JP2011121420A - Resin exterior panel for vehicle and method of manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a resin exterior panel for a vehicle which maintain dimensional stability due to temperature change without increasing the number of parts and does not lose surface quality of a design surface of the exterior of a vehicle. <P>SOLUTION: A fender panel 20A as the resin exterior panel for the vehicle is integrally molded with an exterior wall 21 and an interior wall 25A, the exterior wall 21 comprising an outer surface 2 of the vehicle 1A, the interior wall 25A bending toward the inside of the vehicle from a boundary line 23 with a hood panel which is arranged around the exterior wall 21. The interior wall 25A of the fender panel 20A includes a low linear-expansion material whose liner expansion coefficient is lower than that of the exterior wall 21. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to an outer plate including a design surface on the outside of a vehicle and a method for manufacturing the same, and more particularly to a resin outer plate suitable for use in a vehicle whose main material is a resin material and a method for manufacturing the same.

  Conventionally, a metal material such as iron or aluminum has been used for an outer plate including an outer surface (design surface) of a vehicle because it has excellent workability and can obtain a desired rigidity. However, in recent years, in order to improve the fuel consumption of vehicles, the use of resin materials has attracted attention as a material that is lighter than metal materials.

  For example, as shown in FIG. 8, resin materials have already been applied to the front and rear bumpers 61, 62 of the vehicle 1, and have started to be applied to outer panels such as the fender panel 20 and the door outer panel 30. The weight reduction is achieved.

However, when the resin material is partially applied, there are the following problems. For example, when a metal material such as iron is used for the door outer panel 30 and the hood panel 40 and a resin material is used for the fender panel 20, the linear expansion coefficient of iron is about 1.0 × 10 ⁻⁵ / ° C. (for example, aluminum: 2.35 × 10 ⁻⁵ / ° C.), whereas the linear expansion coefficient of the resin material is about 6.0 to 12.0 × 10 ⁻⁵ / ° C., compared with these panels 30 and 40. The fender panel 20 is more easily deformed due to thermal expansion.

  Accordingly, when the fender panel 20 designed and attached so as to be on the same edge line is exposed to an environment in which the outside air temperature is high, the dimensional deformation is caused by thermal expansion, and the vehicle component disposed around the fender panel 20 For example, a change in a gap or a step may occur at the boundary between the hood panel 40 and the door outer panel 30 (for example, a shift between the edge line 29 of the fender panel 20 and the edge line 49 of the hood panel 40). Step, change of the gap C1 between the panels of the fender panel 20 and the door outer panel 30). As a result, when the resin material is partially applied, the aesthetic appearance of the vehicle 1 may be impaired.

  In view of such a point, for example, an attachment structure for a fender panel 20 shown in FIG. 9 (a cross-sectional view taken along the line AA in FIG. 8) has been proposed (see, for example, Patent Document 1). Specifically, as shown in FIG. 9, the resin-made fender panel 20 has an L-shape that is bent inward from the parting line 23 between the outer wall portion 21 constituting the outer surface 2 of the vehicle 1 and the hood panel 40. The inner wall portion 25 having a cross section is integrally formed. An attachment hole 27 for attachment to the apron member 60 is formed in the inner wall portion 25.

  When attaching the fender panel 20, first, a long metal retainer 78 extending in the direction along the parting line 23 is disposed so as to sandwich the fender panel 20 between the apron members 60. Next, the stepped bolt 71 is penetrated from the retainer 78 side through the washer 73 and tightened with the nut 75 on the apron member side.

  Thereby, the fender panel 20 can be fixed to the apron member 60. Furthermore, since a part of the inner wall part 25 of the fender panel 20 is sandwiched between the retainer 78 and the apron member 60, a part of the inner wall part 25 is pressed by the retainer 78 and is stronger than before. Restrained by By this restriction, the bulging of the fender panel 20 in the forward direction along the parting line 23 and the fluctuation of the gap between the panels can be suppressed, and the dimensional stability of the fender panel 20 can be ensured.

JP-A-4-297384

  However, in the case of the structure shown in Patent Document 1, the retainer 78 must be newly manufactured at the time of attachment, the number of parts at the time of assembling increases, and the assembling work becomes complicated. Furthermore, since the restraining force of the fender panel 20 also changes in accordance with the fastening force of the stepped bolt 71, for example, when loosening due to vibration during vehicle travel occurs, the restraining force decreases. Thereby, there exists a possibility that the dimensional stability of the fender panel 20 may be impaired.

