JP2002282981A - Manufacturing method for panel member for automobile - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method for a panel material for an automobile capable of saving labor in manufacturing and suppressing the number of parts. SOLUTION: In this manufacturing method for a panel member for an automobile, an extruded material 31 which comprises a left-side side sill 12 and an extended part 32 extended from the left-side side sill 12 and having bent parts 34a-34e is pressed and formed. The extended part 32 is formed into a flat left- side panel 35 by developing the bent parts 34a-34e. A required left-side floor 11 is obtained by using the left-side panel 35 and the left-side side sill 12 by press-forming the left side panel 35.

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 panel material for an automobile, which is used to manufacture an automobile floor panel by extrusion.

[0002]

2. Description of the Related Art In recent years, various automobile body structures made of light metals such as aluminum have been proposed in order to reduce the weight of automobiles. For example, Japanese Unexamined Patent Publication No. 9-99870 entitled "Automobile floor structure" is known as a method for manufacturing an automobile floor. In this technique, a component of an automobile floor is extruded into a plurality of aluminum members, and the members are welded to reduce the weight of the automobile floor. This technical content will be described in detail below.

[0003] As an example, when a floor portion of an automobile floor is formed of five extruded members, first, five extruded members are extruded, and the extruded members are welded to form a floor portion. I do. On the other hand, a side sill of an automobile floor is similarly extruded, and an automobile floor is manufactured by welding a floor portion to the extruded side sill.

[0004]

However, the floor for automobiles disclosed in the above publication requires an operation of welding five extruded members to form the floor, and additionally an operation of welding the floor to the side sill. Is required. For this reason, it takes time and effort to manufacture an automobile floor.

Further, the floor for automobiles disclosed in the above publication requires five extruded members to form the floor portion, and additionally requires an extruded member to form the side sill. For this reason, the number of components increases, and it takes time to manage the components.
As described above, the complicated manufacturing and the large number of parts hindered the cost of the automobile floor from being reduced.

SUMMARY OF THE INVENTION It is an object of the present invention to provide a method for manufacturing a panel material for an automobile, which can save the trouble of manufacturing and reduce the number of parts.

[0007]

In order to achieve the above object, a first aspect of the present invention is an extrusion method comprising a hollow cylindrical body and an extending part extending from the cylindrical body and having a bent portion. The material is extruded, a bent portion is developed to form an extended portion into a flat panel, and the panel is press-molded to obtain a desired panel member with a panel and a tubular body.

By providing a bent portion in the extending portion, an extruded material comprising the cylindrical body and the extending portion can be integrally extruded. A desired panel member can be obtained by forming the extended portion into a flat panel and press-molding it. For this reason, since the number of parts of the panel member can be reduced, the management of the parts can be simplified without trouble. In addition, by reducing the number of components, it is possible to omit a joining operation between members. For this reason, the panel member can be easily manufactured without trouble.

[0009]

Embodiments of the present invention will be described below with reference to the accompanying drawings. The drawings should be viewed in the direction of reference numerals. FIG. 1 is a perspective view of an automobile panel member (first embodiment) according to the present invention, and shows an automobile floor 10 as an example. The floor 10 for an automobile has left and right floors (panel members) 11 and 21 formed symmetrically to each other, and a floor panel 14 of a left floor 11 is joined to a floor panel 24 of a right floor 21.

The left floor 11 includes a left side sill 12 constituting the left frame of the vehicle body frame, and a left floor panel 14 extending from the right side wall 12a of the left side sill 12 to the center of the vehicle body. The left side sill 12 is formed as a substantially hexagonal hollow cylindrical body, and upper and lower ridges 12b and 12c of the cylindrical body are provided with upper and lower reinforcing ribs 1 respectively.
3a and 13b.

The left floor panel 14 is formed substantially flat,
The left half of the floor tunnel (hereinafter referred to as “left floor tunnel”) 1 near the end 14a of the left floor panel 14
5 is press-formed, and the recess 16 is press-formed from the left side sill 12 to the left floor tunnel 15.
Thus, the rigidity of the left floor panel 14 can be maintained by press-molding the left floor tunnel 15 and the concave portion 16 on the left floor panel 14.

