JP2001247063A - Method of manufacturing vehicle door and door structure of vehicle - Google Patents

Abstract

PROBLEM TO BE SOLVED: To easily and properly mold a vehicle door by effectively improving a yield of plate materials used at door molding time. SOLUTION: After respectively molding a first plate material 11 for fixing a door hinge 9, a second plate material 12 for arranging a door lock 10 and third and fourth plate materials 13, 14 arranged between an upper end part and a lower end part of the first plate material 11 and the second plate material 12, both end parts of the third and fourth plate materials are welded and joined to side edge parts of the first and second plate materials 11, 12 to form a door inner panel 2 having an opening part 4 in the center. This door structure is formed of the door inner panel 2 and a door outer panel, and after forming a door module unit 25 by incorporating an accessory of a door into a module plate 5 for covering the opening part 4 of the door inner panel 2, the door module unit 25 is installed on the door inner panel 2.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a vehicle door and a vehicle door structure.

[0002]

2. Description of the Related Art Conventionally, for example, Japanese Utility Model Laid-Open No. 59-18242.
As disclosed in Japanese Patent Publication No. 4 (1994), the base material obtained by dividing the door inner panel (inner plate) and joining the cut-out pieces by laser welding is integrally formed, thereby partially forming the material of the split pieces. Change the plate thickness so that the right material can be selected in the right place, and use reinforcements using thicker pieces, split pieces made of high-tensile steel, etc. in places where strength is required. In addition, there is known a door inner panel structure which exhibits required structural characteristics to achieve weight reduction and cost reduction.

[0003]

In the case of the above construction, a door inner panel having required structural characteristics can be manufactured at a low cost by joining a plurality of plate members having the required strength. Can be. However, it is difficult to form a lower part of the door inner panel provided with a window regulator for driving the door glass up and down, various harnesses and cables, and a plurality of work holes by combining a plurality of plate members. For this reason, the main part of the door inner panel main body is formed of a single plate, and there is a problem that, despite the fact that the door inner panel is formed of a plurality of plate members, the yield of the board can not be improved so much. .

SUMMARY OF THE INVENTION The present invention has been made in view of the above points, and a vehicle door capable of easily and properly forming a vehicle door by effectively improving the yield of a plate material used in door molding. It is an object to provide a manufacturing method and a vehicle door structure.

[0005]

The invention according to claim 1 is
A first plate member to which a door hinge is fixed, a second plate member on which a door lock is installed, and third and fourth plate members disposed between upper and lower ends of the first and second plate members. After being formed, one end of each of the third and fourth plate members is welded to the side portion of the first plate member and joined to the side portion of the first plate member. By welding and joining the ends, a door inner panel having an opening at the center is formed, a door structure is formed by the door inner panel and the door outer panel, and the opening of the door inner panel is covered. After assembling the door accessories into the module plate to form the door module unit,
The door module unit is attached to a door inner panel.

According to the above construction, it is possible to easily form a door inner panel having a required strength by welding and joining the first to fourth plate members having predetermined lengths and widths. In addition, by attaching the door module unit formed in a separate process to a door inner panel, a vehicle door having various door accessories can be easily manufactured.

According to a second aspect of the present invention, in the method for manufacturing a vehicle door according to the first aspect, both ends of the third and fourth plate members are abutted on the side portions of the first and second plate members. Then, these butted portions are each laser-welded, at least the first step of the laser welding is straight welding, and at least the last step is weaving welding.

According to the above configuration, in the first stage of welding, the laser welding machine is moved straight,
While being able to perform the above welding work quickly,
In the final stage of welding, even when a gap is formed at the butted portion of each plate material due to a manufacturing error or thermal expansion at the time of welding, the gap is filled with the molten material generated at the time of the weaving welding. It is possible to ensure sufficient bonding strength.

According to a third aspect of the present invention, in the method for manufacturing a vehicle door according to the first or second aspect, after forming a plurality of door structures having an upper side or a lower side connected to each other, the upper side is formed. Alternatively, it is separated into a plurality of door structures by cutting a continuous portion on the lower side.