  In view of such a point, if a fiber reinforced resin material closer to the linear expansion coefficient of the metal material is applied to the outer plate, such a problem can be solved without increasing the number of parts. However, when the outer plate is formed using only the fiber reinforced resin material, as shown in FIG. 10 (a), the outer surface 81 of the outer plate is formed as a smooth surface immediately after the molding. Heat is dissipated, and the matrix resin 85 contracts relatively larger than the reinforcing fibers 82 (so-called sink marks are generated). As a result, as shown in FIG. 10 (b), the outer surface 81 becomes an uneven surface, and when this uneven surface is used for the outer surface (design surface) of the vehicle, unevenness in the outer surface gloss after painting occurs. The surface quality may be impaired.

  The present invention has been made in view of the above-described problems. The object of the present invention is to maintain the dimensional stability accompanying temperature change without increasing the number of parts, and to improve the surface quality of the design surface outside the vehicle. An object of the present invention is to provide a resin outer plate for a vehicle that does not impair the safety.

  In order to solve the above-mentioned problem, the inventors have intensively studied and, as a result, do not forcibly restrain the resin outer plate from the outside, but the linear expansion coefficient of the portion that does not constitute the design surface of the resin outer plate, By making it lower than the others (parts that make up the design surface), the surface quality of the design surface is equivalent to that of the metal outer plate, and furthermore, dimensional stability is ensured even in an environment where the outside air temperature is high. I got new knowledge that I could do it.

  This invention is based on the said new knowledge, The resin outer plate for vehicles which concerns on this invention is the outer side wall part which comprises the outer surface of a vehicle, and the vehicle components arrange | positioned around this outer side wall part. A resin outer plate for a vehicle in which an inner wall portion bent from the parting line to the vehicle inner side is integrally molded, and the inner wall portion has a low linear expansion coefficient lower than that of the outer wall portion. It is characterized by including.

  According to the present invention, since the inner wall portion bent toward the inside of the vehicle includes the low linear expansion material, the expansion (elongation) of the inner wall portion is the expansion (elongation) of the outer wall portion in an environment where the outside air temperature is high. Smaller than As a result, the inner wall portion relatively restrains the extension of the outer wall portion. In this way, it is possible to ensure the dimensional stability in the heat change only with the resin outer plate without restraining by using a new member when incorporating the vehicle. Moreover, since an outer side wall part can be comprised only from resin, it becomes possible to maintain surface quality as before.

  Further, the outer wall portion is curved so as to swell to the vehicle outer side in accordance with the shape of the vehicle, and the inner wall portion surrounds at least a part of the peripheral portion (portion inside from the parting line) of the outer wall portion. It will be. As a result, the extension of the outer wall portion is absorbed when the outer wall portion is further curved (swells outside the vehicle). Thereby, the shift | offset | difference of the elongation between outer plates by the heat change after an assembly | attachment is suppressed. Furthermore, the increase in curvature is unlikely to affect the appearance of the vehicle.

  In this way, even if a metal vehicle component (for example, a panel) having a lower linear expansion coefficient than the resin outer plate is present in the vicinity thereof, the deformation at the parting portion with these components is reduced by the amount of difference in linear expansion. (Ski, step) is suppressed, and the appearance of the vehicle can be maintained.

  In the present invention, “vehicle inside” means inside the vehicle outside (outside the vehicle), while “vehicle outside” means outside the vehicle inside (inside the vehicle). Say. The low linear expansion material referred to in the present invention is a material having a linear expansion coefficient lower than that of the material (resin) constituting the outer wall portion, and the directionality of the expansion is isotropic. However, it is more preferable that the low linear expansion material of the inner wall portion has a linear expansion coefficient at least along the parting line. It is preferable that it is lower than the linear expansion coefficient in the other direction of the part. In particular, the elongation of the resin material in the direction along the parting line tends to affect the aesthetic appearance of the vehicle, and the elongation in this direction is suppressed by lowering the linear expansion coefficient in this direction.

