JP2001515822A - Apparatus for a vehicle and method of manufacturing the apparatus - Google Patents

Abstract

(57) Abstract: A device for a vehicle, in particular a lightweight vehicle, comprises a metal frame (2) forming a support for a body composed of a large body unit (8, 9) of plastic (preferably thermoplastic). ). The frame (1) has pillars (5, 6) projecting upwardly from the base structure, these pillars being intended to support the body of the vehicle and possibly also roof / side beams. The front part of the vehicle, i.e. the front body part (9), is designed as a molded part, which is mounted / mounted on the front set of pillars (5) of the frame. In the same manner, the rear body part (8) of the vehicle is a component that is molded as one part and is attached to the rear pillar (6). The part between the front pillar (5) and the rear pillar (6) is covered by a plate element (10), a door element, etc., together with the part of the roof located at the top, which are all large plastic Consists of elements.

Description

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to an apparatus for a vehicle having a metal frame, and the metal frame includes:
It forms a support for a body composed of a large body unit of plastic, preferably a thermoplastic, especially a colored thermoplastic, wherein the frame has pillars projecting upward from the base structure. Thus, the body of the vehicle and possibly also the roof / side beams are supported. The invention also relates to a method for manufacturing such a vehicle.

[0002] Today's production of vehicles, especially automobiles, is largely by welding plates and panels together into units of a structure having the required strength and rigidity.
Based on constructing the body, assembling the body together using chassis, spring and wheel suspension, and introducing the engine and other parts. This method of construction is a substantial advance over the original vehicle structure (having a rigid frame, with the panel and body parts mounted on the frame).

[0003] This development is largely based on the use of steel, where plates are stamped as panels and welded together in a highly rational and efficient, robotized assembly line. Therefore, this manufacturing method has advanced greatly in control and accuracy, accompanied by great investment. Therefore, this type of production method is appropriate and financially justified for mass production.

[0004] Today, a further development trend is that of vehicles and automobiles that should be small and lightweight, and above all have the ability to be driven with reduced energy consumption, thereby reducing the burden on the environment. Proceed to manufacturing. For this purpose, modern materials and new manufacturing methods are used. An additional feature of this development trend is that
Manufacture of vehicles or automobiles intended to cover gaps in specific requirements or markets. That is, they are not intended for general use, for example, use over long distances. Such "gap" vehicles, which are also considered as vehicles or transports, do not normally meet the requirements in mass production, and for such vehicles therefore special manufacturing methods and use Materials have been developed which are not yet widely used in the manufacture of automobiles at present.

[0005] However, in these vehicles it is also very important that the vehicles provide a sufficiently high level of safety for the user, and thus, in this case, too, to meet the recent safety requirements. It is important that the required strength and deformation conditions can be incorporated into the design for a possible purpose.

The use of frameworks (eg, aluminum) has been shown to provide an interesting configuration method for future vehicle development through so-called “space frames”. To assemble these frames, the frames are connected together by welding, gluing or other mechanical attachment means. Such a frame (eg, aluminum) is light in weight and can provide a very high level of security by being calculated and dimensioned. The panels and body parts must continue to be assembled together on this frame in order to be able to construct the final vehicle. For this purpose, metal, preferably aluminum, or plastic panels are used, which are mounted on this frame in a manner known per se. Even though this may indicate a step back to conventional construction techniques (where frames were used), the only difference is that modern materials (such as aluminum and plastic, etc.) are used, while at the same time Greater security is to be built into the frame, and this type of construction is also very interesting in the new vehicle types described above. One reason for this is that the investment required for the purpose of developing a vehicle on this basis is rather low. Currently,
This method is best suited for smaller production numbers.

A support frame of this kind can also be assembled relatively simply with a steel structure, in which a simple surface treatment must then be performed to prevent corrosion. This process is substantially simplified as compared to conventional bodywork surface treatment, which must then be sprayed.

[0008] The term "space frame" refers to a kind of frame consisting of a framework with connection points. These are used in some types of vehicles and are of great interest. However, the main problem is to be able to achieve a simplified and streamlined installation of the body parts and panels.

[0009] It is known in the prior art to use plastic in combination with aluminum or steel frames for variously designed body parts. While polyester or epoxy body parts are most often used, other types of plastics are also utilized by vacuum forming, injection molding, or by means where panels are made by spraying and fitting.

