JP2009126359A - Automobile side door excellent in collision safety - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an automobile side door excellent in safety at a collision, light in weight, and easy to be molded or assembled. <P>SOLUTION: In a lower structure of the automobile side door, an inner panel constituting a vehicle room side is divided in four and composed of aluminum alloy members 1, 10, 20, 30. These aluminum alloy members mutually joined and integrated in a frame-like shape having a space 41 at the center has configurations a-e as follows: a. the members 20, 30 are thin plate-shaped molded panels; b. the member 10 is a thin plate-shaped molded panel or an extrusion molded member; c. the member 1 is an extrusion molded member, and a wall surface 5 has irregularities 3, 4; d. a wall surface 61 of a locker 60 also has with irregularity 62 in a shape engaged with the irregularities 3, 4; e. these wall surfaces 5, 61 are mutually engaged via their irregularities 3, 4, 62 at the time of a vehicle body-side collision. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to an automobile side door that can cope with a side collision (side collision) of an automobile, has excellent collision safety, is lightweight, and can be easily assembled.

  In recent years, with respect to global environmental problems caused by exhaust gas and the like, improvement in fuel efficiency has been pursued by reducing the weight of the body of a transport aircraft such as an automobile. For this reason, the application of lighter aluminum alloy materials such as rolled plates and extruded shapes, in place of steel materials that have been used in the past, is increasing especially for automobile bodies. Of these, the outer panel (outer plate) and inner panel (inner plate) of panel structures such as automobile doors also have Al-Mg-Si AA to JIS 6000 series (hereinafter simply referred to as 6000 series) and Al- The use of aluminum alloy plates such as Mg-based AA to JIS 5000-based (hereinafter simply referred to as 5000-based) is being studied.

  Conventionally, as an example of applying aluminum alloy plates to automobile doors to reduce weight, the front part is opened and closed via a hinge on the vehicle body as a side door structure of an automobile (hereinafter, the side door is also simply referred to as a door). There is an example in which an inner panel and an outer panel of a front door that is pivotally attached and a rear door that is pivotally attached to a vehicle body via a hinge are made of aluminum alloy plates (see, for example, Patent Document 1). .

  However, in the example in which the inner panel and the outer panel are made of an aluminum alloy plate, the plate thickness is reduced to, for example, 1.2 mm or less in order to reduce the weight. For this reason, in order to cope with a side collision, which has become stricter in recent years, many reinforcing materials are required to ensure the rigidity and strength of the door.

  10 and 11 show examples of side doors in which the inner panel and the outer panel are aluminum alloy plates. 10 is a front view of a conventional aluminum alloy door inner panel, and FIG. 11 is a cross-sectional view of the door in which the inner panel and the aluminum alloy outer panel of FIG. 10 are joined. The example of FIG. 10 is a door inner panel integrally formed with an aluminum alloy plate including the frame 123 of the door window and the door lower structure 124. In this case, since the aluminum alloy plate itself is a thin plate, as described above, many reinforcing materials are required to ensure the rigidity and strength of the door and to ensure the collision safety.

  In the example of FIG. 10, plate reinforcements 127 and 128 formed of aluminum alloy plates extending in the vertical direction of the vehicle body and in the longitudinal direction of the vehicle body are installed on both sides of the door lower structure 124. A reinforce upper 126 made of an extruded hollow shape member or a hollow panel extending in the longitudinal direction of the vehicle body is installed on the upper portion of the door lower structure 124 in order to ensure collision safety in the longitudinal direction of the vehicle body. Further, a door beam 125 made of an extruded hollow member extending in the front-rear direction of the vehicle body is installed at the lower portion of the door main body portion 124 to ensure side collision safety.

  For this reason, the number of joints such as welding and self-piercing rivets associated with the installation of such a reinforcing material is enormous, and the labor for the joint also increases. Moreover, the weight increase accompanying installation of a reinforcing material also impairs the advantage of weight reduction using an aluminum alloy. In addition, the aluminum alloy plate is difficult to press-form to an inner panel having a particularly complicated shape and a high forming depth (height). In particular, in recent years, the inner panel molding depth (door thickness) has increased to about 130 mm in order to cope with the side collision described above. Therefore, it becomes increasingly difficult to press form an aluminum alloy plate on an inner panel having such a high forming depth (height).

  In contrast, the present inventors have proposed an aluminum alloy inner panel for automobile side doors that satisfies the necessary strength and rigidity to cope with a side collision, is excellent in collision safety, is lightweight, and is easy to form and assemble. I have done it. For example, in Patent Document 2, an inner panel of a side door of an automobile is an aluminum alloy plate made of a relatively thick plate, and a rectangular large hollow portion ( We proposed an example with space. Further, in Patent Document 3, an aluminum alloy sheet-formed panel is overlapped on the vehicle compartment side and the outer panel side to form an inner panel, and a closed cross-sectional space is formed at both the inner panel central portion and the peripheral portion. Proposed.