[0010] According to the above configuration, it is possible to simultaneously form a plurality of door inner panels formed of the first to fourth plate members having a required strength.

According to a fourth aspect of the present invention, there is provided a door inner panel having an opening formed in a central portion, a door outer panel which is joined to the door inner panel to form a door structure, and a door inner panel. A door module unit in which a door accessory is incorporated in a module plate attached to cover the opening, wherein the door inner panel is provided with a first plate member to which a door hinge is fixed, and a second plate member in which a door lock is installed. A first plate member disposed between an upper end portion and a lower end portion of the first plate member and the second plate member;
The third and fourth plates are welded to the inner side of the plate and the inner side of the second plate, respectively.

According to the above configuration, by joining the first to fourth plate members having predetermined lengths and widths, it becomes possible to easily form a door inner panel having a required strength, By attaching the door module unit formed in a separate process to the door inner panel, it becomes possible to easily manufacture a vehicle door having various door accessories.

[0013]

1 and 2 show an embodiment of a vehicle door structure according to the present invention. This door structure includes a door outer panel 1 disposed on an outer surface side of a vehicle door.
A door structure 3 composed of a door inner panel 2 disposed on the inner surface side (vehicle interior side) of the vehicle door; a module plate 5 attached so as to cover an opening 4 formed in the door inner panel 2; An impact bar 6 disposed between the door outer panel 1 and the door inner panel 2 so as to extend in the front-rear direction of the vehicle body; a door sash 7 disposed above the door structure 3; And a door trim member 8 arranged on the inner surface side of the door.

As shown in FIG. 2, the door inner panel 2 has a front side (a vehicle body front side) to which a door hinge 9 is fixed.
A first plate 11, a second plate 12 on the rear side (rear side of the vehicle body) on which the door lock 10 is installed, a first plate 11 and a second plate 12.
The third plate 13 is provided between the upper ends of the plate 12 and the fourth plate 14 is provided between the lower ends of the first and second plates 11 and 12. Then, the first plate 1
The front end portions of the third and fourth plate members 13 and 14 are welded to the side portions (rear side portions) of the first plate material 1, and the third and fourth plate materials 13 and 14 are connected to the side portions (front side portions) of the second plate material 12. By welding the rear ends of the four plate members 13 and 14, an opening 4 having a predetermined area is formed at the center.

The module plate 5 has a slightly larger area than the opening 4 of the door inner panel 2 and is made of a synthetic resin plate member having working holes 15 and 16 formed at predetermined positions. The peripheral portion is attached to the door inner panel 2 via an unillustrated engaging clip so as to cover the opening 4 from the inside.

After the assembling work of the door accessory to be described later is completed, as shown in FIG. 4, the unnecessary portions 5a formed at the time of molding the module plate 5 are cut off to form closing portions 15a and 16a. , This closing part 15
The work holes 15 and 16 are configured to be closed by fitting the work holes 15 and 16a into the work holes 15 and 16 and bonding them.

As shown in FIG. 3, the module plate 5 has a window regulator 18 for driving a window glass 17 up and down, and a door lock 10 for engaging a striker on the vehicle body side to lock the vehicle door in a locked state. , A speaker 19 for sound, a lock operation unit 20 for operating the door lock 10 from inside the vehicle, an inner handle 21 for opening and closing the door from the inside of the vehicle, and a harness 22 for electrical connection.
Door accessories consisting of etc. are assembled. Also,
A concave portion 23 for a door pocket and a door pad 24 for protecting an occupant in the event of a collision are integrally formed on the lower inner surface side of the module plate 5. The module plate 5 and the door accessories constitute a door module unit 25 attached to the door inner panel 2.