An example of such a known design can be found, for example, in DE 195 00 361, which discloses a body / frame structure, in which the rear frame part and the outer roof beam consist of one part, This is then attached to the lower floor section. A rear outer panel is then attached to this outside. In EPO 584576, an external structure is used, which forms the actual cabin, on which the front module is mounted and where these parts are glued together. A similar design based on the completed cabin is also described in EPO 547583.

[0011] EP 485 457 and EP 679 974 describe how a metal frame can be used in combination with large body parts of a simple design to form an entire body.

It is an object of the present invention to provide a new shaped assembly for a vehicle, wherein the body of the vehicle is made of plastic, preferably a thermoplastic, particularly preferably a colored thermoplastic. Some large units can be manufactured, where the body parts can also be made in a smaller manufacturing series, and these can be made in a simple and fast manner into the vehicle frame structure (eg, aluminum) It can be mounted without complicated assistance.

To this end, according to the invention, a device of the type described in the introduction is used. This device is characterized by the features recited in the claims. The invention also includes a method for manufacturing such a vehicle. The method is characterized by the features of claim 13.

The present invention presents a highly simplified design, unlike previously known designs. The challenge in previously known designs is the long-winded and difficult process of mounting a solid cast body or a large part body. This is because it is difficult to integrate them or mount them on a pre-assembled frame structure.

In some cases, it is necessary to divide the frame structure so that large body elements can be installed. This not only results in extra work operations in the frame assembly, but also damages the frame structure and costly steps with the aim of ensuring simplified mounting and a satisfactory degree of safety. Often means. For example, the design according to DE 195 00 361 requires a welded and integrated metal plate as the frame structure. This is because the body panel only gives the vehicle its external shape and appearance and does not tightly connect the body module at this time.

In the present invention, the desire is to integrate style and appearance, for the most part, with utility and functional solutions by the combination of metal frames and plastic panels. This is done in such a way that the plastic body part has a more integrated function than is merely covered by external and visual advantages. Furthermore, the plastic body part utilizes a construction method having a function of sealing and separating the inside and outside environments of the vehicle, and this part may have elements such as wheel arches, mudguards, etc. , Seal edges, etc. can be inserted.

A particular feature of the present invention is also that the molding method and materials can be used to produce body parts, which eliminates the need to paint the body parts. Painting is an undesirable operation because of environmental conditions and costs.

In a particular embodiment of the invention, the front and rear vehicle body parts are designed to overlap, which strengthens the central part of the vehicle. This further enhances and separates the external and internal environments, which may be advantageous in certain applications.

The present invention will now be described in more detail by the embodiments illustrated in the drawings.

As described below, these drawings are merely schematic representations, which are only intended to illustrate the basic design of the devices according to the invention and the method of manufacturing them. These drawings contain only those elements necessary to illustrate the concepts of the present invention. This is because other features are techniques that can be changed and can be easily performed by those skilled in the art.

FIG. 1 shows the principle of the device according to the invention, with some body parts set aside, while the final assembled shape is indicated by broken lines.

The basic element in this design is a metal frame, for example a frame of the “space frame” type, which is designated by the reference numeral 1 and whose required mechanical components and systems are simple and Mounted in a rational manner. This frame is an opening with easy access. Thus, the vehicle can be configured using the front and rear chassis systems, engines, and other technical connections without being obstructed by the area enclosed in the frame.

Depending on whether the transmission system, ie the engine (possibly electrically powered and needs space for the battery) is installed before or after the floor, The system 2 can be flexible, so that space for these transmission systems can be created in the lower part of the vehicle, for example in the area of the reference numeral 3. This floor system is designated by 2.

Therefore, the floor 2 is provided with, for example, a space so that the battery can be stored in the lower part 3 of the vehicle.
On two horizontal planes so that it can be mounted in the area of. In this type of design, an attempt is made to place a higher floor surface under the seat 4.

The upwardly projecting pillars of the vehicle (referred to as A-pillars and B-pillars and referenced 5 and 6) are also provided on this frame with a roof frame 7 for a closed vehicle. Along with it. These upwardly projecting pillars
It is preferably arranged substantially vertically, but depending on the design of the body, angled or curved shapes can also be envisaged.