For example, in these Patent Documents 2 and 3, a deep (a door thickness is ensured) cross-sectional space that can cope with a side collision can be formed in the center part and the peripheral part of the inner panel. For this reason, the strength and rigidity of the inner panel's central part and peripheral part can be greatly improved, and it is not necessary to use many reinforcing materials as in the past, and it can cope with side collisions where standards are becoming stricter. Can do. Moreover, the large shaping | molding depth required for an inner panel is securable by thickening a shaping | molding panel or overlapping two shaping | molding panels. Therefore, it is possible to produce an aluminum alloy inner panel having an inner panel forming depth (door thickness) that can solve the problem of the aluminum alloy thin plate that is difficult to press-form compared to a steel plate and can cope with the side collision. it can.
JP 2004-122874 A JP 2006-96179 A JP 2006-306157 A

  According to the above-mentioned safety standards for side collision, even if the speed of side collision increases, the side door should not be greatly deformed and enter the passenger compartment to impair the safety of passengers in the passenger compartment. In the side collision test based on this safety standard, a carriage having a barrier at the tip is caused to collide with the side of the driver's seat of the automobile body at around 50 km / h. For this reason, an impact load is applied to the door panel together with the vehicle body skeleton member such as the B pillar of the automobile body, and the side door is deformed so as to enter the compartment.

  On the other hand, as described above, conventionally, a door beam is arranged as a reinforcing member inside the side door, and the front of the door is hinged, the rear is coupled to the vehicle body with a lock, and the lower part of the door is It interferes with a hollow rocker made of steel or the like that extends in the longitudinal direction of the vehicle body below the side door. For this reason, in the side collision test under the conventional setting conditions, there is an effect of side collision countermeasures such as the reinforcing member, and the deformation of the side door in the direction of the passenger compartment is not relatively large.

  However, Euro-NCAP's proposed side impact test change, which is a third-party evaluation on vehicle safety in Europe, has recently been published in order to make vehicle safety standards more stringent in actual side crashes. It is getting stricter. That is, the weight of the cart used for the test is significantly increased from the conventional 950 kg to 1500 kg, and the aluminum honeycomb in the portion of the barrier on the front of the cart that collides with the door is hardened. Due to such a change, the impact load applied to the side door panel in the side collision test by this Euro-NCAP in Europe becomes much larger than before. For this reason, even if the deformation of the lower part of the side door in the direction of the passenger compartment is not increased in the conventional side collision test, the lower part of the side door is deformed and gets over the locker in this new side collision test. There is a possibility that the vehicle will enter the passenger compartment.

  For such a side impact test by Euro-NCAP in Europe, a side door made of an aluminum alloy inner panel as proposed in Patent Documents 2 and 3 may be used depending on conditions. There is a possibility that the deformation of the lower part of the vehicle over the locker cannot be suppressed. For this reason, even in an automobile side door made of an aluminum alloy inner panel that is lightweight and easy to form and assemble, the deformation of the lower part of the side door at the time of a side collision is interfered by a rocker during a side collision where the conditions are severe. There is a need to improve the effect and to have excellent collision safety that prevents the lower part of the inner panel from being greatly deformed and entering the vehicle interior beyond the locker.

  Therefore, the object of the present invention is excellent in collision safety, even in the case of a side collision in which the above-mentioned conditions are severe, so that the lower part of the inner panel does not greatly deform and enter the vehicle interior beyond the locker. The present invention intends to provide a side door made of an aluminum alloy inner panel.

In order to achieve this object, the gist of the automobile side door excellent in collision safety according to the present invention is as follows. As the lower structure of the automobile side door, the inner side constituting the vehicle compartment side with respect to the outer panel constituting the side surface side of the vehicle body. The panel is made of an aluminum alloy member, and these aluminum alloy members are divided into four parts, a front part and a rear part in the longitudinal direction of the vehicle body and an upper part and a lower part in the vertical direction of the vehicle body, and these members are joined to each other. It is integrated as an inner panel in a frame shape having a space in the center, and the lower member is opposed to the hollow structure rocker extending in the longitudinal direction of the vehicle body substantially in parallel, and each of the aluminum alloy members and the rocker And have the following configurations a to e.
a. The front and rear members of the inner panel are made of an aluminum alloy sheet forming panel.
b. The upper member of the inner panel is composed of either an aluminum alloy sheet forming panel or an aluminum alloy extruded shape.
c. The lower member of the inner panel is made of an aluminum alloy extruded shape having a wall surface extending in the vertical direction of the vehicle body, and the wall surface extending below the lower member is provided with irregularities.
d. On the other hand, the side wall surface of the vehicle body extending in the vertical direction of the vehicle body of the rocker is also provided with unevenness in a shape that engages with the unevenness of the wall surface extending below the lower member.
e. The vehicle body side wall surface of the rocker is the vehicle compartment side, and the wall surface extending to the lower side of the lower member is the vehicle body side side. They are arranged so that they fit together.