The right floor 21 has a right side sill 22 constituting a right frame of the vehicle body frame, a left side wall 22a of the right side sill 22 extending from the right side sill 22 to the center of the vehicle body, and a step portion 24a And a right floor panel 24 joined to the right.
The right side sill 22 is similar to the left side sill 12,
It is formed in a substantially hexagonal hollow cylindrical body, and upper and lower reinforcement ribs 23a, 23a,
23b.

The right floor panel 24 is formed substantially flat,
The right half of the floor tunnel (hereinafter, referred to as “right floor tunnel”) 2 is in the vicinity of the step portion 24 a of the right floor panel 24.
5, and a concave portion 26 is press-formed from the right side sill 22 to the right floor tunnel 25.
As described above, the rigidity of the right floor panel 24 can be maintained by press-molding the right floor tunnel 25 and the concave portion 26 on the right floor panel 24.

According to the automobile floor 10 of the first embodiment, since the left and right floors 11 and 21 as panel members are formed integrally, respectively, the left and right floors 11 and 21 are formed.
Parts can be reduced. In addition, by reducing the number of components, it is possible to omit a joining operation between members. For this reason, the left and right floors 11 and 21 can be easily manufactured without trouble.

Next, a method of manufacturing the automobile floor 10 according to the first embodiment will be described with reference to FIGS. Since the right floor 21 has a symmetrical shape with the left floor 11, a method of manufacturing the left floor 11 will be described below, and a description of a method of manufacturing the right floor 21 will be omitted.

FIGS. 2A and 2B are first explanatory views showing a manufacturing method according to the first embodiment of the present invention. In (a), the extrusion mold 30 is used to prepare for extrusion molding.
The extrusion die 30 includes an extrusion port 30a for extruding an extruded material 31 (shown in (b)) into a predetermined shape. (B)
In the above, the extruded material 31 is passed through the extrusion port 30a of the extrusion die 30.
Is extruded as indicated by the arrow.

FIGS. 3A and 3B are second explanatory views showing the manufacturing method according to the first embodiment of the present invention. In (a), when the extrusion molding process is completed, an extruded material 31 of the left floor 11 shown in FIG. 1 is obtained.

The extruded member 31 is a member formed by integrally extending the extending portion 32 from the right side wall 12a of the left side sill 12 of the hexagonal cylinder. The extending portion 32 extends the first flat portion 33a horizontally to the right from the right side wall 12a of the left side sill 12, and extends the second flat portion 33b to the first flat portion 33a through a first bent portion 34a by approximately 90 °. The third flat portion 33c is connected to the second flat portion 33b via the second bent portion 34b, and the third flat portion 33c is connected to the second flat portion 33b.
The fourth flat portion 33d is connected to the third flat portion 33c via the third bent portion 34c so as to be continuously folded upward, and the fourth flat portion 33d is connected to the fifth flat portion 3 via the fourth bent portion 34d.
The third flat portion 3e is continued by turning 3e downward.
This is a member formed in a bellows shape by continuing the sixth flat portion 33f in a state of being bent at approximately 90 ° through the fifth bent portion 34e at 3e. The bellows-like extension 32 is deployed as shown by the arrow.

In (b), the first to sixth flat portions 33a
The left panel (panel) 35 is obtained by flattening .about.33f (see (a)). The left side panel 35 integrally includes the left side sill 12 on the left side of the first flat portion 33a (see also (a)). The left panel 35 is press-formed.

FIGS. 4A and 4B are third explanatory views showing the manufacturing method according to the first embodiment of the present invention. In (a), the left panel 35 (shown in FIG. 3B) is press-formed to obtain the left floor panel 14 having the left floor tunnel 15 and the concave portion 16. The left floor panel 14 and the left side sill 12 constitute a desired panel member, that is, the left floor 11.

In (b), the extruded material of the right floor 21 is extruded and formed in the same manner as the extruded material of the left floor 11, and the bellows-like extended portion is developed into a flat panel. Similarly, the right floor 21 is obtained by press molding. The right floor 21 is the left floor 11
The right floor panel 24 is provided with a right floor tunnel 25 and a concave portion 26. In addition, when the right floor panel 24 is press-formed, for example, a step portion 24a is formed at an end of the right floor tunnel 25,
The right portion 14a of the left floor 11 is joined to the step portion 24a. Thereby, the floor 10 for a vehicle is obtained.

