JP2002225564A - Door module and its production method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a door module, which can be produced with a low cost, and the wiring structure for the door module. SOLUTION: On a door module 10, each kind of equipment, unit 26 and the like are mounted on an inner panel 21 mounted on an outer panel 22, and a wiring member 30 is formed, the wiring member having a wiring circuit 31 for electrically connecting the equipment with the unit 26. The pattern of the wiring circuit 31 is directly formed on the inner panel 21 by press working, so that the door module 10 can be produced with a low cost.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a door module mounted on an automobile door and a method of manufacturing the same, and more particularly, to a door module which can be manufactured at a low cost and has high expandability and a method of manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, various electric devices, sensors and switches mounted on a vehicle (these devices are collectively referred to as "equipment"), a control device for controlling these devices and a driving device for driving ( A so-called wire harness in which a plurality of electric wires are bundled together is used to electrically connect these devices to each other. It is assembled to the vehicle body on a production line such as a vehicle assembly line. Conventionally, wire harnesses have also been used for equipment and device units mounted on automobile doors.For example, an electric side mirror, a power window, a door lock device, a lock release lever, and the like are incorporated in an automobile door, and the electric harness is used. In order to connect the equipment and the equipment unit to the inner panel and outer panel of the automobile door on the production line, and after attaching the wire harness, it is provided in advance to the wiring of these equipment and the equipment unit. And a connector provided beforehand at the terminal of the wire harness.

However, in order to manufacture a door for an automobile in such a process, a predetermined number of man-hours such as connection work for each equipment and device unit are required, and the number of parts is increased. In such a production line, such assembling work and wiring work of the wire harness, etc. are performed manually by the operator according to a manual specified in advance, so that the number of man-hours increases and the assembling workability is not good. there were.

Therefore, in an automobile production line, in order to improve assembly workability by reducing the number of assembly steps and the number of parts, and to reduce assembly costs and parts costs, for example, an instrument panel, a roof, a door and a back are used. 2. Description of the Related Art Each component of an automobile such as a door is modularized in advance for each part. Here, the module is
It is an integrated combination of existing parts such as various equipment and equipment units and automotive components. In this modularization, for example, for each part such as an instrument panel, necessary parts are assembled in advance by a part maker or the like to make a module (subassembly), and then each module is assembled to a vehicle body in a production line of an automobile maker. Since the work is performed, it is possible to reduce the number of assembly steps and the number of parts, improve the assembling workability, and reduce the assembly cost and the parts cost. In addition, modularization not only reduces such costs, but also contributes to reducing the weight of automobiles by reducing the weight of components as a whole that are assembled into automobiles as part of environmental protection measures. FIG. 8 is an exploded perspective view of the modularized automobile door. According to this, for example, a component such as a power window motor 202, a power window regulator 203, a speaker 204, and a wire harness 205 for connecting these components are previously attached to an inner panel 201 attached to an automobile door 200, and a module as a door module 206 is provided. Has been made.

As a further development of the sub-assembly module as described above, there is a function integration type module. As a further development of this function integration type module, a function fusion type module is considered.
A function-integrated module is a module that integrates the functions between various equipment and equipment units and is integrated with the components, and a function-integrated module is a combination of various equipment and equipment units and these equipment. And wirings such as a wire harness that connects between device units, and is integrally connected to components of an automobile.

Prior to such modularization,
For example, a flexible printed circuit (Flexible printed circuit) is used instead of a conventional wire harness in an automobile manufacturing line.
Printed Circuits (FPC) Even if you want to use a harness, if you want to assemble the FPC harness to the car body, it is necessary to design a structure that allows the FPC harness to be successfully assembled on the car body side, and to use the FP used for ordinary electronic components.
Since a large FPC harness was required as an FPC harness to be attached to a vehicle body rather than a C harness, it was difficult to employ an FPC harness instead of a wire harness.

[0007] However, with the progress of modularization,
For example, it is possible to design a structure that allows the FPC to be assembled successfully on the component parts side (module side) such as the instrument panel, and it is also possible to divide the FPC harness into parts (by module) and to assemble it. Compared to the case where the FPC harness is directly assembled, a small FPC harness can sufficiently cope with the situation, and the FPC harness can be adopted. In addition, by adopting the FPC harness, for example, it is possible to make the module thinner and lighter and to mount components.
In particular, so-called component-mounted FPC harnesses, in which circuit components such as various equipment and device units are mounted on the FPC harness, are capable of higher-density wiring than wire harnesses using electric wires, and also have excellent expandability. ,
It is receiving much attention as wiring for function-integrated modules.

