JP2002172647A - Method for manufacturing car body constituent part - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide manufacturing technique not generating undulation damaging the design effect in a joining part in a vehicle constituent part of a type showing fine lines. SOLUTION: A reinforcing fiber sheet 15 is drawn to the right in a drawing while positioned by a second core 28 to be allowed to conform to the upper surface of a foam core material 14. A reinforcing fiber sheet 16 is allowed to conform to the undersurface of the foam core material 14 and the end part thereof is superposed on the reinforcing fiber sheet 15 as shown by an arrow (1). At this time, the sheet 16 is bonded to the sheet 15 by a proper adhesive. Since the reinforcing fiber sheet 15 is fixed by the core 28, the fine lines of the reinforcing fiber sheet 16 can be accurately and easily aligned with those of the reinforcing fiber sheet 15 and the generation of harmful undulation can be suppressed and design effect can be enhanced.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an improved technique for manufacturing a vehicle body component such as a hardtop.

[0002]

2. Description of the Related Art Techniques for showing a streak on the surface have been developed in order to diversify the appearance of vehicles. One of the techniques is a technique for showing a thread of a reinforced fiber sheet. This technique will be described below.

FIGS. 13A to 13C are views for explaining the structure of a conventional hardtop. (A) shows a vehicle 102 having a removable hard top 101. (B) shows the hard top 101 in a detached state, and an enlarged view of a portion c in FIG.

(C) is an enlarged view of a portion c in (b), in which the hard top 101 is surface-finished with reinforcing fiber sheets 103 and 104, and a plurality of threads 105... The same applies hereinafter) to enhance the appearance design.

[0005]

As shown in the above (c), in the joint portion 107, a gap occurs between the thread 105 of the reinforcing fiber sheet 103 and the thread 105 of the reinforcing fiber sheet 104, and this gap is generated. Appear as an overall undulation at the end, and this undulation may impair the overall design.

SUMMARY OF THE INVENTION It is an object of the present invention to provide a manufacturing technique which does not cause undulation that impairs the design property in a joint portion of a vehicle component having a thread.

[0007]

In order to achieve the above object, a first aspect of the present invention is a method of manufacturing a vehicle body component covered with a reinforced fiber sheet in which a thread is visible. A step of forming a positioning recess in the core material in advance, a step of stopping a positioning hole of the reinforcing fiber sheet in the positioning recess of the core material with a core, and a step of positioning the reinforcing fiber sheet on the core material while positioning the core with the core. And the step of collectively setting the core, the reinforcing fiber sheet and the core material in a mold, the step of injecting lysine into the mold to impregnate the reinforcing fiber sheet and sticking it to the core material, and Removing the core.

[0008] By determining the position of the reinforcing fiber sheet with the core, the occurrence of the misalignment of the thread at the joint portion is prevented.
Since the mold is inserted and the lysine is impregnated while the core is still fitted, there is no fear that the lysine flows into the positioning recess of the core material, and this positioning recess can be reused as a stop for the outfitting component.

[0009] A second aspect of the present invention is characterized in that the recess formed in the core material is constituted by an insert part embedded during molding of the core material. In other words, it is necessary to mold the core material in advance using a molding die, but if the insert part is integrally molded during this molding, it will have the necessary strength as a stopper for the later outfitting parts along with the formation of the recess. Can be made.

According to a third aspect of the present invention, there is provided a method of manufacturing a vehicle body component covered with a reinforcing fiber sheet in which a thread is visible, the method comprising the steps of: forming a positioning hole in the reinforcing fiber sheet; and forming a positioning recess in the core material in advance. A step of fixing the positioning hole of the reinforcing fiber sheet in the positioning recess of the core material with an insert part, a step of covering the core material with the reinforcing fiber sheet while positioning the insert part, the insert part, the reinforcing fiber sheet, and the core material. From the process of injecting lysine into the mold, integrating the insert parts into the core material and attaching the reinforcing fiber sheet to the core material while impregnating the reinforcing fiber sheet, and the demolding process. It is characterized by becoming.