According to the manufacturing method of the first embodiment, the extruded member 31 including the left side sill 12 and the extended portion 32 can be integrally extruded by providing the extended portion 32 with the bent portion. This extension 32 is connected to a flat left panel 35.
Then, a desired left floor panel 14 (panel member) can be obtained by press molding.

As a result, the number of parts on the left floor panel 14 can be reduced, and the management of parts can be simplified without any trouble. In addition, by reducing the number of parts of the left floor panel 14, the joining work between members can be omitted. For this reason, the left floor panel 1
4 can be easily manufactured without trouble.

Next, second and third embodiments will be described with reference to FIGS. In the second and third embodiments, the same members as those in the first embodiment are denoted by the same reference numerals, and description thereof will be omitted. FIGS. 5A and 5B show a second embodiment according to the present invention.
It is explanatory drawing which shows the manufacturing method of embodiment. In (a), the extrusion mold 40 is used to prepare for extrusion molding. The extrusion die 40 has an extrusion port 40a for extruding the extruded material 41 into a predetermined shape. Extrusion port 40 of extrusion die 40
Extruded material 41 is extruded from a as shown by the arrow.

In (b), when the extrusion molding process is completed, the extruded material 41 on the left floor 11 shown in FIG.
Get. The extruded member 41 is formed of the left side sill 12 of the hexagonal cylinder.
This is a member in which the extending portion 42 is integrally extended from the right side wall 12a.

The extending portion 42 extends the first flat portion 43a horizontally to the right from the right side wall 12a of the left side sill 12, and bends the second flat portion 43b upward by about 90 ° to the first flat portion 43a. The second flat portion 43b and the third flat portion 43c are bent upward by about 120 °, and the third flat portion 43c is turned into the fourth flat portion 43d by approximately 120 ° downward. The fifth flat portion 43e is connected to the fourth flat portion 43d so as to be bent downward by approximately 120 °, and the fifth flat portion 43e is connected to the sixth flat portion 43f by approximately 120 °. The second flat portion 43g is continuous with the sixth flat portion 43f in a state where the seventh flat portion 43g is bent upward by approximately 120 °.
The substantially flat portions 43b to 43g constitute a substantially hexagonal cylinder.

The extruded material 41 has first and second flat portions 43.
a, 43b form a first bent portion 44a, and a second, third
The flat portions 43b and 43c form a second bent portion 44b,
The third bent portion 44c is formed by the third and fourth flat portions 43c and 43d.
Is formed, and a fourth bent portion 44d is formed by the fourth and fifth flat portions 43d and 43e, and the fifth and sixth flat portions 43e and 43f are formed.
To form a fifth bent portion 44e, and a sixth and seventh flat portion 43.
A sixth bent portion 44f is formed by f and 43g.

The first to seventh flat portions 43a to 43g are
The extension portion 42 can be configured as a substantially hexagonal cylinder by continuing through the sixth bent portions 44a to 44f.
Thus, the first to sixth bent portions 44a to 44a
With the provision of 44f, the extruded material 41 composed of the right side sill 12 and the extending portion 42 can be integrally extruded.

The left side panel 35 shown in FIG. 3B can be obtained by expanding the extending portion 41 in order from the seventh flat portion 43g to the second flat portion 43b as shown by the arrow. Next, by pressing the left panel 35 in the same manner as in the first embodiment, the left floor 11 shown in FIG. 1 can be obtained. According to the manufacturing method of the second embodiment, the same effects as those of the manufacturing method of the second embodiment can be obtained.

FIGS. 6A and 6B are first explanatory views showing a manufacturing method according to a third embodiment of the present invention. In (a), an extruded material 51 is passed through an extrusion port of an extrusion die (not shown).
Is extruded. The extruded member 51 is a member in which the left side sill 12 of the hexagonal cylinder and the right side sill 22 of the hexagonal cylinder are integrally connected by the extension 52.

