

[0065] The conveying pipe (310) may be formed as a cylindrical pipe. The conveying pipe (310) may be formed straight in one direction, and may be arranged to slope upward or downward.

[0066] The conveying screw (320) is installed in the internal passage of the conveying pipe (310). The conveying screw (320) may include a rotation axis arranged parallel to an imaginary straight line drawn along the longitudinal direction of the conveying pipe (310) and a guide vane formed on the outer circumference of the rotation axis.

[0067] The guide vane may be a rotating blade formed in a spiral shape along the outer circumference of the rotating shaft.

[0068] Alternatively, it could be implemented as a plurality of protruding blocks joined to a rotation axis.

[0069] The conveying screw (320) mixes the mixed material in a passage inside the conveying pipe (310) and extrudes and conveys it in a set direction.

[0070] The mixing extruder (300) is further equipped with a melting heater. The melting heater heats the mixed material introduced into the conveying pipe (310) to a predetermined temperature.

[0071] Specifically, the melting heater ensures that the mixed material, evenly mixed in the mixing extruder (300), is injected into the cavity in a molten state. However, before being injected into the cavity, the temperature and pressure inside the conveying pipe (310) are controlled to prevent bubbles from forming in the mixed material, which is a mixture of the base material (S1) and the foaming agent (S2).

[0072] The foam injection mold (400) includes a base mold (410) and an action core (430).

[0073] The reference mold (410) and the action core (430) have an engraved groove formed on one surface facing each other, corresponding to the outer shape of the molded part (P). When the reference mold (410) and the action core (430) are in contact with each other and are referred to as a closed state, a cavity, which is a space corresponding to the outer shape of the molded part (P), is formed at the contact surface of the reference mold (410) and the action core (430) in the closed state.

[0074] In a closed state, the mixed material passing through the mixing extruder (300) is injected into the cavity through the injection nozzle (412) formed in the standard mold (410) in a molten state.

[0075] The standard mold (410) and / or the action core (430) are equipped with a cooling hardening device that controls (specifically cools) the temperature inside the cavity.

[0076] A cooling hardener hardens a molten mixed material that fills a cavity by cooling it to a predetermined temperature.

[0077] The action core (430) can be translated relative to the reference mold (410).

[0078] That is, the action core (430) can be moved back and forth in a straight line to move away from or closer to the reference mold (410).

[0079] The linear reciprocating movement of the action core (430) can be utilized to secure space for taking out a molded part (P) in a cured state. In addition, it can also be utilized for core-back, in which a high-density surface layer (510) is formed through a cooling curing machine while a molten mixed material is injected into a cavity, and then the action core (430) is pulled back from the standard mold (410) to form a foam layer (520) on one surface of the surface layer (510).

[0080] The foam injection mold (400) may further be equipped with a detection sensor for measuring the temperature and pressure inside the cavity. The action core (430) may be moved core-back as described above when the temperature and / or pressure inside the cavity exceeds a predetermined value.

[0081] Additionally, after the core-back movement of the action core (430), if the temperature and / or pressure inside the cavity is below a predetermined value, the action core (430) is stopped and the cooling hardener operates.

[0082] Through a series of processes such as this, a high-density surface layer (510) can be formed on both sides, and a relatively light foam layer (520) can be formed between the surface layers (510).

[0083] FIG. 7 and FIG. 8 are partial cross-sectional views for explaining the structure and operating state of an injection mold in a manufacturing device for an ultra-light cowl crossbar (100) according to one embodiment of the present invention.

[0084] As shown in FIGS. 7 and 8, in a manufacturing device according to one embodiment of the present invention, the foam injection mold (400) may further include a variable mold (420).

[0085] The variable mold (420) may be provided on the surface facing the action core (430) as a part of the standard mold (410).

[0086] The variable mold (420) can be formed by including the surface of the reference mold (410) that forms a cavity together with the action core (430).

[0087] The variable mold (420) can move forward and protrude from the standard mold (410) or move backward and come into contact with the standard mold (410).

[0088] When the action core (430) is retracted from the reference mold (410) and moves the core-back, the variable mold (420) can move at the same speed and direction as the action core (430).

[0089] That is, the volume and shape of the cavity can be maintained as is through the linked operation of the variable mold (420) even when the core-back movement of the action core (430) occurs.

