Impact Reinforcement Component and Method for Manufacturing Same

The present disclosure relates to an impact reinforcement component and a method for manufacturing the same, and specifically, to an impact reinforcement component with reinforced rigidity to prepare for an impact, such as a sheet cross member, and a method for manufacturing the same.

A Roll stamping technology is a technology which is disclosed in previously registered patents: Roll Stamping Device (Registration No. 10-1417278), Roll Stamping Device (Registration No. 10-1786260), and Roll Stamping Device and Method (Registration No. 10-1917450).

The core of roll stamping technology is to manufacture components of which a cross-section changes in a longitudinal direction using a roll forming device.

However, it is impossible to manufacture components with shape changes in the longitudinal direction while using the conventional roll forming method. Therefore, it is common to manufacture using press molding with a mold. However, when the strength of the material is high, forming of large-sized components requires a very high press capacity, making manufacturing thereof difficult.

Therefore, roll stamping is a useful technology that can solve such limitations. However, since roll stamping is basically a technology using a roll forming device, it is not easy to be applied realistically when there is a change in shape in the longitudinal direction of an elongated component. That is, since the shape of the component in the longitudinal direction should be engraved around a stamping roll, when the length of the component is relatively long, a diameter of the stamping roll should be increased. Such an increase in the diameter of the stamping roll leads to a problem in which the roll forming device should be significantly enlarged as a whole, so it is difficult to be applied realistically in terms of installation space.

The present disclosure is provided to solve the above problems, and an aspect of the present disclosure is to provide an impact reinforcement component that can be manufactured by roll stamping without increasing a diameter of a stamping roll when manufacturing components with an elongated material and a method for manufacturing the same.

According to an aspect of the present disclosure, an impact reinforcement component includes: a component body having side walls on both sides thereof in a longitudinal direction and an upper plate connecting upper ends of the side walls on both sides; and an end flange formed by being bent at each of both ends of the component body in the longitudinal direction, wherein the component body is formed by continuous repetition of roll stamping in which a stamping roll rotates multiple times and presses a material, and the component body includes a body portion having beads formed on an upper plate thereof in a longitudinal direction; and a boundary portion which is integrated with the body portion and the end flange, as a connecting portion between the body portion and the end flange, and has a flat upper plate.

Here, the body portion may include a plurality of bead regions located to be spaced apart from each other in a longitudinal direction and having the beads formed on an upper plate thereof; and a middle beadless region located between the plurality of bead regions and having a flat upper plate.

In the case, in the bead region, the plurality of beads may be disposed on the upper plate to be spaced apart from each other in a width direction.

In addition, a longitudinal length of the middle beadless region may be equal to or greater than twice a longitudinal length obtained by adding the boundary portion and the end flange.

Meanwhile, according to another aspect of the present disclosure, a method for manufacturing an impact reinforcement component is provided, the method including: a roll stamping operation of continuously repeating roll stamping in which a stamping roll rotates multiple times and presses a material in a longitudinal direction; and a flange forming operation of bending each of both ends of the material to form an end flange, wherein in the roll stamping operation, a plurality of bead regions are formed in the material, a middle beadless region is formed between the plurality of bead regions, and an end beadless region is formed at each of both ends.

Specifically, the roll stamping operation includes a full bending process in which the stamping roll rotates multiple times and presses the material, to bend the material to form side walls on both sides and an upper plate; a first end beadless process of forming a flat upper plate at one end of the material in a longitudinal direction to form the end beadless region; a bead process of forming a plurality of beads on an upper plate of the material to be spaced apart from each other in the longitudinal direction to form the plurality of bead regions; a middle beadless process of forming a flat upper plate between the plurality of beads to form the middle beadless region; and a second end beadless process of forming a flat upper plate at the other end of the material in the longitudinal direction to form the end beadless region, wherein the first end beadless process, bead process, middle beadless process, and second end beadless process may be performed during the full bending process, and the middle beadless process may be performed during the bead process.

In this case, a longitudinal length of the middle beadless region formed by the middle beadless process may be equal to or greater than twice a longitudinal length of the end beadless region formed by the first end beadless process or the second end beadless process.