The extension portion 52 is a bellows-like member like the extension portion 32 shown in FIG. 3A, and is formed by connecting first to tenth flat portions 53a to 53j to first to ninth bent portions. The left end is connected to the left side wall 12 a of the left side sill 12, and the right end is connected to the left side wall 2 a of the right side sill 22.
2a. The bellows-like extension 52 is deployed as shown by the arrow.

In (b), the first to tenth flat portions 53
Panels 55 are obtained by flattening a to 53j (see (a)). The panel 55 includes a first flat portion 53a.
The left side sill 12 is integrally provided on the left side of (see also (a)), and the right side sill 12 is integrally provided on the right side of the tenth flat portion 53j (see also (a)). This panel 55 is press-formed.

FIG. 7 is a second explanatory view showing the manufacturing method according to the second embodiment of the present invention. By pressing the panel 55 (shown in FIG. 6B), a floor panel 56 having a floor tunnel 57 and a recess 58 is obtained. The floor panel 56 includes the left side sill 12 and the right side sill 2
2 together with a desired panel member, that is, an automobile floor 50.

According to the manufacturing method of the second embodiment, since the extension portion 52 is provided with a bent portion, the left and right side sills 1 are provided.
The extruded member 51 composed of the extension portions 52 and 22 can be integrally extruded. After forming the extending portion 52 on the flat left panel 55, a desired automobile floor 50 (panel member) can be obtained by press molding.

As a result, the number of parts on the automobile floor 50 can be reduced, and the management of parts can be simplified without trouble. In addition, by reducing the number of parts of the automobile floor 50, the joining operation of members can be omitted. For this reason, the automobile floor 50 can be easily manufactured without trouble. further,
Since it is not necessary to join the left and right floors 11 and 21 by welding as in the first embodiment, the automobile floor 50 can be manufactured more easily by reducing the number of parts.

FIG. 8 is a perspective view showing another embodiment of the vehicle panel member according to the present invention. In the first embodiment, the vehicle floor 10 has been described as an example of the vehicle panel member. However, the present invention is not limited to this, and may be applied to other vehicle panel members. For example, the dashboard 60 and the parcel shelf 70 correspond to other vehicle panel members.

The dashboard 60 includes a cross member 61 extending across the left and right ends of the vehicle.
A panel member for partitioning the engine room 17 and the room 18 from each other. The parcel shelf 70 includes a cross member 71 extending across the left and right ends of the vehicle, and a shelf panel 72 formed integrally with the cross member 71, and is a panel member for partitioning the trunk room 19 and the room 18 from each other. Hereinafter, a method of manufacturing the dashboard 60 and the parcel shelf 70 will be described with reference to FIGS.

FIGS. 9A and 9B are first explanatory views showing a manufacturing method according to a fourth embodiment of the present invention. In FIG. 8A, an extruded material is extruded from an extrusion port (not shown) of an extrusion die to thereby form a dashboard 6 shown in FIG.
0 extruded material 64 is obtained. The extruded member 64 is a member in which an extending portion 66 is integrally extended from a lower side wall 65 a of a hollow quadrangular cylindrical body (cylindrical body) 65.

The extension 66 is provided on the lower side wall 6 of the rectangular cylinder 65.
5a, the first flat portion 67a extends vertically downward,
The second flat portion 67b is continuously bent forward by approximately 90 ° from the flat portion 67a via the first bent portion 68a, and the third flat portion 67c is connected to the second flat portion 67b via the second bent portion 68b. Is continuously folded back, and the fourth flat portion 67 is formed on the third flat portion 67c via the third bent portion 68c.
d is continuously folded forward, and the fourth flat portion 67
d, the fifth flat portion 67e is continuously folded backward via the fourth bent portion 68d, and the sixth flat portion 67f is bent approximately 90 ° on the fifth flat portion 67e via the fifth bent portion 68e. It is a member formed in a bellows shape by continuing in a bent state. The bellows-like extension 66 is deployed as shown by the arrow.

In (b), the first to sixth flat portions 67a
６９67f (see (a)) is flattened to obtain a panel 69. The panel 69 includes a first flat portion 67a.
A rectangular cylinder 65 is integrally provided on the upper part of (see also (a)). The panel 69 and the rectangular cylinder 65 are press-formed.