  Here, in the said summary, it is preferable that the member of the lower part of the said inner panel has a solid cross-sectional shape. Moreover, it is preferable to provide an aluminum alloy reinforcing material on the side of the joint portion with the lower member of the inner panel in the hollow structure of the rocker.

  The present invention can be applied to an automobile side door having a hybrid structure with a steel plate outer panel including an all-aluminum side door in which both an outer panel and an inner panel are made of an aluminum alloy.

  In the present invention, first, the inner panel as the lower structure of the automobile side door is made of an aluminum alloy member divided into four parts, a front part and a rear part in the longitudinal direction of the vehicle body and an upper part and a lower part in the vertical direction of the vehicle body. The front and rear members are each composed of an aluminum alloy sheet forming panel. The upper member is made of either an aluminum alloy sheet-formed panel or an aluminum alloy extruded shape. And the said lower member is comprised from the aluminum alloy extrusion shape material which has the wall surface extended in a vehicle body up-down direction.

  Then, these aluminum alloy members are joined to each other and integrated as an inner panel in a frame shape having a space at the center, and the lower member is made of a hollow structure such as steel that extends in the longitudinal direction of the vehicle body. Supported by a locker. Thereby, first, the inner panel itself and the side door can be reduced in weight by the space of the central portion.

  At this time, in order to increase the degree of interference between the wall surface extending downward of the lower member and the side wall surface of the vehicle body of the hollow rocker made of steel or the like, Concavities and convexities having shapes that engage with each other are provided on both the wall surface extending below the lower member and the wall surface on the outer side in the vehicle body width direction of the rocker having a hollow structure such as steel. As a result, the outer wall surface of the rocker is the vehicle interior side, and the wall surface extending to the lower side of the lower member is the vehicle body side surface. In other words, at the time of a vehicle body side collision, the wall surfaces are arranged so that these wall surfaces engage with each other through the irregularities.

  By engaging these irregularities, the outer wall surface and the lower part of the rocker are lower than those of the conventional smooth (even) wall surfaces, even in side collisions where the standard is stricter The degree of interference with the member wall surface is significantly increased. For this reason, the lower part of the inner panel is firmly restrained by the locker, and the lower part of the side door inner panel does not easily get over the locker and deform even in a side collision where the standard is strict. Even if the engaging portion is broken, the deformation and movement of the lower part of the inner panel in the direction of the vehicle interior is greatly restricted, and the possibility of entering the vehicle interior is reduced. Therefore, it can be set as the motor vehicle side door excellent in the collision safety with respect to the side collision in which the standard | standard becomes severe. For this reason, the required rigidity and intensity | strength of a door which can respond to the side collision which has become severe in recent years can be ensured, without requiring many reinforcement materials conventionally. Moreover, it can be used as an automobile side door that is lightweight and can be easily molded and assembled.

  Embodiments of the present invention will be described below in detail with reference to the drawings. First, an embodiment of the automobile side door of the present invention will be described with reference to FIGS. 1 is a perspective view of the automobile side door of the present invention (after assembly), FIG. 2 is a perspective view of each member constituting the automobile side door of the present invention (before assembly), and FIG. 3 is a view of the automobile side door of the present invention. It is sectional drawing. In addition, in the aspect of FIGS. 1-2, the structure of only a door inner panel part is shown among a motor vehicle side door.

Inner panel 40:
As shown in FIG. 3, the inner panel 40 constituting the lower structure on the vehicle compartment side of the automobile side door is premised on the outer panel 50 constituting the lower structure on the vehicle body side surface of the automobile side door. It is arranged on the passenger compartment side with a gap. As shown in FIG. 3, the inner panel 40 is supported on a lower wall surface 5 of the lower member 1 described later by a rocker 60 having a hollow structure made of steel or the like extending in the longitudinal direction of the vehicle body. ing.

  The inner panel 40 of the present invention is not composed of a single plate (single plate), but, as a premise, as shown in FIG. 2, the front member 20 and the rear member 30 in the longitudinal direction of the vehicle body, and the vertical direction of the vehicle body The upper member 10 and the lower member 1 in the direction are divided into four aluminum alloy members.

  In addition, as shown in FIG. 1, the inner panel 40 of the present invention has these members 1, 10, 20, and 30 overlapped with each other at the joints indicated by dotted lines, so that welding means or mechanical joining is achieved. Means, and these are combined and combined to be integrated. At this time, each of the members 1, 10, 20, and 30 is integrated as an inner panel 40 in a rectangular frame shape having a large space 41 at the center.