[0011] By determining the position of the reinforcing fiber sheet by the insert part, the occurrence of a thread shift at the joint portion is prevented. By using an insert part used for attaching the outfitting parts later as a positioning member of the reinforcing fiber sheet, the occurrence of a thread shift at the joint portion is prevented.

[0012]

Embodiments of the present invention will be described below with reference to the accompanying drawings. The vehicle body components include a hardtop, a door, a sunroof, a bonnet, and the like, and among them, the hardtop will be described below as a specific example.

FIG. 1 is a perspective view of a hardtop according to the present invention. A hardtop 10 is a typical vehicle body component whose outer surface faces outward.
The cross-sectional structure of FIG. FIG. 2 is a cross-sectional view taken along the line 2-2 of FIG. 1. The side edge 11 of the hard top 10 has reinforcing fiber sheets 15 on both sides of a solid foam core material 14 into which an insert part 12 has been integrally formed in advance. , 16 with
This is a sandwich structure in which the end portions of the reinforcing fiber sheets 15 and 16 are overlapped at the joint portion 17 and then impregnated with lysine. The fibers constituting the reinforcing fiber sheets 15, 16 are as follows:
Carbon fiber, glass fiber, and resin fiber can be adopted. In addition,
Lysine uses a transparent thermosetting resin from the viewpoint of showing the texture of the reinforcing fiber sheet.

Next, a method of manufacturing a hardtop having the above structure will be described. FIG. 3 is an explanatory view of a step of forming a positioning hole in the reinforcing fiber sheet according to the present invention. A necessary number of positioning holes 18 are formed in the reinforcing fiber sheet 15 cut into a predetermined shape. Of course, providing holes or notches other than the positioning holes 18 does not hinder.

FIGS. 4 (a) and 4 (b) are explanatory views of a step of forming a positioning recess in the core material according to the present invention in advance.
In (a), what inserts the pin part 23a of the 1st core 23 into the insert part 12 which consists of the flange part 21 and the nut part 22 as a positioning recessed part is preset in the predetermined part of the cavity 24 of the core forming mold 19. FIG. Then, a resin 27 is injected into the cavity 24 by a pump 26 from a tank 25 containing a raw material such as urethane. When the resin 27 has hardened, the mold is released.

(B) shows the foam core material 14 after the mold is released, and shows that the insert part 12 has been integrally molded. Then, the used first core 23 is removed. Thus, the core member 1 integrally provided with the positioning recess (nut portion 22)
4 can be obtained.

FIG. 5 is an explanatory view of the step of fixing the positioning hole of the reinforcing fiber sheet in the positioning concave portion of the core material with the core according to the present invention. The insert component 12 integrally formed with the foam core material 14 includes the reinforcing fiber sheet. 15 positioning holes 18
And the pin portion 29 of the second core 28 communicates with the positioning hole 18 and the nut portion 22 of the insert component 12 to position the positioning hole 18 in the nut portion 22 as a positioning recess.

FIG. 6 is an explanatory view of the step of covering the core material with the reinforcing fiber sheet while positioning with the core according to the present invention.
The reinforcing fiber sheet 15 is pulled to the right in the figure while being positioned by the second core 28, and is attached to the upper surface of the foam core material 14.
Then, the reinforcing fiber sheet 1 is provided on the lower surface of the foam core material 14.
6 is attached to the reinforcing fiber sheet 15, and the end portion is superimposed on the reinforcing fiber sheet 15 as indicated by an arrow. It is still desirable to join the sheet 16 to the sheet 15 with a suitable adhesive at the time of the arrow.

It is important that the reinforcing fiber sheet 15
Is positioned by the second core 28, so that the thread of the reinforcing fiber sheet 16 can be accurately and easily aligned with the thread of the reinforcing fiber sheet 15.

FIG. 7 is an explanatory view of the step of collectively setting the core, the reinforcing fiber sheet and the core material according to the present invention in a mold and the step of impregnating with lysine.
The core 28, the reinforcing fiber sheets 15, 16 and the foam core material 14 (including the nut portion 22 and the like) are collectively stored.