FIG. 10 is a second explanatory view showing the manufacturing method according to the fourth embodiment of the present invention. The square cylinder 65 (FIG. 9)
(Shown in (b)), the left and right end portions 61a, 61b are respectively bent into left and right bent portions 61c, 61c.
It is bent at d to obtain a substantially curved cross member 61.

In addition, a panel 69 (shown in FIG. 9B)
Of the left and right end panels 62a, 62
2b (left end panel 62a is not shown) is bent at left and right bent portions 62c and 62d, respectively, and left and right lower end panels 62e and 62f are bent at 62g and 62, respectively.
Bend at h.

By trimming the press-formed panel member, the periphery is cut into a desired shape, and the trimmed panel member is pierced to form a harness opening 62j and a bolt hole 62k at desired locations. To obtain a board 62. Thus, a desired panel member, that is, a dashboard 60 is constituted by the cross member 61 and the board 62.

According to the manufacturing method of the fourth embodiment, since the extending portion 66 is provided with the bent portion, the extruded material 64 composed of the left rectangular cylindrical body 65 and the extending portion 66 can be integrally extruded. The same effects as those of the first embodiment can be obtained.

In addition, according to the manufacturing method of the fourth embodiment, the panel member can be formed into more various shapes by press-forming the square cylindrical body into a desired shape. Therefore, the present invention can be applied to a method of manufacturing a panel member, that is, the dashboard 60. Therefore, the applicable range of the manufacturing method can be expanded, and the application can be expanded.

FIGS. 11A and 11B show a fifth embodiment of the present invention.
It is a 1st explanatory view showing the manufacturing method of an embodiment. In (a), an extruded material is extruded from an extrusion opening (not shown) of an extrusion die to obtain an extruded material 74 of the parcel shelf 70 shown in FIG. The extruded member 74 is a member in which an extending portion 76 is integrally extended from a front side wall 75 a of a hollow quadrangular cylindrical body (cylindrical body) 75.

The extension 76 is provided on the front side wall 7 of the rectangular cylinder 75.
5a, the first flat portion 77a is extended horizontally to the front side,
The second flat portion 77b is connected to the flat portion 77a via the first bent portion 78a in a state where the second flat portion 77b is bent downward by about 90 °, and the second flat portion 77b is connected to the third flat portion 77c via the second bent portion 78b. Is continuously turned upward, and the fourth flat portion 77 is formed on the third flat portion 77c via the third bent portion 78c.
d is continuously folded downward, and the fourth flat portion 77
d, the fifth flat portion 77e is continuously folded upward through the fourth bent portion 78d, and the sixth flat portion 77f is bent at the fifth flat portion 77e through the fifth bent portion 78e by approximately 90 °. It is a member formed in a bellows shape by continuing in a bent state. The bellows-like extension 76 is deployed as shown by the arrow.

In (b), the first to sixth flat portions 77a
７７77f (see (a)) is flattened to obtain a panel 79. The panel 79 includes a first flat portion 77a.
(See also (a).) A rectangular cylinder 75 is integrally provided at the rear end. The panel 79 and the rectangular cylinder 75 are press-formed.

FIG. 12 is a second explanatory view showing the manufacturing method of the fifth embodiment according to the present invention. The square cylinder 75 (FIG. 11)
(Shown in (b)) by press forming, the left and right end portions 71a, 71b are respectively bent into left and right bent portions 71c, 71b.
It is bent at d to obtain a substantially curved cross member 71.

In addition, the panel 79 (shown in FIG. 11 (b)) is press-formed, so that
a, 72b and a step 72c are obtained. The peripheral edge is cut into a desired shape by trimming the press-formed panel member, and the trimmed panel member is pierced to open the speaker mounting openings 72d and 7 at desired locations.
The shelf panel 72 is obtained by opening an opening 72e for mounting 2d or an air conditioner. . Thus, a desired panel member, that is, a parcel shelf 70 is constituted by the cross member 71 and the shelf panel 72.

According to the manufacturing method of the fifth embodiment, since the extending portion 66 is provided with the bent portion, the extruded material 64 composed of the left rectangular cylindrical body 65 and the extending portion 66 can be integrally extruded. The same effects as those of the first embodiment can be obtained. In addition, according to the manufacturing method of the fifth embodiment, the same effect as that of the fourth embodiment can be obtained by press-forming the square cylindrical body into a desired shape.