  The low linear expansion material is not particularly limited as long as it satisfies the relationship of the linear expansion coefficient described above. For example, a composite material in which a metal material such as iron or aluminum is coated with a resin, a composite material in which a fiber such as carbon or glass is impregnated with a resin material, mica, clay, and / or glass particles are included in the resin material. A composite material etc. can be mentioned. However, more preferably, the low linear expansion material of the vehicle resin outer plate according to the present invention is a fiber reinforced resin material.

  According to the present invention, by using the fiber reinforced resin material, the inner wall portion can obtain a linear expansion coefficient comparable to that when a metal material is used. Further, the outer wall portion can be made of only a resin, and the inner wall portion can be a fiber reinforced resin material containing the same type of matrix resin as the resin of this resin. Bondability between the outer wall portion and the inner wall portion can be improved.

  The “fiber reinforced resin material” as used in the present invention is a composite material composed of a reinforced fiber and a matrix resin impregnated with the reinforced fiber and can be molded in a mold, and keeps a predetermined strength together with the reinforced fiber. If it is possible, the type is not particularly limited.

  The “reinforcing fiber” referred to in the present invention refers to a fiber for resin reinforcement for reinforcing the mechanical strength of the composite material. For example, glass fiber, carbon fiber, aramid fiber, alumina fiber, boron fiber, steel fiber, Examples thereof include fibers such as PBO fibers or high-strength polyethylene fibers, and any of short fibers, long fibers, and cloth fibers may be used. Further, in the case of a cloth-like fiber, it may be either a woven fabric or a non-woven fabric. In the case of a woven fabric, the weaving method may be any of a woven structure such as plain weave, twill weave, satin weave, etc. Good. In addition, when performing the injection molding mentioned later, the fiber reinforced resin material of a short fiber or a long fiber can be used.

  As the matrix resin, a thermoplastic resin used for a fiber reinforced resin material or a thermosetting resin can be used. As the thermoplastic resin, a crystalline thermoplastic resin or an amorphous thermoplastic resin can be used. For example, an olefin resin such as nylon resin, polycarbonate resin, polyamide resin, polypropylene resin, acrylic resin, or Examples thereof include ABS resins. Examples of the thermosetting resin include vinyl ester resins, epoxy resins, fiber reinforced resins, unsaturated polyester resins, and the like. For injection molding, a thermoplastic resin is more preferable. The “same type of resin” in the present invention refers to a resin having the same resin system as exemplified above.

  Furthermore, when the low linear expansion material is a fiber reinforced resin material, it is more preferable that the reinforcing fibers contained therein are oriented at least in the direction along the parting line. According to the present invention, since the reinforcing fibers are oriented in the direction along the parting line, the expansion of the outer plate in the direction along the parting line can be reliably suppressed. Here, the phrase “the reinforced fiber according to the present invention is“ orientated in the direction along the parting line ”” means that the direction along the parting line and the length direction of the fiber substantially coincide.

  Furthermore, the vehicle resin outer plate according to the present invention has an attachment portion formed in the direction along the parting line in order to attach directly or indirectly to the vehicle body on the inner wall portion. According to the present invention, by having the attachment portion in the direction along the parting line, the expansion of the outer plate in the direction along the parting line can be suppressed more reliably. In addition, when the low linear expansion material is made of a fiber reinforced resin material, the surface of the mounting portion becomes an uneven surface (rough surface) as shown in FIG. ) Can be expected to have an anchor effect, and the outer plate can be firmly restrained by the vehicle body.

  Furthermore, in this application, the manufacturing method suitable for manufacturing the resin outer plate for vehicles mentioned above as this invention is also disclosed. A method for manufacturing a resin outer plate for a vehicle according to the present invention includes: an outer wall portion constituting an outer surface of the vehicle; and an inner wall portion bent inward of the vehicle from a parting line between components disposed around the outer wall portion. , Wherein the outer wall member corresponding to the outer wall portion is formed by injecting a first resin material into a pair of molds. A first molding step of molding, a mold opening step of opening the molding die in a state where the outer wall member is held in one of the molds, a mold holding the outer wall member, A second mold having a cavity corresponding to the inner wall portion is clamped, and a second resin material having a lower linear expansion coefficient than that of the first resin material is injected into the clamped mold. A second molding step of integrally molding the inner wall portion on the outer wall member, Characterized in that it contains.