  These integrated inner panels play the same role as the bottom plate (surface) on the passenger compartment side of an ordinary (conventional) single panel inner panel. However, since these integrated inner panels 40 have a large space 41 in the central portion, compared to an inner panel made of a normal single plate (a single plate having no large space 41 in the central portion). Can be significantly lighter.

(Joining)
Specifically, the two members 6 and 7 of the lower member 1 are overlapped with the end 25 of the front member 20 and the end 35 of the rear member 30 in the vehicle body longitudinal direction. Combined and joined. Both end portions 15 and 16 of the upper member 10 are overlapped and joined to the end portion 24 of the front member 20 and the end portion 34 of the rear member 30 in the longitudinal direction of the vehicle body.

  The joining of the members in these overlapping portions does not require any special means, and a normal (generally used) joining method can be used. For example, various welding methods such as spot welding, friction stir welding (FSW) welding, arcing, and laser can be applied in consideration of joining conditions, joining strength, workability, and the like. Further, mechanical joining such as SPR (self-piercing rivet), bolt coupling (a normal bolt, nut system or stud bolt system), mechanical clinching or the like can be applied. Furthermore, adhesion by an adhesive can also be applied. These joining means may be applied alone or in various combinations. The overlapping portion indicated by the dotted line is an example. The joining of the members may be performed by additionally or newly providing an overlapping portion in a portion other than the overlapping portion indicated by the dotted line. Moreover, you may join each member using other 3rd fastening members (mediating) in these overlapping parts and the part which does not overlap.

  1 to 3, a central portion of the inner panel 40 has a large space 41 formed by the members 1, 10, 20, and 30, each having a square frame shape as a whole. The thickness of the space 41 (the thickness in the vehicle body width direction) ensures a door thickness corresponding to a side collision. The space 41 also serves as a space for accommodating a window regulator as a door glass lifting mechanism, a door mirror driving motor, a door latch mechanism, and the like in an integrally set state.

  In FIG. 3, the lower structure of the automobile side door forms a box-shaped hollow structure having a space 41 by the members 1, 10, 20, and 30 constituting the inner panel and the outer panel 50. This ensures the necessary rigidity and strength as a side door even when a load (collision energy) due to a side collision from the side of the vehicle body (left side in the figure) indicated by the arrow direction in FIG. 3 is applied. it can. In addition, in each of sectional views 4, 5, 6, and 8, which will be described later, other than FIG. 3, the direction of the load due to the side collision is indicated by an arrow as in FIG.

  Here, as the outer panel 50, a panel having a normal plate thickness of 1.2 mm or less can be used, and a panel obtained by press forming a steel plate may be used, and an aluminum alloy plate is press formed to reduce the door weight. It may be a panel (a panel made of a molded aluminum alloy plate).

  Based on the basic configuration described above, the inner panel 40 of the present invention is characterized by having the following configurations a to e as an automobile side door in order to be excellent in collision safety.

a. Front and rear members of the inner panel:
The front and rear members 20 and 30 extend in three dimensions in the vehicle vertical direction, the front-rear direction, and the vehicle width direction, and have a complicated three-dimensional shape (inner panel shape). The size and depth (thickness) of the vehicle interior side inner panel of the side door are defined.

  Specifically, as shown in FIG. 2, the front and rear members 20 and 30 extend in the vertical direction of the vehicle body and define a size of the inner panel. Each has a vehicle compartment side bottom (or top) 21, 31. Further, from the peripheral portions of the bottom portions 21 and 31, there are wall portions 22 and 32 that respectively extend in the vehicle body width direction and define the depth (thickness) of the inner panel. Furthermore, it has flange portions 23 and 33 that project outward from the peripheral portions of the wall portions 22 and 32, extend in the longitudinal direction of the vehicle body and in the vertical direction, and are joined to other door frame members.

  Note that the upper side of the front and rear members 20, 30 serves as an opening of the door, so that the upper end of the vehicle compartment side bottom 21, 21, the upper end of the walls 22, 32, or the flange 23, The upper end part of 33 becomes a periphery and these wall parts and flange parts are not provided.

  A panel having such a large area and a complicated shape is difficult to produce with an extruded profile, and it is easier to make a panel formed from a thin aluminum alloy sheet such as the cold-rolled sheet. Accordingly, the front and rear members 20 and 30 of the inner panel are composed of thin plate-formed panels obtained by press-molding aluminum alloy plates that have been tempered after cold rolling so that the plate thickness is 2.5 mm or less. To do. If the plate thickness is too thick, the weight becomes heavy, and the advantages of weight reduction using an aluminum alloy compared to the conventional thin steel plate material are lost, and the formability such as bendability also deteriorates. However, if the aluminum alloy plate is too thin, the strength and rigidity required for the inner panel for a door cannot be satisfied, so the plate thickness is preferably 0.5 mm or more.

b. Upper panel of inner panel:
The upper member 10 of the inner panel is formed of either an aluminum alloy sheet-formed panel or an aluminum alloy extruded profile. The upper member 10 of the inner panel does not have a complicated three-dimensional shape as compared with the lower member 1 and does not require a larger area than the front and rear members 20 and 30 of the inner panel. Therefore, it can be made from either a panel formed from a thin plate or an extruded profile, and is made according to the shape conditions.