In the above embodiment, the example in which the extruded material is provided with a plurality of bent portions (5, 6, or 9) has been described. It can be arbitrarily selected. In addition, the bending state of the rolled portion is not limited to the first to fifth embodiments, but can be bent into an arbitrary shape.

In the above embodiment, the left and right side sills 12 and 22 are formed as substantially hexagonal cylinders, and the cross members 61 and 71 are formed as substantially square cylinders. However, the present invention is not limited to this. Thus, it is also possible to form other polygons.

Further, in the above-described embodiment, an example has been described in which the floors 12 and 21, the dashboard 60, and the parcel shelf 70 are manufactured by the method of manufacturing an automobile panel member. It is possible to apply to other members as long as the shape is similar to that of the member.

[0055]

According to the present invention, the following effects are exhibited by the above configuration. Claim 1 is that the extension portion is provided with a bent portion,
An extruded material consisting of a cylinder and an extension can be integrally extruded. A desired panel member can be obtained by forming the extended portion into a flat panel and press-molding it.

For this reason, the number of parts of the panel member can be reduced, and the management of the parts can be simplified without trouble. In addition, by reducing the number of components, it is possible to omit a joining operation between members. For this reason, the panel member can be easily manufactured without trouble. As described above, the cost of the panel member can be reduced by reducing the number of components and omitting the joining operation.

[Brief description of the drawings]

FIG. 1 is a perspective view of a vehicle panel member (first embodiment) according to the present invention.

FIG. 2 is a first explanatory view showing the manufacturing method according to the first embodiment of the present invention;

FIG. 3 is a second explanatory view showing the manufacturing method according to the first embodiment of the present invention;

FIG. 4 is a third explanatory view showing the manufacturing method according to the first embodiment of the present invention;

FIG. 5 is an explanatory view showing a manufacturing method according to a second embodiment of the present invention.

FIG. 6 is a first explanatory view showing a manufacturing method according to a third embodiment of the present invention.

FIG. 7 is a second explanatory view showing the manufacturing method according to the second embodiment of the present invention;

FIG. 8 is a perspective view showing another embodiment of the automotive panel member according to the present invention.

FIG. 9 is a first explanatory view showing a manufacturing method according to a fourth embodiment of the present invention.

FIG. 10 is a second explanatory view showing the manufacturing method according to the fourth embodiment of the present invention.

FIG. 11 is a first explanatory view showing a manufacturing method according to a fifth embodiment of the present invention.

FIG. 12 is a second explanatory view showing the manufacturing method according to the fifth embodiment of the present invention.

[Explanation of symbols]

10, 50: automobile floor, 11: left floor (automobile panel member), 12: left side sill (hollow cylindrical body), 14: left floor panel, 21: right floor (automobile panel member), 22 ... Right side sill (hollow cylindrical body), 24 Right floor panel, 31, 41, 51,
64, 74 ... extrusion part, 32, 42, 52, 66, 76 ...
Rolling parts, 34a to 34e: first to fifth panels, 35: left panels (panels), 44a to 44f: first to sixth panels, 50: automobile floor (automobile panel members), 5
4a to 54i ... first to ninth panels, 55, 69, 79 ...
Panel, 56: Floor panel, 60: Dashboard (automobile panel member), 61, 71: Cross member,
62: board, 65, 75: square cylinder (hollow cylinder), 68a to 68e: first to fifth panels, 70: parcel shelf (automobile panel member), 72: shelf panel, 78a to 78e First to fifth panels.

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) B62D 25/20 B62D 25/20 FD (72) Inventor Hirotatsu Kanda 1-10-10 Shinsayama, Sayama City, Saitama Prefecture 1 Honda Engineering Co., Ltd. F-term (reference) 3D003 AA04 BB02 CA05 CA09 CA14 CA17 CA18 CA42

Claims (1)

[Claims] An extruded material comprising a hollow cylindrical body and an extended portion extending from the cylindrical body and having a bent portion is extruded, and the extended portion is expanded by expanding the bent portion. A method for manufacturing a panel member for an automobile, comprising forming a flat panel and press-molding the panel to obtain a desired panel member from the panel and the tubular body.