That is, at the central portion on the outer surface side of the module plate 5, a first mounting portion 26 to which the upper portion of the window regulator 18 is screwed is engaged, and an engagement portion to be fitted into an engagement hole provided in the window regulator 18. The second and third mounting portions 27 and 28 having a stopping protrusion and the fourth mounting portion 29 having a locking portion of a locking protrusion provided at a lower portion of the window regulator 18 are vertically fixed. They are provided at intervals (see FIG. 1).

As shown in FIG. 5, an installation hole 30 for the speaker 19 is provided in front of the lower portion of the module plate 5.
And a waterproof cover 31 that covers an upper part of the speaker 19. Further, as shown in FIG. 6, the door lock 10 is provided on the rear outer side of the module plate 5.
The door lock 10 housed in the housing part 32 is temporarily fixed to the module plate 5 by a screw 33. After the door module unit 25 is attached to the door inner panel 2, the door lock 10 is fixed to a predetermined position of the door inner panel 2.

On the inner side of the module plate 5,
Operation rods 35 and 36 for transmitting the operation force of the lock operation unit 20 and the inner handle 21 to the door lock 10.
Are integrally formed. As shown in FIG. 6, operation rods 35 and 36 extending rearward along the inner surface of the module plate 5 are provided on the outer side of the module plate 5 (outside of the vehicle). A through hole 39 for leading out is formed, and the operation rods 35 and 36 penetrating the through hole 39 are formed.
Is connected to the door lock 10.

Further, the module plate 5 includes:
As shown in FIG. 7, the support portions 41 and 42 of the harness 22 are disposed at predetermined positions, and the harness 22 connected to an electric component such as a drive motor disposed in a door mirror (not shown) is connected to the support portion 41. , 42. As shown in FIG. 1, the recess 23 formed in the center of the lower part of the module plate 5 and the door trim material 8
The lower part of the door pad constitutes a door pocket for storing an atlas and the like, and the rear side thereof has, as shown in FIG.
Are formed.

On the outer periphery of the module plate 5,
A concave portion for holding the filling foam type sealing material 43 is formed, and an elevating guide 45 for supporting the door glass 17 so as to be able to move up and down is integrally formed on the outer surface side of the module plate 5 as shown in FIG. Have been. Further, on the inner side of the center of the module plate 5, a protrusion 46 constituting a bottom of a recess for closing the vehicle door is provided.
(See FIG. 3).

A method for manufacturing a vehicle door having the above configuration is described below.
Description will be made based on the process chart shown in FIG. After the door outer panel 1 and the door inner panel 2 are formed on the door outer panel forming line and the door inner panel forming line, the door outer panel 1 and the door inner panel 2 are joined on the door forming line to form a door structure. Form 3

In the above-mentioned door inner panel forming line, as shown in FIG.
After each of the first to fourth plate materials 11a to 14a is formed, as shown in FIG. 12, one end of each of the third and fourth plate materials 13a and 14a is attached to the side of the first plate material 11a. In the abutted state, laser welding is performed by irradiating a laser beam from the laser welding machine 50 to the abutting portion to join the laser beam. Similarly, the third and fourth plate materials 13a, 14a are provided on the side portions of the second plate material 12a.
In the state where the other end of the a is abutted, laser welding is performed by irradiating a laser beam from the laser welding machine 50 to the abutted portion to join the abutting portion, so that the opening 4
Is formed.

In the case where the plate materials 11a to 14a have different thicknesses, for example, the first and second plate materials 11a and 12a may be used.
In the case where the thickness of “a” is larger than the thickness of the third and fourth plate materials 13a and 14a, the side end surfaces of the first and second plate materials 11a and 12a located above the abutting portion are provided. The butted portion is welded by irradiating a laser beam toward the portion and melting this portion. When the butted portion is melted in this manner, the corner portion is chamfered in an arc shape, so that during the press working described later, the machined portion of the press machine comes into contact with the corner portion and is worn or damaged. Can be effectively suppressed.

When joining the first to fourth sheet materials 11a to 14a by laser welding the butted portions,
At least the first step is straight welding for moving the laser beam straight along the welding direction, and at least the last step is weaving welding for moving the laser beam zigzag along the welding direction.