  According to the present invention, in the first molding step, the outer wall member corresponding to the outer wall portion of the resin outer plate for a vehicle is molded, and then continuously, the low coefficient of linear expansion is lower than that of the first resin material. An inner wall portion made of a linear expansion material can be integrally formed with the outer wall member. At this time, if the other mold (the mold that does not hold the outer wall member) and the second mold are formed of the same mold, the resin outer plate can be manufactured more quickly and easily. can do.

  In the second molding step, the material and the molding method are particularly limited as long as a low linear expansion material having a lower linear expansion coefficient than the outer wall portion can be formed as the inner wall portion. It is not something. For example, only resin is used for the first resin material, and the second resin material includes (1) a resin material containing a metal material such as iron or aluminum, (2) carbon fiber, carbon fiber, inorganic fiber, and / or Alternatively, it is preferable to use a resin material containing reinforcing fibers of natural fibers, or (3) a resin material containing particles such as mica, clay, and / or glass. The resin constituting the resin material is preferably the above-described thermoplastic resin that can be injected. Among these, more preferably, a resin material containing reinforcing fibers is used for the second resin material, and even more preferably, in the second molding step, the reinforcing fibers contained in the second resin material are parting lines. The second resin material is injected so as to flow along.

  In this way, the reinforcing fibers of the fiber reinforced resin material, which is a low linear expansion material, can be oriented at least in the direction along the parting line, and the expansion of the outer plate in the direction along the parting line is ensured. Can be suppressed. This can be achieved by setting the mold shape of the mold and the arrangement of the inlet and outlet of the second resin material of the mold.

  Further, when the vehicle resin outer plate is attached to the vehicle body by a fastening member such as a bolt, it is necessary to provide an attachment hole on the inner wall portion of the vehicle resin outer plate, and this attachment hole can be provided. If it is, it may be any timing at the time of the second molding step or thereafter, but more preferably, after the second molding step, mounting hole processing is performed on the inner wall portion.

  According to the present invention, after the second resin material is injected and the inner wall portion is molded so that the reinforcing fibers contained in the second resin material flow along the parting line in the second step. Since the mounting hole is processed, the resin flow at the time of injection of the second resin material is stabilized, and the reinforcing fiber of the fiber reinforced resin material which is a low linear expansion material is preferably oriented in the direction along the parting line Can do.

  In addition, as described above, the resin of the first resin material and the resin of the second resin material are more preferably the same type of resin, whereby the integrally formed outer wall and inner The bonding strength with the wall can be further increased.

  ADVANTAGE OF THE INVENTION According to this invention, while increasing the number of parts, while maintaining the dimensional stability accompanying a temperature change, the resin outer plate for vehicles which does not impair the surface quality of the design surface of a vehicle outer side can be obtained.

It is a figure for demonstrating an example at the time of applying the resin outer plate for vehicles of 1st embodiment which concerns on this invention to a fender panel, and the principal part perspective view showing the attachment state by the side of a hood panel. FIG. 9 is a cross-sectional view taken along line AA in FIGS. 1 and 8. It is a figure explaining an example at the time of applying the resin outer plate | board for vehicles of 2nd embodiment which concerns on this invention to a fender panel, and the principal part perspective view showing the attachment state by the side of a door outer panel. FIG. 9 is a cross-sectional view taken along line BB in FIGS. 3 and 8. It is a figure explaining an example at the time of applying the resin outer plate for vehicles of 3rd embodiment which concerns on this invention to a door outer panel, and arrow sectional drawing along the CC line of FIG. It is a figure for demonstrating the manufacturing method of the resin outer plate for vehicles which concerns on embodiment of this invention (manufacturing method), (a) is a typical perspective view for demonstrating the structure of the shaping | molding die used for a manufacturing method. (B) is arrow sectional drawing along the DD line of (a), The figure for demonstrating a 1st shaping | molding process, (c) is a figure for demonstrating a mold opening process. (D) is a figure for demonstrating a 2nd shaping | molding process. The figure for demonstrating the resin flow in the 2nd shaping | molding process shown in FIG.6 (c). The typical perspective view for demonstrating the vehicle which concerns on the past and this invention. FIG. 9 is a cross-sectional view taken along line AA in FIG. It is typical sectional drawing for demonstrating the surface state at the time of shaping | molding of a fiber reinforced resin material, (a) is sectional drawing of the fiber reinforced resin material immediately after shaping | molding, (b) is after shaping | molding (after heat radiation). Sectional drawing of a fiber reinforced resin material.