[0090] The variable mold (420) can be connected to the standard mold (410) by a guide member (422). The variable mold (420) can move forward or backward from the standard mold (410) along the guide member (422), and the guide member (422) can press the variable mold (420) forward with a predetermined force.

[0091] That is, when the action core (430) retreats from the reference mold (410) through core-back movement, the variable mold (420) moves together with the action core (430) at the same speed and direction to maintain the cavity.

[0092] When a molten mixed material is injected into the cavity from the injection nozzle (412), the pressure inside the cavity increases, and when the pressure inside the cavity is higher than a predetermined value, the variable mold (420) returns toward the reference mold (410). When the variable mold (420) moves toward the reference mold (410), the volume inside the cavity increases, and the mixed material forms a foam layer (520) inside the cavity.

[0093] When the variable mold (420) comes into contact with the standard mold (410) and the pressure inside the cavity increases again, the cooling hardening machine operates so that both sides of the molded part (P) in contact with the variable mold (420) and the action core (430) form a surface layer (510) with a relatively high density.

[0094] FIG. 9 is a partial cross-sectional view of a cowl crossbar (100) manufactured using a manufacturing device for an ultra-light cowl crossbar (100) according to one embodiment of the present invention.

[0095] FIG. 9 schematically illustrates a cross-section of an ultra-light cowl crossbar (100) that can be manufactured through a manufacturing device according to one embodiment of the present invention.

[0096] The ultra-light cowl crossbar (100) has a surface layer (510) with high rigidity due to its high material density formed on both exposed surfaces. In addition, a foam layer (520) is formed between the surface layers (510), and the foam layer (520) firmly supports the surface layers (510) while also containing a large number of pores (S), thereby enabling the molded part (P) to be lightweight.

[0097]

[0098] This explains the manufacturing method of an eco-friendly, ultra-light cowl crossbar (100).

[0099] FIG. 10 is a flowchart showing a method for manufacturing a cowl crossbar (100) using a manufacturing device for an ultra-light cowl crossbar (100) formed as an integral body according to one embodiment of the present invention.

[0100] As illustrated in Fig. 10, a method for manufacturing an eco-friendly, ultra-light cowl crossbar (100) using the aforementioned manufacturing device includes an input step of inputting a base material (S1), which is a polymer composite material, and a foaming agent (S2), which is an additive that forms foam in the base material (S1), into a main hopper (200) at a predetermined ratio.

[0101] Each inlet and path through which the base material (S1) and the foaming agent (S2) are introduced can be separated inside the main hopper (200).

[0102] The main hopper (200) may be equipped with a mixing ratio controller that adjusts the weight ratio of the base material (S1) and the foaming agent (S2) to a predetermined weight ratio, and in the feeding stage, the mixing ratio controller controls the weight ratio of the fed base material (S1) and the foaming agent (S2) to form a mixed material.

[0103] The base material (S1) and the foaming agent (S2) are mixed in a predetermined weight ratio, and in the mixing step, the mixed material is injected into a mixing extruder, heated, and mixed.

[0104] The conveying step may be performed together with the mixing step. In the conveying step, the mixed material is extruded along a predetermined direction.

[0105] In the injection stage, the mixed material is injected into the foam injection mold (400) in a molten state.

[0106] The first curing step is a step of cooling and curing the mixed material injected into the cavity to form a surface layer (510) of a predetermined thickness.

[0107] The core back step includes an action core (430) moving step. The action core (430) moving step is a step for increasing the volume of the cavity by retracting (moving) the action core (430) of the foam injection mold (400) from the reference mold (410). Even in the core back step, the molten mixed material is continuously injected into the cavity, and the action core (430) moves at a low speed, so that a foam layer (520) having a predetermined thickness is formed on one surface of the surface layer (510) generated through the first curing step.

[0108] The secondary curing step additionally injects molten mixed material into the cavity and cools both sides of the molded part (P) in contact with the reference mold (410) and the action core (430) or the reference mold (410) to form a surface layer (510).

[0109] The extraction step is a step of taking out a molded part (P) from a foam injection mold (400), wherein the base mold (410) and the action core (430) are sufficiently spaced apart, and the molded part (P) is separated from the base mold (410) and / or the action core (430) in a state where molding and hardening are completed.

[0110] Additionally, in a manufacturing method according to another embodiment of the present invention, the core back step may include a cavity movement step, a foam layer (520) forming step, and a cavity expansion step.