Next, the lysine in the lysine container 32 is
In 3, it is poured into the impregnation mold 31. Lysine impregnates and hardens the gaps between the reinforcing fiber sheets 15 and 16 and also serves as an adhesive for attaching the reinforcing fiber sheets 15 and 16 to the foam core material 14. At this time, there is no possibility that the lysine may enter the nut portion 22 due to the closing action of the pin portion 29. Once the lysine is sufficiently hardened, the impregnation mold 31
May be disassembled (molded apart) and the used second core 28 may be removed. Thus, the hard top 10 shown in FIG. 2 has been manufactured.

The main parts of the above embodiment can be summarized as follows: a step of forming a positioning hole in the reinforcing fiber sheet, a step of forming a positioning recess in the core material in advance, and a step of forming a positioning hole of the reinforcing fiber sheet in the positioning recess of the core material. A step of stopping with a core, a step of covering the core material with a reinforcing fiber sheet while positioning with the core, a step of collectively setting the core, the reinforcing fiber sheet and the core material in a mold, The present invention can provide a method for manufacturing a vehicle body component, comprising: a step of injecting a reinforcing fiber sheet by injecting the reinforcing fiber sheet and attaching the core to a core material; and a step of removing the core after demolding.

FIG. 8 is an explanatory view for attaching outfitting parts to the hardtop manufactured by the method of the present invention.
A positioning hole 18 is formed in the reinforcing fiber sheet 15 as a skin, and the positioning hole 18
There is a collar 21 and a nut portion 22 at the back of the box. Then, screw 3
By screwing the nut 5 into the nut portion 22, the weatherstrip stopper 36 is fixed to the insert component 12, and the weatherstrip 37 as an outfitting component can be fixed to the weatherstrip stopper 36.

Although an external force acts on the weather strip 37, a large strength can be expected because the insert part 12 is integrally formed with the foam core material 14. Therefore, there is no fear that the hard top 10 is damaged.

Next, another embodiment of FIGS. 4 to 7 will be described with reference to FIGS.
2 will be described. Elements common to FIGS. 4 to 7 are denoted by reference numerals. FIGS. 9A and 9B are views for explaining another embodiment of the step of forming the positioning recess in the core material according to the present invention in advance. In (a), a third core 39 having a cylindrical pin 38 is preset at a predetermined position of the cavity 24 of the core mold 19. Then, a resin 27 is injected into the cavity 24 by a pump 26 from a tank 25 containing a raw material such as urethane. When the resin 27 has hardened, the mold is released.

(B) shows the foam core material 14 after the mold release, and the foam core material 1 is obtained by removing the third core 39.
4 shows that the positioning recess 41 was formed simultaneously.

FIG. 10 is an explanatory view of the step of fixing the positioning hole of the reinforcing fiber sheet in the positioning concave portion of the core material according to the present invention with an insert part. The positioning hole 18 of the reinforcing fiber sheet 15 faces the foam core material 14. In addition, the positioning hole 18 and the positioning concave portion 41
The positioning holes 18 are positioned in the positioning recesses 41 by communicating the nut portions 22 of the positioning. If the nut 22 is provided with a barb 22a that protrudes radially outward, the barb 22a will not bite into the foam core material 14 and the insert part 12 will not float up later (see FIG. 11).

FIG. 11 is an explanatory view of a step of covering a core material with a reinforcing fiber sheet while positioning with an insert part according to the present invention. At the time of stacking, the reinforcing fiber sheets 15 and 16 are put on the core material 14. Then, the fourth core 42 is attached to the foam core material 14 such that the pin portion 43 of the fourth core 42 is inserted into the insert part 12.

It is important that the reinforcing fiber sheet 15
Is positioned by the insert part 12, so that the thread of the reinforcing fiber sheet 16 can be accurately and easily aligned with the thread of the reinforcing fiber sheet 15.

FIG. 12 is an explanatory view of a step of collectively setting the insert part, the reinforcing fiber sheet and the core material according to the present invention in a mold and a step of impregnating lysine with a fourth core. 42, the reinforcing fiber sheets 15, 16 and the foam core material 14 (including the nut portion 22 and the like) are collectively stored.