  Hereinafter, the present invention will be described based on some embodiments. FIG. 1 is a view for explaining an example in which the resin outer plate for a vehicle according to the first embodiment of the present invention is applied to a fender panel 20A, and is a perspective view of a main part showing an attached state on the hood panel 40 side. FIG. 2 is a cross-sectional view taken along the line AA in FIGS. 1 and 8.

  The vehicle according to the first and second embodiments described below is an example of an example vehicle based on FIGS. 8 and 9 except that the material of the inner wall portion of the fender panel and the mounting structure of the fender panel are different. It may be the same. Therefore, detailed description of the vehicle is omitted by giving the same reference numerals to the same members.

  As shown in FIGS. 1 and 8, a fender panel 20A of a vehicle 1A according to this embodiment is a resin outer plate for a vehicle, and includes at least an outer wall portion 21 and an inner wall portion 25A. ing. The outer side wall portion 21 is made of polypropylene resin, and is curved so as to swell outside the vehicle 1A. Further, the swelled outer surface 2 of the outer wall portion 21 is a design surface (vehicle outer surface) that can be seen from the outer side of the vehicle 1A, and the outer surface is painted to enhance rust prevention and aesthetics. .

  On the other hand, the inner wall portion 25A is bent so as to be L-shaped on the vehicle inner side from a parting line 23 with the hood panel 40 (vehicle component) arranged around (next to) the outer wall portion 21. . Specifically, the inner wall portion 25A is formed with a vertical wall portion 26A that hangs down from the parting line 23 and a mounting portion 26B that extends further from the vertical wall portion 26A in the horizontal direction. A plurality (four in FIG. 1) of attachment holes 27 are formed in the attachment portion 26 </ b> B in the direction LA along the parting line 23.

  In the present embodiment, the vertical wall portion 26 </ b> A and the attachment portion 26 </ b> B of the inner wall portion 25 </ b> A are made of a low linear expansion material having a lower linear expansion coefficient than the outer wall portion 21. Specifically, the low linear expansion material is a fiber reinforced resin material made of short fiber reinforced fiber 25a (glass fiber or carbon fiber) and a matrix resin (polypropylene resin). As shown in FIG. 2, the film is oriented in the direction along the parting line 23.

As described above, since the outer wall portion 21 is made of only the resin, the surface quality of the vehicle 1A can be maintained as before, and further, the inner wall portion 25A is made of a fiber reinforced resin material. The linear expansion coefficient is lower than that of the resin of the wall portion 21. In the case of the present embodiment, the reinforcing fibers 25a are oriented in the direction LA along the parting line 23. Therefore, in particular, the linear expansion coefficient in the direction LA is larger than that in the other direction of the inner wall portion 25A. Further lower. According to the inventors' experiment, when glass fiber is used as the reinforcing fiber and polypropylene is used as the matrix resin, the linear expansion coefficient in the direction LA along the parting line 23 is about 3.0 × 10 ⁻⁵ / ° C. The linear expansion coefficient in the direction orthogonal to the direction LA (width direction) is about 6.0 × 10 ⁻⁵ / ° C., and it is known that the linear expansion coefficient in the direction LA is further reduced.

  As a result, even in an environment where the outside air temperature is high, the expansion (elongation) of the inner wall portion 25A is smaller than the expansion (elongation) of the outer wall portion 21, and along the parting line 23 in the heat change. Expansion of the fender panel 20A in the direction LA is reliably suppressed, and the dimensional stability is ensured.

  Furthermore, since the outer wall 21 is curved so as to swell toward the outer side of the vehicle in accordance with the shape of the vehicle 1 </ b> A, the slight extension in the direction along the parting line 23 of the outer wall 21 is less than the outer wall 21. Is absorbed by further curving (swelling outside the vehicle).

  Thereby, even if the fender panel 20A further swells due to the thermal change after assembly, the shift of the edge line due to the difference in elongation between the metal hood panel 40 and the resin fender panel 20A is suppressed. Since the increase in the curvature of the plate is difficult to visually discern, the aesthetic appearance of the vehicle 1A can be maintained.