  For example, the member 10 in the upper part of the inner panel shown in FIG. 3 in particular has a hollow portion 15 surrounded by a cabin side rib (side) 11 and a vehicle body side rib (side) 12 and has a uniform shape in the longitudinal direction of the vehicle body. It has a cross-sectional shape extending at The upper member 10 also has flanges 13 and 14 for joining with other members in a substantially vertical direction. A cross-sectional shape extending in a uniform shape in the longitudinal direction of the vehicle body having such a hollow portion and a flange can be more easily obtained by extrusion. In addition, since the upper member 10 is an inner panel structural member supported by joining with other members, the upper member 10 is 1.2-4. In the case of a relatively thick wall thickness (plate thickness) of about 0 mm, it is difficult to form from a flat plate such as the cold-rolled plate, and an extruded shape is easier to make. On the other hand, if it is a solid shape having no hollow part and is relatively thin, it can be made from either a panel formed from a thin plate or an extruded profile.

c. The lower part of the inner panel:
The lower member 1 of the inner panel is made of an aluminum alloy extruded profile having a wall surface extending in the vertical direction of the vehicle body. As shown in FIG. 3, the lower member 1 is a solid member made up of a wall (vertical wall) 2 extending above the lower member 1 and a wall (vertical wall) 5 extending downward. It has a shape (a shape that does not have a hollow portion). In this invention, the unevenness | corrugations 3 and 4 are provided in the wall surface of the wall (vertical wall) 5 extended to this downward side. As shown in FIG. 3, the lower member 1 is formed on the side surface of the vehicle body of the rocker 60 having a hollow structure made of steel or the like extending in the longitudinal direction of the vehicle body on the wall surface 5 provided with the irregularities 3 and 4. It arrange | positions so that the wall surface 61 may be opposed substantially parallel.

(Uneven shape)
The unevenness has a cross-sectional shape in which the direction is convex toward the vehicle body side or the vehicle compartment side in the vehicle width direction (or substantially horizontal direction), and the length of the lower member 1 in the longitudinal direction of the vehicle body. , Extending in a substantially uniform shape. The projections 3 and 4 shown in FIG. 3 are provided with a projection 3 extending toward the side of the vehicle body and a projection 4 protruding toward the passenger compartment on the wall surface of the wall (vertical wall) 5 in the vertical direction. .

  The number and shape (size) of these irregularities provided on the lower member 1 are such that the outer wall surface of the rocker and the lower member wall surface are engaged at the time of a side collision. A mode in which the lower part of the panel does not easily enter the vehicle interior due to interference with the locker is appropriately selected. If the number of irregularities is too large or the shape is too large, the engagement efficiency between the outer wall surface of the rocker and the lower member wall surface may deteriorate, and the effect of the irregularities may be weakened.

(Comparative example)
Here, FIGS. 8 and 9 are reference diagrams for comparison showing an embodiment in which such unevenness 3 and 4 are not provided. FIG. 8 is a front view of the side door inner panel, and FIG. 9 is a cross section taken along a section A in FIG. 8 and 9, the central portion of the inner panel has a rectangular frame shape, which is the lower member 90 (corresponding to the lower member 1), the upper member 10, the front member 20, and the rear portion. The point which has the big space 41 formed of the member 30 is the same as above-mentioned FIGS.

  However, in the embodiment of FIGS. 8 and 9, the wall surface of the vertical wall 5 is relatively not provided on the wall surface of the vertical wall 5 of the lower member 90 without providing the irregularities 3 and 4 of the lower member 1 as described above. As a flat wall surface, it faces the flat outer wall surface 61 of the locker 60. In such flat wall surfaces, since the wall surfaces are not engaged with each other, the outer wall surface 61 of the rocker 60 may sufficiently restrain the deformation of the lower member wall surface 5 in a side collision where the standard is strict. Can not. For this reason, as described above, there is a high possibility that the member 1 at the lower part of the inner panel will be greatly deformed and get over the locker 60 and enter the vehicle interior in a side collision with strict standards.

(Modification of lower part)
FIG. 4 shows that the concave and convex portions 3 and 4 are provided on the lower wall surface with concave and convex portions 6 and 7 (6 convex toward the vehicle side surface side and 7 convex toward the passenger compartment side). 4 is the same as FIGS. 1 to 3 described above.