In this way, the first to fourth plate material 11
After forming the door inner panel material 2a composed of a to 14a, the door inner panel 2 having a predetermined shape is formed by press working. Then, the door inner panel 2, the door assembly 3 formed by the door inner panel 2, and the vehicle body manufactured in the vehicle body assembly line are transported to a painting line to perform painting.

Thereafter, the door module unit 25 formed in the door module unit forming line,
The vehicle door is manufactured by transporting the door assembly 3 carried out from the painting line to the door assembly line and attaching the door module unit 25 to the door assembly 3. Next, the vehicle body unloaded from the body outfitting line and the vehicle door unloaded from the door assembly line,
It will be transported to the door mounting line and mounted with the vehicle door on the vehicle body, and fine-tuned for each part.

The first plate 11 to which the door hinge 9 is fixed as described above and the second plate 1 to which the door lock 10 is installed
2 and the third and fourth plate members 13 and 14 disposed between the upper end and the lower end of the first plate 11 and the second plate 12, respectively, and then the side of the first plate 11 is formed. Part 3
One end portions of the fourth plate members 13 and 14 are welded and joined, and the third and fourth plate members 1 are attached to the side portions of the second plate member 12.
By welding and joining the other ends of the doors 3 and 14, a door inner panel 2 having an opening 4 in the center is formed, and the door inner panel 2 and the door outer panel 1 form a door structure 3 A door module unit 25 is formed by incorporating a door accessory such as a window regulator 18 into a module plate 5 covering the opening 4 of the door inner panel 2, and then attaching this to the door inner panel 2. Because we configured
The vehicle door can be properly molded by effectively improving the yield of the plate material used in molding the door.

That is, the window regulator 18
The door module unit 25, which is a unit formed by incorporating door accessories consisting of
Because it was configured to be attached to the door inner panel 2,
The first to fourth plate members 11 to 14 having a predetermined length and width are provided so as to surround the opening 4, and these are joined to form a door inner panel 2 having a predetermined shape.
Can be easily formed, and by attaching the door module unit 25 formed in a separate process, a vehicle door having various door accessories can be easily manufactured.

Further, the first plate member 11 to which a large load acts by being connected to the vehicle body via the door hinge 9 and the second plate member to which a large load is input from the door lock 10 when the door is opened and closed. The inner thickness of the door inner panel 2 is increased by making the thickness of the second inner plate 12 larger than that of the other third and fourth plate members 13 and 14, or by making the materials of the first and second plate materials 11 to 14 different in accordance with the load and the like. The door inner panel 2 in which the strength of each part is set to an appropriate value can be manufactured at low cost without increasing the weight of the door inner panel 2.

Further, one end portions of the third and fourth plate members 13 and 14 are welded to the side portions of the first plate member 11 to which the door hinge 9 is fixed, and the door lock 10 is joined.
The other end portions of the third and fourth plate members 13 and 14 are welded and joined to the side portions of the second plate member 12 on which the door hinges 9 are installed. Breakage of the welded portion can be effectively prevented.

That is, as shown in FIG. 13, the first and second plate materials are placed between the front end and the rear end of the third and fourth plate materials 53 and 54 which are arranged vertically opposite to each other. 51,5
It is also conceivable to arrange and join the two. However, in the case of the above configuration, the front end A of the joint between the first plate member 51 and the fourth plate member 54 is used as a fulcrum according to the load corresponding to the weight G of the door, and the rear end of the joint is Since a large moment load C acts in the direction in which B is peeled off, there is a problem that the above-mentioned joint is easily peeled off. On the other hand, as shown in FIG. 11, the first and second sheet material 11a, 12
a, 3 between the upper end and the lower end of the sheet material 1
In the case where the joints 3a and 14a are arranged, a load corresponding to the dead weight G of the door acts in the shearing direction of the joint, so that the shearing force is stably supported by the joint, and Is effectively prevented from being broken.