[0111] The cavity movement step is a step in which the action core (430) and variable mold (420) move a predetermined distance away from the reference mold (410) and the space formed by the cavity moves.

[0112] And, in the pressurization step, additional mixed material is injected into the cavity, and the pressure inside the cavity increases.

[0113] When the pressure inside the cavity increases through the pressurization step and reaches a pressure higher than a predetermined value, the variable mold (420) returns to its original position toward the reference mold (410). That is, the pressure inside the cavity remains lower than the predetermined value, and the volume of the space formed by the cavity expands. Accordingly, the additionally injected mixed material forms a foam layer (520) containing pores (S).

[0114] When the variable mold (420) comes into contact with the standard mold (410) and the space inside the cavity cannot be expanded, the injection nozzle (412) adjusts the input of the mixed material so that the pressure inside the cavity is maintained at a predetermined value. The inside of the cavity is maintained at the predetermined pressure value, and the cooling hardener operates so that a surface layer (510) is formed on both sides of the molded part (P) that comes into contact with the variable mold (420) and / or the action core (430).

[0115] Embodiments of the present invention have been described above with reference to the drawings. These are merely exemplary, and the present invention is not limited to the above-described embodiments and the contents of the drawings.

[0116] It will be apparent to those skilled in the art that modifications to the present invention can be made within the scope of the disclosed technical concept. The described embodiments should be considered part of the present invention, and the scope of the present invention should not be limited to the described embodiments.

[0117] The scope of the present invention should be determined by the technical concepts described in the claims. Furthermore, even if the functions or effects of a specific configuration are not explicitly described in the description of embodiments of the present invention, it is self-evident that any functions or effects foreseeable by that configuration should be recognized as part of the present invention.

Claims

1. A main hopper into which a polymer composite material base material and a foaming agent that forms foam in the base material are injected; A mixing extruder in which the base material and the foaming agent fed into the main hopper are transported in a predetermined direction and mixed; A melting heater equipped in the above mixing extruder to heat and melt the material to be extruded; A foam injection mold, wherein a cavity, which is a space corresponding to the outer shape of a molded part, is formed between a base mold and an action core, and the base mold is connected to the mixing extruder and includes an injection nozzle, which is an inlet through which a molten material is injected into the cavity; and Including a cooling hardening device that cools the above-mentioned standard mold and the above-mentioned action core; The above standard mold is, A variable mold, which comprises at least a portion forming the cavity and is translated in the direction of the action core; An eco-friendly, ultra-light cowl crossbar manufacturing device.

2. In paragraph 1, The above foam injection mold is, The above action core moves back and forth in a straight line so as to approach or move away from the above reference mold. An eco-friendly, ultra-light cowl crossbar manufacturing device.

3. In paragraph 2, The above variable mold is, In conjunction with the movement of the above action core, it protrudes forward to maintain the shape of the cavity, and returns toward the reference mold to control the volume of the cavity. An eco-friendly, ultra-light cowl crossbar manufacturing device.

4. In paragraph 3, The above variable mold is, When the pressure inside the cavity is greater than a predetermined value, moving toward the reference mold, An eco-friendly, ultra-light cowl crossbar manufacturing device.

5. A feeding step of feeding a polymer composite material, which is a parent material, and a foaming agent that forms foam in the parent material into the main hopper at a predetermined ratio; A mixing step of heating and mixing the above-mentioned parent material and the above-mentioned foaming agent; A conveying step for extruding mixed materials in a predetermined direction; An injection step of injecting the above mixed material into a foam injection mold; A first curing step of cooling the mixed material filled in the cavity inside the foam injection mold; A core back step for increasing the volume of the cavity by moving the action core of the foam injection mold; A secondary curing step of additionally injecting the mixed material into the cavity and cooling it; and Including a step of taking out a molded part from the foam injection mold; How to make an eco-friendly, ultra-light cowl crossbar.

6. In paragraph 5, The above core back step is, An action core moving step in which the action core moves a predetermined distance away from the reference mold; How to make an eco-friendly, ultra-light cowl crossbar.

7. In paragraph 5, The above core back step is, A cavity movement step in which the action core and variable mold move a predetermined distance away from the reference mold; A pressurizing step of additionally injecting the mixed material into the cavity; and A cavity expansion step in which the variable mold returns toward the reference mold when the pressure inside the cavity is higher than a predetermined value; How to make an eco-friendly, ultra-light cowl crossbar.

Images