  Furthermore, by having the attachment portion 26B in the direction LA along the parting line 23, expansion of the fender panel 20A in the direction LA along the parting line 23 can be suppressed more reliably. In the present embodiment, since the inner wall portion 25A is made of a fiber reinforced resin material, the surface 26a of the attachment portion 26B that contacts the fastening surface 61 of the apron member 60 is an uneven surface as shown in FIG. Yes. Thereby, the anchor effect can be expected with respect to the fastening surface 61, and the fender panel 20A can be firmly restrained by the vehicle body. As a result, it is possible to suppress changes in gaps and steps between the outer plates.

  The fender panel 20A can be attached to the apron member 60 constituting a part of the vehicle body (vehicle body) with fewer parts without using the retainer described above, reducing the weight of the vehicle and eliminating the complexity of installation. can do.

  FIG. 3 is a diagram for explaining an example in which the vehicle resin outer plate according to the second embodiment of the present invention is applied to the fender panel 20B, and is a perspective view of a main part showing an attachment state on the door outer panel 30 side. FIG. 4 is a cross-sectional view taken along line B-B in FIGS. 3 and 8. In addition, you may make the inner wall part by the side of the food panel 40 of the fender panel 20B of this embodiment like 1st embodiment.

  As shown in FIGS. 3 and 8, the outer wall portion 21 of the fender panel 20 </ b> B of the vehicle 1 </ b> B according to this embodiment is the same as that of the first embodiment, and the inner wall portion 25 </ b> B is around the outer wall portion 21. A parting line 23 </ b> B with the arranged door outer panel 30 (vehicle component) is bent inward of the vehicle.

  Specifically, the inner wall portion 25B is formed with a folded wall portion 28A that is bent so as to be folded back from the parting line 23B, and a mounting portion 28B that extends further from the folded wall portion 28A to the vehicle inner side. A plurality of attachment holes 27B are formed in the attachment portion 28B in the direction LB along the parting line 23B.

  In the present embodiment, the folded wall portion 28A and the attachment portion 28B of the inner wall portion 25B are fiber reinforced resin materials that are low linear expansion materials having a lower linear expansion coefficient than the outer wall portion 21, as in the first embodiment. The reinforcing fibers 25a are oriented in the direction along the parting line 23B as shown in FIG. Note that the iron door outer panel 30 is bonded to the door inner panel 38 via an adhesive 77 at a portion folded back inward.

  As a result, similar to the first embodiment, even if the door outer panel 30 is made of metal such as iron, deformation (skip, step) at the parting part between the fender panel 20B and the door outer panel 30 is suppressed. The

  In this way, even if there are peripheral parts (for example, iron parts) having a lower linear expansion coefficient than the resin outer plate, it is possible to ensure an uncomfortable appearance as the difference in linear expansion is reduced. In addition, a conventional retainer is not required, and the weight of the vehicle can be reduced, and the complicated installation can be eliminated.

  Further, the fender panel 20B can be attached to the guide 62 constituting a part of the vehicle body without using the above-described retainer, so that the weight of the vehicle can be reduced and the complexity of the attachment can be eliminated.

  FIG. 5 is a view for explaining an example when the vehicle resin outer plate of the third embodiment according to the present invention is applied to a door outer panel, and is a cross-sectional view taken along the line CC of FIG. . Other members and the like are denoted by the same reference numerals as described in the first embodiment, and detailed description thereof is omitted.

  As shown in FIGS. 5 and 8, the outer wall portion 31 of the door outer panel 30 </ b> A according to the present embodiment is made of the same material as that of the first embodiment, and is curved so as to swell outside the vehicle 1 </ b> C. The swelled outer surface 3 of the outer wall portion 31 is a design surface (an outer surface of the vehicle) that can be seen from the outside of the vehicle 1C, and the outer surface is painted.

  Furthermore, the inner side wall part 35 is bent inward of the vehicle so as to be folded back from a parting line 33 with a front door panel (vehicle component) arranged around the outer side wall part 31. The folded portion (attachment portion) of the inner wall portion 35 is bonded to the door inner panel 38 via an adhesive 77.

