Cowl Crossbar Pipe Manufacturing with Compression Molding
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Solution Overview
Problem
The manufacturing of cowl crossbar pipes for vehicles faces challenges in achieving increased rigidity while reducing weight, leading to higher production costs and complexity due to the need for separate large and small diameter sections with varying reinforcing material windings, which limits design flexibility.
Innovation Solution
The use of an extruder and compression molding machine with molds that form both large and small diameter sections from a combination of polypropylene (PP) and long glass fiber (LGF) materials, allowing for the creation of pipes with distinct rigidity and weight characteristics, and the incorporation of an insert bracket made of aluminum to enhance structural integrity and reduce weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If separate large-diameter and small-diameter pipes are manufactured and bonded through brackets, then weight is reduced and rigidity is improved in specific sections, but manufacturing cost and process complexity increase
Solution Approach 1:
The mold is divided into multiple cavities (first cavity for large-diameter section, second cavity for small-diameter section) that can form different pipe sections in a single manufacturing process, eliminating the need for separate pipe production and bonding operations while maintaining section-specific rigidity requirements
Solution Approach 2:
The patent combines multiple pipe sections (large-diameter and small-diameter) into a single integrated pipe structure manufactured in one process, merging what were previously separate components into one unified part that reduces assembly complexity and manufacturing cost
2Strength
If reinforcing materials are wound with varying ratios to adjust rigidity, then section-specific rigidity is achieved, but pipe bending capability is lost
Solution Approach 1:
The mold includes different cavity configurations (first cavity with first curvature radius, second cavity with second curvature radius) that allow different sections of the pipe to have different rigidity characteristics and bending capabilities suited to their specific functional requirements
Solution Approach 2:
The manufacturing process allows the pipe to be formed with varying curvature radii in different sections, enabling the pipe to dynamically adapt its shape and rigidity distribution according to the specific requirements of each section rather than having uniform properties throughout
3Weight of moving object
If multiple manufacturing processes are used for separate pipes, then weight reduction and rigidity optimization are achieved, but manufacturing cost increases
Solution Approach 1:
The patent merges multiple pipe sections into a single integrated manufacturing process using a mold with multiple cavities, eliminating the need for separate production and bonding operations while maintaining weight optimization through section-specific diameter control
Solution Approach 2:
The mold is designed as a multi-functional tool that can simultaneously produce different pipe sections with different diameters and curvature radii in a single operation, replacing multiple specialized manufacturing processes with one universal system
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables the production of pipes with improved rigidity and reduced weight, enhancing vehicle safety and design flexibility by allowing for the creation of pipes with specific thickness and shape profiles, while also reducing manufacturing complexity and costs.
Implementation Method 1
an extruder configured to receive a pipe material and extrude the pipe material
Implementation Method 2
a compression molding machine, configured to compress the pipe material extruded and form the pipe, including a hydraulic cylinder configured to form a hollow part at a center of the pipe material in longitudinal direction
Implementation Method 3
an upper mold configured to press an upper portion of the pipe material extruded, and a lower mold configured to press a lower portion of the pipe material extruded
Data Source
AI summary
An apparatus for manufacturing a pipe for a cowl crossbar disposed inside a vehicle body in a lateral direction, includes an extruder configured to receive a pipe material and extrude the pipe material; and a compression molding machine, configured to compress the pipe material extruded and form the pipe, comprising a hydraulic cylinder configured to form a hollow part at a center of the pipe material in a longitudinal direction.