  FIG. 5 shows a modified example of the lower member 1, and the lower member 1 has a closed section hollow portion having higher strength and rigidity such as bending and crushing against a side collision than a solid shape. It is a hollow material. That is, as a hollow material having a vertical wall 2b on the side surface of the vehicle body with respect to the vertical wall 2 on the passenger compartment side and connected to this by a horizontal wall (horizontal rib) 2a, a hollow portion having a closed cross section at the center. Yes. As shown in FIG. 5, the vertical wall 2 b on the side of the vehicle body has a length extending from the lower part of the vertical wall 2 along the back side of the outer panel 50 toward the lower side of the door beam 70. ing. The hollow portion may have an open cross section, but the closed cross section has higher strength and rigidity such as bending and crushing against a side collision. In the example of FIG. 5, the wall surface of the wall (vertical wall) 5 extending downward on the vertical wall 2 on the passenger compartment side is provided with the same unevenness 3 and 4 as in FIG. Is substantially the same as FIGS.

  FIG. 6 shows a modified example of the lower member 1. A separate vertical wall 2 b is arranged on the side of the vehicle body to face the vertical wall 2 on the vehicle body side of the lower member 1. The reinforcing effect by the wall 2b is improved. As shown in FIG. 6, the vertical wall 2 b extends upward from the lower portion of the vertical wall 2 along the back side of the outer panel 50 in the same manner as the vertical wall 2 b of FIG. 5. It has a length that extends down (FIG. 6 can be said to have a shape without the lateral wall 2a in FIG. 5). In the example of FIG. 6, the wall surface of the wall (vertical wall) 5 extending downward on the vertical wall 2 on the passenger compartment side is provided with the same unevenness 3 and 4 as in FIG. The aspect of is substantially the same as FIGS.

(Production of the lower part)
The lower member 1 having a complicated cross-sectional shape such as the unevenness 3 and 4 extending in a uniform shape in the longitudinal direction of the vehicle body, even if it is a solid shape, is formed rather than being formed from a plate. It is easier to obtain by extrusion. Moreover, even when it is set as the hollow material which has a hollow part like FIG. 5, the direction by extrusion is obtained simply. Further, the lower member 1 has a role of suppressing deformation of the door due to interference with the locker, and therefore is relatively thick, about 1.2 to 4.0 mm, compared to the front and rear members 20, 30 and the like. Thickness (plate thickness) is preferable. Such a thick member is not easily formed from a flat plate such as the cold-rolled plate, and the extruded shape member is provided with the unevennesses 3 and 4 extending with the same cross-sectional shape in the longitudinal direction of the vehicle body. Easy (easy to design)

d. Locker:
The locker is mainly made of steel, and a normal steel hollow member having a closed section hollow portion 64 having high strength and rigidity such as bending and crushing against a side collision can be used. The locker is not necessarily made of steel, but may be made of other metals such as an aluminum alloy, synthetic resin, FRP, or a composite material thereof. However, in the present invention, as shown in FIG. 3, the rocker 60 is provided with irregularities 62 (62 convex toward the vehicle compartment side) on the side wall surface (vertical wall surface) 61 of the vehicle body extending in the vertical direction of the vehicle body. The point is characteristic. The unevenness 62 has a shape that engages with the unevenness 3 and 4 of the wall surface 5 that extends to the lower side of the lower member 1. , 61 are joined to support the member 1 at the bottom of the inner panel.

  At this time, the e. As an item, as shown in FIG. 3, the side wall surface 61 of the vehicle body of the rocker 60 is the vehicle compartment side, and the wall surface 5 extending to the lower side of the lower member 1 is the vehicle body side. However, it arrange | positions mutually so that it may mutually engage through the said unevenness | corrugations. In order to prevent the lower side of the door inner 40 from bending and deforming over the locker 60 and entering the vehicle compartment that can be easily destroyed in response to a side collision with stricter standards, the side collision is thus performed. When this occurs, the irregularities 3 and 4 provided on the wall surface 5 of the lower member 1 are engaged with the irregularities 61 and 62 provided on the rocker 60.

(Evening effect)
By providing the unevenness described above, the wall surface 5 of the lower member 1 and the vehicle body side wall surface 61 of the rocker 60 are engaged with each other via the unevenness (the unevenness 3, 4 and the unevenness 62). Placed in position. For this reason, even when a load (collision energy) from the left direction of the figure, as indicated by the arrow in FIG. It interferes and restrains deformation of the inner panel into the passenger compartment. Such an interference action between the concaves and convexes is naturally absent or equal to the conventional smooth (coplanar) wall surfaces without the concaves and convexes of FIGS. Therefore, by providing unevenness, compared with the case of wall surfaces without such unevenness, mutual interference and restraint action between the outer wall surface 61 of the rocker 60 and the wall surface 5 of the lower member 1 at the time of a side collision. Is significantly higher.