Next, the lysine in the lysine container 32 is
In 3, it is poured into the impregnation mold 31. The lysine impregnates the gap between the nut portion 22 of the insert part and the preform material 14 to integrate them, and also impregnates the gap between the reinforcing fiber sheets 15 and 16, and the reinforcing fiber sheets 15 and 16 are added to the foam core material 14. It plays a role as an adhesive to be attached.

Although the flange 21 of the insert part appears to protrude from the reinforcing fiber sheet 15 in FIG.
The action of 2a can prevent the insert part 12 from coming off or floating, and as a result, an appropriate clearance can be secured between the insert part 12 and the fourth core 42, and lysine flows through this clearance. Then, the insert part 12 is buried in the lysine together with the reinforcing fiber sheets 15 and 16. As a result, due to the waterproofing action of lysine,
There is no danger of flooding the preform material 14 from outside.

On the other hand, there is no possibility that lysine may enter the nut portion 22 due to the closing action of the pin portion 43 of the fourth core 42. If the lysine is sufficiently hardened, the impregnation mold 31 may be disassembled (mold separated) and the used fourth core 42 may be removed. Thus, the hard top 10 shown in FIG. 2 has been manufactured.

3 and FIG. 9 to FIG. 12 are summarized as follows: a step of forming a positioning hole in the reinforcing fiber sheet;
A step of forming a positioning recess in the core material in advance, a step of stopping the positioning hole of the reinforcing fiber sheet in the positioning recess of the core material with an insert component, and a step of covering the core material with the reinforcing fiber sheet while positioning with the insert component. A step of collectively setting these insert parts, reinforcing fiber sheet and core material in a mold, injecting lysine into the mold to integrate the insert parts into the core material, and impregnating the reinforcing fiber sheet into the core material. The present invention can provide a method for manufacturing a vehicle body component, which includes a step of attaching and a step of removing a mold.

According to this method, the position of the reinforcing fiber sheet is determined by the insert part, thereby preventing the occurrence of a thread shift at the joint portion. By using an insert part used for attaching the outfitting parts later as a positioning member of the reinforcing fiber sheet, the occurrence of a thread shift at the joint portion is prevented. In addition, the insert component can be covered with lysine together with the reinforcing fiber sheet, and the waterproofing action of this lysine can effectively prevent water from infiltrating the foam core material from the outside. Since water infiltration can be prevented, deterioration and weight increase of the foam core material can be prevented.

In the first and third aspects, the step of forming a positioning hole in the reinforcing fiber sheet and the step of forming a positioning recess in the core material in advance may be performed in reverse order or simultaneously. The shape of the core is arbitrary as long as the shape corresponds to the positioning recess.

In claim 2 which is a dependent claim of claim 1, the insert part is integrally formed with the foam core material (see FIG. 4). In this case, since the insert part is firmly connected to the foam core material, a high-load outfitting part (such as a lock part for locking the hard cover to the vehicle body) can be attached to such an insert part. In claim 3, the insert component is bonded to the foam core material with lysine (see FIGS. 11 and 12). In this case, since the insert part is slightly weakly bonded to the foam core material, a low-load outfitting part may be attached to such an insert part.

Although the vehicle body components have been described above by taking the hardtop as an example, the vehicle body components may be doors, sunroofs, bonnets, and the like, and there is no particular limitation on the type or shape.

The outfitting parts are not limited to weather strips, and may be of any type and shape as long as they are interior parts and mounting equipment (including parts) of a vehicle.

[0040]

According to the present invention, the following effects are exhibited by the above configuration. According to the manufacturing method of the first aspect, by determining the position of the reinforcing fiber sheet with the core, it is possible to prevent the occurrence of undulation or the like on the entire design surface in the alignment preventing misalignment of the end seam at the seam. The appearance of the component parts can be easily improved. In addition, since the mold is inserted and the lysine is impregnated while the core is still fitted, there is no risk that the lysine flows into the positioning recess of the core material, and this positioning recess can be reused as a stop for the outfitting component. .

The manufacturing method according to claim 2 is characterized in that the recess formed in the core material is constituted by an insert part embedded during molding of the core material. In other words, it is necessary to mold the core material in advance using a molding die, but if the insert part is integrally molded during this molding, it will have the necessary strength as a stopper for the later outfitting parts along with the formation of the recess. Can be made.