As set forth above, in the impact reinforcement component, as a component body is formed by continuous repetition of roll stamping in which a stamping roll rotates multiple times and presses a material, a bead region is formed in a body portion of the component body, and a boundary portion having a beadless region extends from the body portion thereof and is connected to an end flange, which is integrated with the body portion and the end flange, rigidity may be reinforced by the bead region of the body portion, and at the same time, bending deformation of the end flange by the beadless region of the boundary portion is formed smoothly and easily.

In the method for manufacturing an impact reinforcement component according to the present disclosure, a roll stamping operation in which a stamping roll rotates multiple times and presses a material in a longitudinal direction may be performed, so that a component having a very long length may be manufactured without increasing a diameter of the stamping roll by configuring the component so that a change in shape thereof in the longitudinal direction is periodically repeated, and the boundary portion described above may be easily formed.

Hereinafter, preferred embodiments of the present disclosure will be described in detail so that those skilled in the art could easily practice the present disclosure with reference to the accompanying drawings. However, in describing a preferred embodiment of the present disclosure in detail, if it is determined that a detailed description of a related known function or configuration may unnecessarily obscure the subject matter of the present disclosure, the detailed description will be omitted. In addition, the same reference numerals are used throughout the drawings for parts having similar functions and actions. In addition, in the present specification, terms such as ‘upper,’ ‘upper portion,’ ‘upper surface,’ ‘lower,’ ‘lower portion,’ ‘lower surface,’ ‘side surface,’ and the like are based on the drawings, and in practice, it may be different depending on a direction in which the components are disposed.

In addition, throughout the specification, when a part is said to be ‘connected’ to another part, this is not only when it is ‘directly connected,’ but also when it is ‘indirectly connected’ with other components therebetween. In addition, ‘including’ a certain component means that other components may be further included without excluding other components unless otherwise stated.

is a diagram illustrating a sheet cross member according to the prior art.

Referring, a sheet cross memberis a reinforcement component provided in preparation for an impact in a vehicle, that is, an impact reinforcement component, and is disposed below the vehicle.

Such a sheet cross memberhas a hat-shaped cross-section and comprises one unit component.

Such a sheet cross membermay be manufactured by roll forming as there is no change in cross-sectional shape in a longitudinal direction. That is, the sheet cross membermay be welded to a seal sideby creating a flangethrough post-processing at both ends of a roll forming component.

However, a structure simply formed of both side wallsand a flat upper platehas a limitation in that it lacks reinforcement against impacts.

To overcome such a limitation, although not shown in the drawings, a sheet cross member including a bead (a portion raised relatively compared to other portions) may be formed on an upper plate thereof.

However, when beads are formed on an entire upper plate in a longitudinal direction, that is, when beads are formed elongated to both ends in the longitudinal direction, it becomes very difficult to form a flange which is deformed by being bent during the manufacturing process.

In other words, an end of the sheet cross member is not a simple hat-shaped cross-section, but has a complex cross-sectional shape with a cross-sectional edge which is bent several times due to the beads, it becomes significantly difficult that the end is deformed by being bent to form a flange.

Accordingly, in order to form a simple hat-shaped cross-sectional structure without beads only at the end of the sheet cross member, the sheet cross member is composed of a plurality of unit components rather than one unit component. That is, the unit component with a beaded structure and a separate unit component having a simple hat-shaped cross-sectional structure without beads may be connected to each other (bonded by welding, or the like), to form a sheet cross member.

However, in the case of a simple model cross-sectional structure without beads at an end thereof, it is easy to form a flange by bending and changing the end thereof, but when a sheet cross member is created by combining a plurality of unit components, which are not integrated, the rigidity of a portion to which unit components are connected (for example, a welded portion) is relatively low compared to other portions, so there is a problem of being used as an impact reinforcement component.

is a diagram illustrating an impact reinforcement component according to the present disclosure,is an enlarged view illustrating A in, andis an enlarged view illustrating B in.

Referring to the, the impact reinforcement componentaccording to the present disclosure, in order to solve the above-described problem, a boundary portionhaving a simple cross-sectional structure without a bead (a portion raised upwardly relatively compared to other portions) may be formed at an end thereof, and the boundary portionis composed of an integrated structure rather than a member separate from other portions.