  As a result, the lower part of the inner panel 40 is firmly restrained by the locker 60, and the engagement between the lower part of the side door inner panel 40 and the rocker 60 can be easily disengaged even in a side collision with strict standards. There is nothing. Moreover, even if this engaging portion is destroyed at the time of a side collision, the impact energy corresponding to the deformation generated there is consumed. For this reason, the deformation | transformation and movement to the vehicle interior direction (right direction of FIG. 3) of the lower part of the inner panel 40 are restrict | limited largely, and the possibility that the inner panel 40 will remove | deviate from the locker 60 and will enter into a vehicle interior becomes low. Therefore, it can be set as the motor vehicle side door excellent in the collision safety with respect to the side collision in which the standard | standard becomes severe.

(Modification of locker)
FIG. 7 shows a modified example of the rocker, in which the vehicle body side wall surface 61 of the rocker 60 is reinforced from the vehicle compartment side (inside the rocker hollow 64). In FIG. 7, the reinforcing member 80 is a hollow member having a closed section with a high strength and rigidity such as bending and crushing against a side collision. This reinforcing member 80 is for partially reinforcing the vehicle body side wall surface 61 of the rocker 60 joined to the wall surface 5 of the lower member 1 so as not to increase the weight as much as possible. Therefore, as shown in FIG. 7, the reinforcing member 80 has a relatively small cross-sectional area, and only the uneven portion 62 provided on the side wall surface (vertical wall surface) 61 of the vehicle body is disposed on the vehicle compartment side (the locker hollow interior). Support and reinforcement from the 64th side).

  As shown in FIG. 7, the reinforcing member 80 is provided with a vertical wall 84 on the side of the vehicle body with respect to the vertical wall 84 on the passenger compartment side, and the horizontal walls (horizontal ribs) 82 (upper), 83 (lower) Side) and a hollow material having a hollow section with a closed cross section at the center. Further, the vertical wall 84 on the side surface of the vehicle body is provided with an unevenness 86 (86 convex toward the vehicle compartment side) that engages with the unevenness 62 provided on the side wall surface 61 of the vehicle body side surface of the rocker 60. . The irregularities 86 naturally engage with the irregularities 3 and 4 of the wall surface 5 extending below the lower member 1 to reinforce strength and rigidity such as bending and crushing against a side collision. . As shown in FIG. 7, the reinforcing member 80 is inserted into the predetermined position inside the rocker hollow 64, joined to the rocker wall surface 61 by an appropriate joining means, and integrated with the rocker 60.

Other side door structures:
(Door beam)
The door beam 70 receives a load due to a side collision of the vehicle body and absorbs energy for protecting passengers in the vehicle. For this purpose, it is necessary that the door beam 70 protrudes and extends from the side of the vehicle body and receives a side collision load earlier. For this purpose, the door beam 70 is provided so as to protrude from the outer panel 50 side to the vehicle body side by a mounting bracket (flange) (not shown). The door beam 70 may be made of steel, but is preferably made of an aluminum alloy for reducing the door weight. In this respect, if the door beam 70 is an aluminum alloy extruded hollow member having a substantially rectangular cross section, it is preferable from the viewpoint of high energy absorption capability at the time of the side collision.

(Regulator base)
Although not shown, a regulator base for holding a window regulator as a door glass raising / lowering mechanism is preliminarily set in a space 41 in the center of the inner panel in a state where a door driving motor, a door latch mechanism, etc. are set in advance. Is housed. The hollow portions 6a and 6b described above serve as work holes (work spaces) at this time. In addition, the upper member of the door inner 40 may be extended downward, or the lower member 1 may be extended upward to reduce the opening of the work hole.

(Top door)
The door lower structure described above is not shown, but the frame 123 constituting the window part of the upper part of the door as shown in FIG. 10 has its tip part, for example, the left and right flange parts of the members 20 and 30. 23 and 33 are joined and integrated by welding or mechanical joining. The frame body 123 may also be made of a steel plate, or made of an aluminum alloy (formed by forming an aluminum alloy tube or hollow shape by hydroforming or forming an aluminum alloy plate) to reduce the door weight. There may be.

(Reinforce)
In the present invention, the embodiment described above is further allowed to be provided with a reinforcement for ensuring collision safety. For example, in order to ensure the collision safety in the front-rear direction of the vehicle body, a reinforcement 126 made of an extruded hollow shape member extending in the front-rear direction of the vehicle body as shown in FIGS. The vehicle longitudinal direction may be reinforced.

  However, in the door inner panel of the present invention, as described above, the strength and rigidity necessary for the door inner panel can be secured. Therefore, except for such reinforcement for ensuring collision safety, reinforcement for increasing the overall rigidity and strength of the door inner panel itself is unnecessary. However, as a door, reinforce installation that is attached to reinforce door components such as an inner reinforcement upper that is a reinforcing material on the upper inner side of the door lower structure and a door opening / closing hinge is allowed as necessary.