[0008]

As shown in FIG. 9, an FPC harness 100 has an adhesive 102 on an insulating film 101 made of, for example, polyethylene terephthalate (PET) or polyethylene naphthalate (PEN). A wiring 103 made of a conductive pattern is formed by laminating a copper foil through the interposer, and the insulating film 101 and the wiring 103 are formed in order to protect a circuit made of the formed wiring. It is common to adopt a structure in which a coverlay film made of a synthetic resin or the like having electrical insulation properties is covered thereon as the upper cover 104, or a structure in which a cover is formed by resist printing instead of the coverlay film. . In particular, when an FPC harness is applied to the module or the like, the cover is often covered with a cover lay film to improve the damage resistance.

[0009] However, the FPC harness has a high cost and a high cost of the copper clad laminate (CCL) itself, which is a material for covering a coverlay film, and has a high number of manufacturing steps, which is complicated and high. Low yield, etc., the mere use of FPC harnesses instead of wire harnesses has increased the cost of parts for modules such as instrument panels, despite lowering assembly costs in the production line of angle-cut automobiles. And
As a result, the entire manufacturing cost increases, and there has been a problem that it is difficult to actively introduce the FPC harness as a wiring member of the module.

[0010] The present invention has been made in view of the above problems, and has as its object to provide a door module which can be manufactured at low cost and a method of manufacturing the same.

[0011]

A first method of manufacturing a door module according to the present invention comprises combining an inner panel disposed on the vehicle interior side with an outer panel disposed on the vehicle exterior side. A method for manufacturing a door module integrating an equipment and a device unit attached to an automobile door to be mounted and a wiring circuit for electrically connecting the equipment and the device unit, wherein the inner member made of a resin member The method is characterized in that a foil-like conductive material is pressed on a panel by press working, and the wiring circuit is directly patterned on the inner panel.

[0012] A second method of manufacturing a door module according to the present invention is directed to an automobile door configured by combining an inner panel disposed on the vehicle interior side and an outer panel disposed on the vehicle exterior side. A method for manufacturing a door module integrating an attached equipment and device unit and a wiring circuit for electrically connecting the equipment and device unit, wherein the door trim is made of a resin member attached to the inner panel. The present invention is characterized in that a foil-like conductive material is pressed by press working, and the wiring circuit is directly patterned on the door trim.

According to the door module of the present invention, an inner panel made of a resin member of an automobile door constituted by combining an inner panel and an outer panel, or a door trim (decorative board) made of a resin member attached to the inner panel. Then, for example, a copper foil or the like is pressed by press working such as a die stamping method or the like to directly form a wiring circuit pattern. Therefore, the manufacturing process is simple, and the remaining copper foil other than the copper foil on which the wiring circuit is formed can be reused by press working, so that the yield is good. As a result, the door module itself can be manufactured at lower cost than when a wiring member such as an FPC harness is attached.

The wiring circuit is formed by a hot stamping method such as die stamping using a conductive material having at least one surface subjected to a surface roughening treatment or a conductive material having a thermosetting or thermoplastic adhesive applied thereto. It is good to be formed by processing. By doing so, the wiring circuit can be formed with high adhesion on the inner panel or the door trim. Also, it is considered that an electrolytic copper foil or a rolled copper foil is suitable as the conductive material. This is because the electrolytic copper foil or the rolled copper foil is relatively inexpensive, is easily processed, and is most commonly used.

[0015] The first door module according to the present invention comprises:
Equipment and equipment units attached to an automobile door configured by combining an inner panel arranged on the vehicle interior side and an outer panel arranged on the exterior side of the automobile, and a connection between these equipment and equipment units. A door module that is integrated with a wiring circuit that is electrically connected, wherein the wiring circuit presses a foil-shaped conductive material on the inner panel made of a resin member by pressing to form the wiring circuit on the inner panel. Characterized by being directly patterned.