The body consists mainly of a rear part 8 which is attached to the rear sides, wheel arches and mudguards, and the floor part (which is then mounted on the B-pillar 6 of the vehicle, possibly also elsewhere). To form a large body part.
If the vehicle has four doors, this part 8 can be mounted on the so-called C pillar of the vehicle, the B pillar thereby becoming the central pillar. The front part 9 of the vehicle is designed as a downwardly open cover, so that it can be located above the engine and wheels and is mounted in the area around the A-pillar 5 of the vehicle. Inside, the torpedo wall is separated from the pedal mounted on the dashboard,
Convenient for closing and sealing the internal cabin. This cover 12 also
It can also be an elongated part of the floor plate. The loose roof 10 can be mounted on a frame above the windows, and the doors are mounted on the A-pillars 5 and B-pillars 6, respectively, possibly with three pillars on each side, between these pillars.

FIGS. 2 to 4 show a second embodiment of the invention, wherein the rear part 8 and the front part 9 overlap each other. The rear body part 8 is thereby designed in the external shape and dimensions required by the vehicle, up to the area of the rear pillar, ie the B pillar 6. On the other hand, the front body part 9 of the vehicle extends rearward in the area up to the A-pillar 5, having the external dimensions and design of the vehicle. In this embodiment, the front part of the rear body part 8 extends forward inside the pillars 5 and 6,
A wall 11, which leads to an anterior area inside the cabin, where it projects or extends upwards, is formed between the interior partition of the cabin and the external technical or motor partition, where the lower part is located. It can be attached or sealed to window frame 13 to terminate. Similarly, the part may include a vehicle dashboard or dashboard base 12, as shown in FIG.

By using suitable plastics materials and molding techniques, the bumper cover can be molded into the front part 9 together with other details, such as grills, recesses and fixing means for lighting.

The door can be installed as a part after this assembly process, is attached to the front pillar 5 and is locked at the pillar 6 closed. An important feature of this design is that the separation line between the door and the rear body part can be adjusted in a simple manner by adjusting or moving the hinge point of the door on the pillar 5. The front can then be adjusted towards the front door line, so that it is perfectly aligned with the door separation.

If three pillars are used, namely the A, B and C pillars, the procedure is the same, and so is the case of mounting the rear door. FIG. 1 shows an apparatus for a vehicle having a roof structure. FIG. 4 can also be used in roofless designs,
The same vehicle device is shown.

The present invention relates to a highly rational and effective method of configuring a vehicle. Both the front and back body parts, 9 and 8, are mounted after all mechanical components, chassis, springs, engines, etc. have been installed on the open frame. They can be made from different types of plastics by different manufacturing methods, which show the possibility of constructing large parts in three dimensions. One example of such a part is a rotational molded part, and vacuum forming and spraying may also be used in the case of given design criteria. The preferred material is a thermoplastic, especially a colored thermoplastic, but other plastic materials having similar properties can also be used.

The assembly of plastic body parts and metal structures shows good sealing possibilities. This is because there are no other body panels to be joined and sealed together. The plastic edge can be pushed into the metal structure and locked, for example by clamping means. Even though these relatively large body parts do not provide any structural strength to their structure, when they are finished vehicles,
It has obvious functional effects.

The present invention is described by merely general terms and the fact that mentions, for example, that instead of two, three pillars can also be used on both sides. This device can be modified in many ways, while retaining the main features, within the scope of the claims. That is, the main property is to use large components as the front and large components as the rear, these components have a three-dimensional shape, which gives them a great strength and rigidity And thereby provide a secure body. It is possible to vary the actual design and shape.

[Brief description of the drawings]

FIG. 1 is a complete schematic diagram showing the design of the device according to the invention, with the parts separated from each other.

FIG. 2 is a schematic horizontal sectional view of a second embodiment of the present invention.

FIG. 3 is a cross-sectional side view of the embodiment corresponding to FIG. 2, associated with a cabriolet design.

FIG. 4 is a side view of the cabriolet design in FIG. 3;

──────────────────────────────────────────────────続 き Continuation of front page (81) Designated country EP (AT, BE, CH, CY, DE, DK, ES, FI, FR, GB, GR, IE, IT, LU, MC, NL, PT, SE ), OA (BF, BJ, CF, CG, CI, CM, GA, GN, GW, ML, MR, NE, SN, TD, TG), AP (GH, GM, KE, LS, MW, SD, SZ, UG, ZW), EA (AM, AZ, BY, KG, KZ, MD, RU, TJ, TM), AL, AM, AT, AU, AZ, BA, BB, BG, BR, BY, CA, CH, CN, CU, CZ, DE, DK, EE, ES, FI, GB, GE, GH, GM, HR, HU, ID, IL, IS, JP, KE, KG, KP , KR, KZ, LC, LK, LR, LS, LT, LU, LV, MD, MG, MK, MN, MW, MX, NO, NZ, PL, PT, RO, RU, SD, SE, SG, SI, SK, SL, TJ, TM, TR, TT, UA, UG, US, UZ, VN, YU, ZWF terms (reference) 3D003 AA11 BB01 CA03 CA09 CA18 CA33 CA34 CA36 CA38 CA40 CA48 DA14 DA16