  For this reason, in the door inner panel of the present invention, there are relatively few joints such as welding and self-piercing rivets associated with the installation of such a reinforcing material, and the labor for joining is reduced. Moreover, the weight increase accompanying installation of a reinforcing material does not impair the advantage of weight reduction using an aluminum alloy.

(Material aluminum alloy)
The material aluminum alloy used for each member such as the front member 20 in the longitudinal direction of the vehicle body, the rear member 30 and the upper member 10 in the vertical direction of the vehicle body and the lower member 1 constituting the inner panel is required as a door inner panel. In order to ensure strength and rigidity, it is preferable that the 0.2% proof stress when used as a vehicle body is high strength of 180 MPa or more. The same applies to various reinforcing materials such as the door beam described above.

  The aluminum alloys satisfying these properties such as strength and formability are generally 5000 series, 6000 series, 7000 series and other general-purpose alloys generally used for this kind of structural member, and are tempered if necessary. An alloy is appropriately selected. However, there is no need to make all the members and reinforcing materials the same, and different aluminum alloys may be combined depending on the characteristics of the members and the reinforcing materials. For example, the upper member 10 and the lower member 1 are made of a high-strength 6000 or 7000-shaped material, and the front member 20 and the rear member 30 are relatively low in age hardening ability and the amount of alloying elements and are excellent in scrap recyclability. It may be a 6000 series thin plate or a 5000 series thin plate having excellent formability. Further, the door beam or the reinforcing material may be a 6000 series or 7000 series profile.

  According to the present invention, the joint strength between the lower part of the aluminum alloy inner panel of the side door and the rocker is not easily broken even in a side collision that has a high joint strength with the rocker having a hollow structure and is severe. In this way, it is possible to provide an automobile side door that is excellent in collision safety, does not enter the vehicle interior due to a large deformation of the lower portion of the inner panel, and is lightweight and easy to mold and assemble. Therefore, the present invention can be applied to an automobile side door panel in which an outer panel is made of an aluminum alloy, including an all-aluminum door, and an automobile side door inner panel in which the outer panel is made of a steel plate.

It is a perspective view which shows the motor vehicle side door using this invention door inner panel. It is a perspective view of each member before the side door assembly of FIG. It is sectional drawing in the cross section A of FIG. It is sectional drawing which shows the other aspect of this invention door inner panel. It is sectional drawing which shows the other aspect of this invention door inner panel. It is sectional drawing which shows the other aspect of this invention door inner panel. It is sectional drawing which shows the other aspect of this invention door inner panel. It is a front view which shows the comparative example door inner panel aspect. It is sectional drawing in the cross section A of FIG. It is a front view of the conventional aluminum alloy door. It is sectional drawing of the door which joined the inner panel and outer panel made from the conventional aluminum alloy.

Explanation of symbols

1: Inner panel lower member, 2, 5: Wall, 3, 4, 6, 7: Concavity and convexity, 10: Inner panel upper member, 20: Inner panel front member, 30: Inner panel rear member, 40: Inner panel, 50: Outer panel, 60: Locker, 70: Door beam, 80: Reinforcing material,

Claims (3)

As the lower structure of the automobile side door, the inner panel constituting the vehicle compartment side is made of an aluminum alloy member with respect to the outer panel constituting the side surface of the vehicle body, and these aluminum alloy members include the front and rear parts in the vehicle longitudinal direction and the vehicle body. The upper member and the lower member in the vertical direction are divided into four parts, and these members are joined to each other, and are integrated as an inner panel in a frame shape having a space in the center part. A vehicle side having excellent collision safety, characterized by facing substantially parallel to a hollow rocker extending in the longitudinal direction of the vehicle body, and each of the aluminum alloy members and the rocker having the following configurations a to e: door.
a. The front and rear members of the inner panel are made of an aluminum alloy sheet forming panel.
b. The upper member of the inner panel is composed of either an aluminum alloy sheet forming panel or an aluminum alloy extruded shape.
c. The lower member of the inner panel is made of an aluminum alloy extruded shape having a wall surface extending in the vertical direction of the vehicle body, and the wall surface extending below the lower member is provided with irregularities.
d. On the other hand, the side wall surface of the vehicle body extending in the vertical direction of the vehicle body of the rocker is also provided with unevenness in a shape that engages with the unevenness of the wall surface extending below the lower member.
e. The vehicle body side wall surface of the rocker is the vehicle compartment side, and the wall surface extending to the lower side of the lower member is the vehicle body side side. They are arranged so that they fit together.   The automobile side door excellent in collision safety according to claim 1, wherein the lower member of the inner panel has a solid cross-sectional shape.   The automobile side door excellent in collision safety according to claim 1 or 2, wherein an aluminum alloy reinforcing material is provided on a joint portion side with a lower member of the inner panel in the hollow structure of the rocker.

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