[0016] The second door module according to the present invention comprises:
Equipment and equipment units attached to an automobile door configured by combining an inner panel arranged on the vehicle interior side and an outer panel arranged on the exterior side of the automobile, and a connection between these equipment and equipment units. A door module integrated with a wiring circuit to be electrically connected, wherein the wiring circuit presses a foil-like conductive material by pressing to a door trim made of a resin member attached to the inner panel, It is characterized in that the pattern is directly formed on the door trim.

[0017]

Embodiments of the present invention will be described below with reference to the accompanying drawings. FIG. 1 is a side view showing an automobile door equipped with a door module according to one embodiment of the present invention.

The door module 10 includes an automobile door 20.
An inner panel 21 attached to an outer panel 22 arranged on the outside of a vehicle (not shown) constituting
In addition, a device unit 26 for driving / controlling various kinds of equipment such as a speaker 23 and a door lock release lever 24 and electric equipment such as an electric side mirror (not shown) attached to the vehicle door 20 and a power window 25. And a wiring member 30 including a wiring circuit 31 for electrically connecting these electrical equipment, equipment and the device unit 26 is formed. Wiring member 30 and device unit 2
6 (including electrical equipment and equipment) is connected, for example, to a connector part 32 previously connected to a wiring circuit 31 of a terminal part of the wiring member 30 and a terminal part of a wiring 28 such as the device unit 26. It can be performed only by a simple operation of fitting a connector portion 29 prepared in advance to the connector. The inner panel 21 of the door module 10 is
For example, the wiring member 30 is made of a resin member such as a synthetic resin.
Is a so-called flat wire, and the wiring circuit 31 is formed by forming a copper foil or the like directly on the inner panel 21 by patterning.

The inner panel 21 of the vehicle door 20 is provided with a work hole used for connecting the electrical equipment to the equipment and the equipment unit 26 attached to the inner panel 21 and the like. A plurality of working openings 27 are provided. By using the door module 10, an assembler of the automobile door 20 uses the work opening 27 to provide, for example, an electric device such as an electric side mirror mounted on the outer panel 22 side, an equipment device, and the like. By electrically connecting the device unit 26 and the like via the wiring circuit 31 of the wiring member 30 and simply attaching the inner panel 21 constituting the door module 10 to the outer panel 22, wiring and connection work of the automobile door 20, etc. Can be assembled in a unified manner. As a result, the number of man-hours for assembling the vehicle door 20 on the production line can be reduced, so that the production cost can be reduced.

FIG. 2 is a flowchart showing a manufacturing process of the door module 10 mounted on the vehicle door 20.

First, an inner panel 21 of an automobile door 20 is formed by molding a resin member such as a synthetic resin (step S1). After forming the inner panel 21,
Next, for example, a rolled copper foil subjected to a surface roughening treatment using a polishing solution or an abrasive, a copper foil such as an electrolytic copper foil, or a copper foil coated with an adhesive such as thermosetting and thermoplastic. A conductive material such as is placed on the wiring circuit formation position on the inner panel 21 (step S2). In addition, for example, when copper foil is used as the conductive material, when the copper foil is subjected to a surface roughening treatment, as shown in FIG. Since fine copper particles precipitate on the surface, the adhesive strength to the inner panel 21 at the time of, for example, thermocompression bonding can be higher than usual. Next, in step S2, a pressing process such as a die stamping method is performed on the conductive material such as copper foil placed on the inner panel 21 to directly pattern the wiring circuit 31 on the inner panel 21 ( Step S3).

Here, FIG. 4 and FIG.
FIG. 9 is a diagram for explaining a method of forming the wiring circuit 31 by die stamping method used in the step 3; for example, the processing circuit 33 of the die stamp die 37 has the wiring circuit 3;
1 is formed in a pattern, and a circuit forming portion 34 formed of a convex portion or a ridge for thermocompression bonding to the inner panel 21 is formed. After the die stamping die 37 is heated in advance, it is pressed against the conductive material 35 placed on the inner panel 21, so that the conductive material 35 where the circuit forming portion 34 is in contact is thermocompression-bonded to the inner panel 21. Then, the wiring circuit 31 is formed directly on the inner panel 21 by removing the conductive material 35 of the other portion from the inner panel 21 with a recycle roll (not shown) or the like. As shown in FIG. 5, die stamping may be performed between the inner panel 21 and the conductive material 35 via a thermosetting or thermoplastic adhesive 38. This is because the bonding reliability between the inner panel 21 and the conductive material 35 can be improved in this way.