Specifically, the present disclosure includes a component bodyand an end flange.

The component bodyis formed by continuous repetition of roll stamping in which a stamping roll rotates multiple times and presses a material.

The component bodymanufactured through this method has structurally, side walls S formed on both sides in a longitudinal direction, and an upper plate U connecting upper ends of both side walls S.

The end flangeis formed by being bent at each of both ends of the component bodyin the longitudinal direction. The end flangeis a portion welded to another component, such as a sill side, as an example.

Here, the component bodyincludes a body portionand a boundary portion.

The body portionhas a beadformed on an upper plate U in a longitudinal direction.

In addition, the boundary portionis a connecting portion between the body portionand the end flangeand is integrated with the body portionand the end flange.

In this case, the upper plate U of the boundary portionhas a flat structure without beads. The boundary portionis a portion having a substantially short length, and is the same portion as a boundary line between the body portionand the end flange.

More specifically, the body portionincludes a bead regionand a middle beadless region.

The plurality of the bead regionsare located to be spaced apart from each other in a longitudinal direction, and a beadis formed on the upper plate U. That is, the bead regionis formed elongated in the longitudinal direction, and since there is a middle beadless region in the middle, a plurality of bead regionsis located to be spaced apart from each other. As an example, as illustrated in the drawings, two bead regions may be disposed to be spaced apart from each other.

A plurality of bead regionsdisposed to be spaced apart in the longitudinal direction as described above are formed by being manufactured using roll stamping as described in a method for manufacturing a component to be described later. That is, the material is rotated and pressed multiple times by the stamping rolls, a plurality of beadsare formed to be spaced apart in the longitudinal direction.

Furthermore, in the bead region, a plurality of beadsmay be arranged on an upper plate U to be spaced apart from each other in a width direction. As described above, when the plurality of bead areasare disposed to be spaced apart in the width direction, the rigidity of the impact reinforcement componentis increased.

In addition, the middle beadless regionis located between the plurality of bead regions, and has a flat upper plate U.

As described above, a plurality of bead regionsare disposed in the body portionto be spaced apart from each other in the longitudinal direction, and a middle beadless regionhaving a flat upper plate U is formed between the plurality of bead regions, which are spaced apart from each other.

The stamping roll has a concavo-convex structure to form the beadand has a flat portion to form the boundary portion, and when a size (diameter) of the stamping roll is appropriate considering various factors such as an installation space, in order to manufacture a long impact reinforcement component, as it is rotated and pressed multiple times, a middle beadless regionhaving a flat upper plate U is formed like the boundary portion.

That is, due to the same structure as the middle beadless region, the impact reinforcement componentof the present disclosure may be implemented through a manufacturing method in which a stamping roll rotates multiple times and presses a material.

The boundary portionis located at each of both ends of the component bodyin the longitudinal direction, and is a portion having a flat upper plate U and is a portion, the same as a boundary line of the end flange, which may allow an end flangeto be formed smoothly and easily when formed by being bent.

The end flangehas a structure extending integrally from the boundary portionbefore deformed by being bent. Since the boundary portionhas a simple hat-shaped cross-sectional structure without a bead, bending deformation of the end flangemay be smoothly and easily achieved.

In the present disclosure, in a manufacturing method in which a stamping roll rotates multiple times, a longitudinal length of the middle beadless regionis equal to or greater than twice a longitudinal length obtained by adding the boundary portionand the end flange.

When manufacturing a plurality of impact reinforcement componentswith a set length using a long material, since the material is roll stamped and then cut and divided to form a plurality of impact reinforcement components, a length of the middle beadless regionshould be twice a length obtained by adding the boundary portion, an end beadless regionhaving a flat upper plate U and the end flange, and since a portion thereof may be lost during cutting, in consideration of forming a sufficient end flange, the length of the middle beadless regionmay be more than twice the length thereof.

is a flow chart illustrating a method for manufacturing an impact reinforcement component according to the present disclosure, andis a flow chart illustrating a roll stamping operation in the method for manufacturing the impact reinforcement component of.