In the above embodiment, the first and second plate materials 11a and 12a are brought into contact with the side edges of the first and second plate materials 12a and 12a. Laser welding the butted portions of each, at least the first step of this laser welding is straight welding, and at least the last step is weaving welding, in the initial stage of welding, the laser welding machine 50 along the welded portion By moving it straight, this welding operation can be performed quickly and easily. Moreover, in the final stage of the welding, even if a gap is formed at the butted portion of each of the materials 11a to 14a due to a manufacturing error or thermal expansion during welding, the molten material generated at the time of the weaving welding is formed. Thus, since the gap can be filled, there is an advantage that the bonding strength can be sufficiently secured.

Further, after a plurality of door inner panel materials 2a, 2a of which upper side or lower side are connected to each other are formed from a plate material having a predetermined length and width as described below, the upper side or the upper side is formed. A plurality of door inner panel materials 2a, 2a may be manufactured at the same time by cutting the continuous portion at the lower side.

For example, as shown in FIG. 14, a first plate material 61 and a second plate material 62 each having a length approximately twice as long as that of forming a single door are arranged facing each other. A third plate material 63, 63 is disposed between the upper and lower ends of the first and second plate materials 61, 62, respectively, and the first and second plate materials 61, 62 are provided. In the state where the fourth plate material 64 having a width approximately twice as large as that of forming a single door is disposed between the central portions, the joints of the materials 61 to 64 are formed by means such as laser welding. Then, as shown by an imaginary line, the central portion of the fourth plate material 64 is cut along its length direction to simultaneously manufacture a pair of door inner panel materials 2a. Can be.

In this case, in order to perform the laser welding quickly while preventing a gap from being formed in the joint, at least the first step of the laser welding, for example, the first and second plate material The joint between the central portions of the raw materials 61 and 62 and the fourth plate material 64 is formed by straight welding, and at least the final step, for example, the end portions of the first and second plate materials 61 and 62 and the It is desirable that the joint with the three-plate material 63 be weaving welded.

As shown in FIG. 15, the first plate material 71 having a width twice or more as large as that of forming a single door and a pair of second plate materials 72, 72 are relatively positioned. And a pair of third plate materials 73, 7 between both ends of the first and second plate materials 71, 72, respectively.
In a state in which the material 3 is arranged, the joints of the respective materials 71 to 74 are joined by means such as laser welding, so that a pair of door inner panel materials 2a, 2a connected to each other at the front end or the rear end is formed. After molding, as shown by the imaginary line,
A pair of door inner panel materials 2a, 2a can be formed simultaneously by cutting the central portion of the first plate material 61 along the length direction.

However, as shown in FIG.
74, the number of movements of the welding machine to move along each welded portion is four, whereas when the materials 61 to 64 are provided as shown in FIG. The joints can be welded only by moving the welding machine twice along each weld. Therefore, as shown in FIG. 14, a plurality of door inner panel materials 2a, 2a having an upper side or a lower side connected to each other are formed by the respective materials 61 to 64 having predetermined lengths and widths. Thereafter, it is preferable that a plurality of door inner panel materials 2a, 2a be simultaneously formed by cutting the continuous portion at the upper side or the lower side.

[0040]

As described above, according to the present invention, the first plate member to which the door hinge is fixed, the second plate member to which the door lock is installed, and the upper and lower ends of the first and second plate members are provided. After molding the third and fourth plate members disposed between the portions, respectively, one end portions of the third and fourth plate members are welded and joined to the side portions of the first plate member, and the second and third plate members are joined together. A door inner panel having an opening in the center is formed by welding and joining the other ends of the third and fourth plate members to side portions of the plate member, and the door inner panel and the door outer panel form a door structure. After forming the body, after forming a door module unit incorporating door accessories on the module plate covering the opening of the door inner panel,
Since the door module unit is attached to the door inner panel, the door module unit is connected to the vehicle body via the door hinge, so that a large load acts on the first module.
The weight of the door inner panel is increased by increasing the thickness of the plate material and the thickness of the second plate material to which a large load is input from the door lock when the door is opened and closed, for example, as compared with the other third and fourth plate materials. There is an advantage that the strength of each part is set to an appropriate value without increasing, and a door inner panel having various door accessories can be easily and inexpensively manufactured.