After forming the wiring circuit 31 on the inner panel 21 in step S3, the insulating protection layer 36 made of a synthetic resin or the like for protecting the wiring circuit 31 is covered with the wiring circuit 31.
The wiring member 30 such as a flat wire is formed on a predetermined area of the inner panel 21 including the first and second wires by a method such as thermocompression bonding (step S4). Finally, the equipment and the device unit 26 are mounted on the inner panel 21 on which the wiring member 30 is formed (step S5), and the door module 10 is mounted.
Is completed. Thus, the wiring circuit 31 is formed directly on the inner panel 21 of the door module 10,
The provision of the wiring member 30 can reduce the material cost, the operation cost, and the like as compared with the case where a wiring member such as an FPC harness is attached, so that the door module 10 can be manufactured at low cost.

FIG. 6 is a side view showing a door trim constituting a door module according to another embodiment of the present invention.
Note that a description of a portion overlapping with the portion already described in the above example is omitted.

The door module 40 is an automobile door (FIG. 1) constructed by combining an inner panel (not shown) arranged on the vehicle interior side and an outer panel (not shown) arranged on the vehicle exterior side. The device unit 26 and the like are mounted on a door trim (decorative board) 41 attached to an inner panel (not shown), and the wiring member 30 including the wiring circuit 31 for electrically connecting the mounted device units 26 and the like is formed. Do it. Wiring member 30 and device unit 2
The connection with 6 or the like can be made using a connector portion 39 or the like formed in advance. The door trim 41 of the door module 40 is made of a resin member such as a synthetic resin, for example.
The wiring member 30 is a so-called flat wire, and the wiring circuit 31 is formed by directly patterning a copper foil or the like on the door trim 41.

By using the door module 40, an assembler of an automobile door connects the electrical equipment mounted on, for example, an outer panel or an inner panel with the device unit 26 to the wiring circuit 31 of the wiring member 30. By simply connecting the door trim 41 constituting the door module 40 to the inner panel through the electrical connection via the inner panel, assembly work such as wiring and connection work of the automobile door can be performed collectively. As a result, it is possible to reduce the number of assembling steps and the manufacturing cost in the automobile door manufacturing line.

FIG. 7 is a flowchart showing a manufacturing process of the door module 40. First, a door trim 41 to be attached to an inner panel of an automobile door is formed by molding a resin member such as a synthetic resin or the like (step S1).
0). Next, it is placed at the wiring circuit forming position on the door trim 41 on which a conductive material such as a copper foil subjected to a surface roughening treatment or a copper foil coated with an adhesive is formed (step S11). Subsequently, the conductive material such as a copper foil placed on the door trim 41 is subjected to press working such as the die stamping method as described above, and the wiring circuit 31 is directly patterned on the door trim 41 (step S12). ). Then, an insulating protective layer 36 made of a synthetic resin or the like is formed on a predetermined area of the door trim 41 including the wiring circuit 31, and the wiring member 30 is formed (Step S13). After the wiring member 30 is formed, finally, the device unit 26 and the like are mounted on the door trim 41 (Step S14), and the door module 40 is completed. In this manner, the wiring member 31 is formed directly on the door trim 41 of the door module 40 to form the wiring member 3.
By providing 0, material costs and work costs can be reduced as compared with a case where a wiring member such as an FPC harness is attached, for example, so that the door module 40 can be manufactured at low cost.

[0028]

As described above, according to the present invention,
An inner panel made of a resin member of an automobile door formed by combining an inner panel and an outer panel, or a door trim (decorative plate) made of a resin member attached to the inner panel, is formed by a press working such as a die stamping method. The wiring circuit is directly patterned by pressing a foil or the like. Therefore, the manufacturing process is simple,
In addition, since the remaining copper foil other than the copper foil on which the wiring circuit is formed can be reused by press working, the yield is good. As a result, there is an effect that the door module itself can be manufactured at a lower cost as compared with a case where a wiring member such as an FPC harness is attached.

[Brief description of the drawings]

FIG. 1 is a side view showing an automobile door equipped with a door module according to an embodiment of the present invention.

FIG. 2 is a flowchart showing a manufacturing process of the door module.

FIG. 3 is an enlarged view showing a state of a copper foil surface.