Claims (13)

[Claims] 1. A vehicle having a metal frame (1) forming a support for a plastic body (8, 9), wherein the metal frame (1) comprises a base structure and at least two sets. A pillar (5, 6) projecting upwards, said pillar supporting a plastic body (8, 9) of the vehicle and possibly roof / side beams, and a front part (9) of the vehicle. I.e. the front part of the plastic body is designed as a one-piece molded component, mounted / mounted in the area of the pillars (5) of the previous set of metal frames, and the same In the manner, the rear part of the plastic body is a component formed as one piece, which is attached to the rear set of pillars (6), as well as the front set of pillars (5
) And the rear set of pillars (6) are covered by plate elements (10), door elements, etc., together with the roof part located at the top, these elements being made of large plastics. A vehicle characterized by being molded as a main body element. 2. The vehicle as claimed in claim 1, wherein additional pillars are provided between the pillars (5, 6) for installing two door elements on each side of the vehicle. Vehicle. 3. The vehicle according to claim 1, wherein the rear body part (8) is designed with the side wall, wheel arch, rear and floor as a single part. 4. The front body part (9) having a bumper, a side surface, a wheel arch and a bonnet, preferably having an opening leading down to an engine or the like for service or the like, The vehicle according to claim 1. 5. A floor is mounted on the metal frame structure (1), preferably a metal floor is welded, and from the rear end of the rear wheel of the vehicle, a torpedo wall of the vehicle is provided. 2. The two horizontal planes of the vehicle, wherein the drive train, batteries, tanks, etc. can be mounted below the horizontal plane of the highest floor of the car. Vehicle. 6. The end of said rear body part, and possibly the floor, is introduced inside / locked against the contour of said metal frame structure (1), this being said frame (1) and said plastic The vehicle according to claim 1, characterized in that a mounting and a seal are formed between the body parts (8, 9). 7. The front body part (9) is attached to a lower part and an upper part of the front set of pillars (5) in front of a bumper part, and when the door is opened. 2. The vehicle according to claim 1, wherein the vehicle can turn to form an opening. 8. One or more of the plastic body parts (8, 9).
) Is designed from a translucent plastics material.
The vehicle described in the above. 9. The rear body part (8) is connected to the rear set of pillars (6).
And preferably extends beyond and beyond the previous set of pillars (5) so that the previous set of pillars (5) project upwardly 2. The vehicle according to claim 1, wherein the vehicle ends at an opened front wall, an opening required for a door cut out of the main body part, and the like. 10. A rear part (8) of the vehicle inside the pillars (5, 6),
10. The vehicle according to claim 9, wherein the front facing portion has an upper portion, the upper portion forming a seal and attachment to the lower frame portion of the windshield. 11. The front-facing part of the rear part (8) of the vehicle, ie the front part, has an upper part which, in whole or in part, connects the dashboard of the vehicle or its base. The vehicle according to claim 9, wherein the vehicle is formed. 12. The vehicle according to claim 9, wherein the rear body part (8) is molded / formed as one part together with the vehicle roof (10). 13. A metal frame structure (1), a set of pillars (5, 6) projecting upwards in the side area of the vehicle, and a large construction which is preferably a thermoplastic, especially a colored thermoplastic. A method for manufacturing a vehicle using a plastic body consisting of elements (8, 9), comprising: forming a plastic component (1) on the metal frame (1) from the rear end area of the vehicle on the frame. 8) is mounted as one part, the component being attached to the rear set of pillars (6) and the actual frame (1), preferably by clamps, with a rear body part extending laterally According to (8), a mounting is also formed on the possible central pillar and the preceding set of pillars (5), the plastic front body part (9) then being mounted in a similar manner from the front of the vehicle. Is, doors, mounted between such windows of the pillar, and all the open roof area, also characterized in that it is covered by the plate elements (10) is a plastic, method.