[Brief description of the drawings]

FIG. 1 is a sectional view showing an embodiment of a vehicle door structure according to the present invention.

FIG. 2 is an explanatory diagram showing a specific structure of a door inner panel.

FIG. 3 is a perspective view showing a specific configuration of a door module unit.

FIG. 4 is an explanatory diagram showing a specific configuration of a module plate.

FIG. 5 is a cross-sectional view showing a specific configuration of a speaker installation section.

FIG. 6 is a cross-sectional view showing a specific configuration of an installation portion of a door lock.

FIG. 7 is a perspective view showing a specific configuration of a support portion of the harness.

FIG. 8 is a sectional view showing a specific configuration of a door pad.

FIG. 9 is a cross-sectional view showing a specific configuration of a lifting guide.

FIG. 10 is a process chart showing a specific configuration of a vehicle production line.

FIG. 11 is an explanatory diagram showing a specific configuration of a door inner panel material.

FIG. 12 is an explanatory diagram showing a manufacturing process of the door inner panel material.

FIG. 13 is an explanatory view showing a comparative example of a door inner panel material.

FIG. 14 is an explanatory diagram showing a specific configuration of a door inner panel material.

FIG. 15 is an explanatory view showing another specific example of a door inner panel material.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Door outer panel 2 Door inner panel 3 Door structure 4 Opening part 5 Module plate 9 Door hinge 10 Door lock (Accessory of door) 11 1st board material 12 2nd board material 13 3rd board material 14 4th board material 18 Window regulator (of door) (Accessories) 19 Speaker (Accessories of door) 20 Lock operation part (Accessories of door) 21 Inner handle (Accessories of door) 22 Harness (Accessories of door)

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Kenichi Ogawa 3-1 Shinchi, Fuchu-cho, Aki-gun, Hiroshima Mazda Co., Ltd. (72) Inventor Noboru 3-1, Shinchi Fuchu-cho, Aki-gun, Hiroshima Mazda Co., Ltd. F-term (reference) 3D114 AA03 BA13 EA05 4E068 BE00 DA00

Claims (4)

[Claims] 1. A first plate member to which a door hinge is fixed, a second plate member to which a door lock is installed, and third and third members disposed between upper and lower ends of the first and second plate members. After each of the fourth plate and the fourth plate is formed, one end of each of the third and fourth plate is welded and joined to the side of the first plate, and the third and fourth plates are joined to the side of the second plate. The other end of the fourth plate is welded and joined to form a door inner panel having an opening at the center, and a door structure is formed by the door inner panel and the door outer panel. A door module unit is formed by incorporating a door accessory into a module plate covering the opening of the vehicle, and the door module unit is attached to a door inner panel. In a state where both end portions of the third and fourth plate materials are butted against the side portions of the first and second plate materials, these butted portions are respectively laser-welded, and at least the first part of the laser welding is performed. 2. The method for manufacturing a vehicle door according to claim 1, wherein said step is straight welding and at least the final step is weaving welding. 3. A method of forming a plurality of door structures in which an upper side or a lower side is connected to each other and then cutting the connected portion of the upper side or the lower side into a plurality of door structures. The method for manufacturing a vehicle door according to claim 1, wherein: 4. A door inner panel having an opening formed in a central portion, a door outer panel which is joined to the door inner panel to form a door structure, and an opening of the door inner panel. A door module unit in which a door accessory is incorporated in a module plate to be mounted, wherein the door inner panel includes a first plate member to which a door hinge is fixed, a second plate member to which a door lock is installed, and the first plate member. The inner side of the first plate and the second side are disposed between the upper end and the lower end of the plate and the second plate.
A door structure for a vehicle, comprising a third plate member and a fourth plate member welded to inner side portions of the plate member, respectively.