FIG. 4 is a diagram for explaining a method of forming a wiring circuit by a die stamping method.

FIG. 5 is a diagram for explaining a method of forming a wiring circuit by a die stamping method.

FIG. 6 is a side view showing a door trim constituting a door module according to another embodiment of the present invention.

FIG. 7 is a flowchart showing a manufacturing process of the door module.

FIG. 8 is an exploded perspective view of a conventional modularized automobile door.

FIG. 9 is a cross-sectional view illustrating a structure of an FPC harness.

[Explanation of symbols]

10, 40 ... door module, 20 ... car door, 2
DESCRIPTION OF SYMBOLS 1 ... Inner panel, 22 ... Outer panel, 23 ... Speaker, 24 ... Door lock release lever, 25 ... Power window, 26 ... Device unit, 27 ... Working opening,
28 ... wiring, 29, 32, 39 ... connector part, 30 ... wiring member, 31 ... wiring circuit, 33 ... processing surface, 34 ... circuit forming part, 35 ... conductive material, 36 ... insulation protection layer, 37 ... die stamp Mold, 38: adhesive, 41: door trim.

 ──────────────────────────────────────────────────続 き Continuing from the front page (72) Inventor, Takehisa Ide, 1440, Mukurosaki, Sakura City, Chiba Prefecture Inside Fujikura Sakura Office (72) Inventor, Seiji Ohba 1440, Musaki, Sakura City, Chiba Prefecture Inside Fujikura Sakura Office Terms (reference) 4E351 AA02 BB01 BB30 CC17 CC18 CC19 DD01 DD04 DD54 DD55 GG20 5E343 AA02 AA12 AA38 BB24 BB67 CC21 CC22 DD54 DD55 DD56 EE21 EE52 FF08 FF21 GG02 GG04 GG11

Claims (8)

[Claims] 1. An equipment and an equipment unit to be mounted on an automobile door configured by combining an inner panel disposed inside a vehicle and an outer panel disposed outside the automobile, and these equipment. And a method of manufacturing a door module integrating a wiring circuit for electrically connecting between device units, wherein a foil-like conductive material is pressed by press working on the inner panel made of a resin member, A method of manufacturing a door module, wherein the wiring circuit is directly patterned on a panel. 2. An equipment and an equipment unit to be mounted on an automobile door configured by combining an inner panel arranged on the indoor side of an automobile and an outer panel arranged on the exterior of the automobile, and these equipment. And a method of manufacturing a door module integrating a wiring circuit for electrically connecting the device units, wherein a foil-like conductive material is pressed by pressing into a door trim made of a resin member attached to the inner panel. A method of manufacturing the door module, wherein the wiring circuit is directly patterned on the door trim. 3. The wiring circuit according to claim 1, wherein the wiring circuit is formed using a conductive material having at least one surface subjected to a roughening treatment, and the pressing is a hot pressing by a die stamping method. Item 3. The method for manufacturing a door module according to Item 1 or 2. 4. The wiring circuit is formed using a conductive material having at least one surface coated with a thermosetting adhesive, and the press working is a hot press working by a die stamping method. The method for manufacturing a door module according to claim 1. 5. The wiring circuit is formed by using a conductive material having a thermoplastic adhesive applied to at least one surface, and the press working is a hot press working by a die stamping method. A method for manufacturing a door module according to claim 1. 6. The method of manufacturing a door module according to claim 1, wherein the conductive material is an electrolytic copper foil or a rolled copper foil. 7. An equipment and a device unit to be mounted on an automobile door configured by combining an inner panel disposed inside a vehicle and an outer panel disposed outside the automobile, and these equipment. And a wiring circuit that integrates a wiring circuit for electrically connecting the device units, wherein the wiring circuit is formed by pressing a foil-shaped conductive material by press working on the inner panel made of a resin member. A door module formed directly on the inner panel by patterning. 8. An equipment and an equipment unit attached to an automobile door, which is constituted by combining an inner panel arranged on the indoor side of an automobile and an outer panel arranged on the exterior of the automobile, and these equipment. And a wiring circuit for electrically connecting the device units to each other, wherein the wiring circuit is a foil-shaped conductive material formed by pressing a door trim made of a resin member attached to the inner panel. A door module formed by pressing the door trim directly on the door trim.