According to the manufacturing method of the third aspect, the position of the reinforcing fiber sheet is determined by the insert part, thereby preventing the occurrence of a thread shift at the joint portion. By using an insert part used for attaching the outfitting parts later as a positioning member of the reinforcing fiber sheet, the occurrence of a thread shift at the joint portion is prevented. In addition, the insert component can be covered with lysine together with the reinforcing fiber sheet, and the waterproofing action of this lysine can effectively prevent water from infiltrating the foam core material from the outside. Because it can prevent inundation,
Deterioration and weight increase of the foam core material can be prevented.

[Brief description of the drawings]

FIG. 1 is a perspective view of a hardtop according to the present invention.

FIG. 2 is a sectional view taken along line 2-2 of FIG.

FIG. 3 is an explanatory view of a step of forming a positioning hole in the reinforcing fiber sheet according to the present invention.

FIG. 4 is an explanatory view of a step of forming a positioning recess in the core material according to the present invention in advance.

FIG. 5 is an explanatory diagram of a step of fixing a positioning hole of a reinforcing fiber sheet with a core in a positioning recess of a core material according to the present invention.

FIG. 6 is an explanatory view of a step of covering a core material with a reinforcing fiber sheet while positioning with a core according to the present invention.

FIG. 7 is an explanatory view of a step of collectively setting a core, a reinforcing fiber sheet and a core material according to the present invention in a mold and a step of impregnating with lysine.

FIG. 8 is an explanatory view for attaching outfitting parts to a hardtop manufactured by the method of the present invention.

FIG. 9 is an explanatory view of another embodiment of the step of forming a positioning recess in the core material according to the present invention in advance.

FIG. 10 is an explanatory view of a step of fixing the positioning hole of the reinforcing fiber sheet in the positioning recess of the core material according to the present invention with an insert part.

FIG. 11 is an explanatory view of a step of covering a core material with a reinforcing fiber sheet while positioning with an insert part according to the present invention.

FIG. 12 is an explanatory view of a step of collectively setting an insert part, a reinforcing fiber sheet, and a core material according to the present invention in a mold and a step of impregnating with lysine.

FIG. 13 is a structural explanatory view of a conventional hardtop.

[Explanation of symbols]

10: vehicle body components (hard top), 12: insert parts, 14: core material (foam core material), 15, 16
... Reinforcing fiber sheet, 18 ... Positioning hole, 19 ... Core mold, 22 ... Nut as positioning recess, 28 ... Core used for positioning, 31 ... Implantation mold, 41 ... Positioning recess.

Claims (3)

[Claims] 1. A method of manufacturing a vehicle body component covered with a reinforcing fiber sheet with visible threads, comprising the steps of: forming a positioning hole in the reinforcing fiber sheet; forming a positioning recess in the core material in advance; A step of fixing the positioning hole of the reinforcing fiber sheet in the positioning recess of the material with a core, a step of covering the core material with the reinforcing fiber sheet while positioning with the core, and collectively setting the core, the reinforcing fiber sheet and the core material. A vehicle body comprising: a step of setting the mold into a mold; a step of injecting lysine into the mold to impregnate the reinforcing fiber sheet and affixing it to a core material; and a step of removing the core after the mold is released. Manufacturing method of component parts. 2. The method of manufacturing a vehicle body component according to claim 1, wherein the recess formed in the core material is formed by an insert part embedded during molding of the core material. 3. A method of manufacturing a vehicle body component covered with a reinforcing fiber sheet in which a thread is visible, the method comprising: forming a positioning hole in the reinforcing fiber sheet; forming a positioning recess in the core material in advance; A step of fixing the positioning hole of the reinforcing fiber sheet in the positioning recess of the material with an insert part, and a step of covering the core material with the reinforcing fiber sheet while positioning with the insert part;
A step of collectively setting the reinforcing fiber sheet and the core material in a mold, a step of injecting lysine into the mold to integrate the insert component into the core material, and attaching the reinforcing fiber sheet to the core material while impregnating the reinforcing fiber sheet; And a demolding step.