  In this embodiment, the inner side wall part 35 consists of the fiber reinforced resin material which is a low linear expansion material with a low linear expansion coefficient compared with the outer side wall part 31 similarly to 1st embodiment, and a reinforced fiber is FIG. As shown in FIG. 3, the orientation is in the direction along the parting line 33.

  As a result, deformation (skip, step) at the parting part between the door outer panel 30A and its surrounding parts is suppressed, maintaining the dimensional stability accompanying the temperature change and impairing the surface quality of the design surface outside the vehicle. There is nothing.

  Specifically, in a door outer panel such as a side door panel or a back door panel, the inner wall portion also serves as an adhesive surface with the inner panel. By using a fiber reinforced resin material, the adhesive 77 Bonding distortion during baking can be suppressed, and further deterioration in appearance can be suppressed. This is because the fiber reinforced resin material has higher elastic modulus (higher rigidity) than the non-fiber reinforced resin material, so the tensile stress associated with the shrinkage of the adhesive, which is the cause of the adhesive strain. This is because the adhesive strain is reduced because it can withstand more.

  In addition, when the low linear expansion material is made of a fiber reinforced resin material, the surface of the mounting portion becomes an uneven surface (rough surface) as shown in FIG. ) Can be expected to have an anchor effect, and the outer plate can be firmly restrained by the vehicle body.

  Hereinafter, preferred embodiments for producing resin outer plates such as the fender panel and door outer panel of the above-described embodiment will be described.

  FIG. 6 is a view for explaining a method for manufacturing a vehicle resin outer plate according to the present embodiment, and (a) is a schematic perspective view for explaining the structure of a mold used in the manufacturing method. ) Is a cross-sectional view taken along the line DD in (a), and is a diagram for explaining the first molding step, and (c) is a diagram for explaining the mold opening step. d) is a figure for demonstrating a 2nd shaping | molding process. FIG. 7 is a view for explaining the resin flow in the second molding step shown in FIG.

  In the present embodiment, the above-described resin outer plate can be manufactured by injection molding the following first and second resin materials into the mold 50. As shown in FIG. 6A, the mold 50 is composed of a pair of molds, a disc-shaped upper mold 51 and a lower mold 52.

  The upper mold 51 is a movable mold, and is connected to a turntable (not shown) so as to be rotatable about the central axis CL as a rotation axis, and further for mold opening or clamping with respect to the lower mold 52. Further, it is connected to a lifting device (not shown) that moves up and down.

  When the upper mold 51 and the lower mold 52 are clamped, at least two types of cavities 57 and 58 are formed as shown in FIG. 6B. The lower mold 52 is a fixed mold, and the lower mold 52 communicates with the cavities 57 and 58 and is formed with introduction ports 54 and 55 for introducing a resin material. The cavity 57 is a molding space that matches the shape of the outer wall member 11 </ b> A corresponding to the outer wall portion 11 of the outer plate 10, and the cavity 58 is a molding space that matches the shape of the outer plate 10.

  The resin outer plate 10 for vehicles such as the above-described fender panels 20A and 20B and the door outer panel 30A is molded using an injection molding apparatus including the molding die 50, the turntable, the lifting device, and the injection device.

  First, the first molding step is performed using the mold 50 in the clamped state shown in FIG. Specifically, in the first molding step, a first resin material (for example, polypropylene-based resin) R1 is injected from the introduction port 54 of the lower mold 52 into the cavity 57 of the molding mold 50, whereby the outer wall An outer wall member 11A corresponding to the portion 11 is formed.

  Next, as shown in FIG.6 (c), the mold opening which opens the shaping | molding die 50 using a raising / lowering apparatus in the state which hold | maintained the outer wall member 11A to the upper mold | type 51 (one type | mold) of the shaping | molding die. (Mold opening process). Further, using the turntable, the upper mold 51 is rotated 180 ° with the central axis CL as the rotation axis. The outer wall member 11A can be held by suction or the like to the upper mold 51. If the second injection process can be performed while leaving the outer wall member 11A in the upper mold 51, the method is particularly It is not limited.

  Furthermore, as shown in FIG. 6 (d), a second molding step is performed. Specifically, the upper die 51 holding the outer wall member 11 </ b> A is lowered using the lifting device, and the upper die 51 and the lower die (second molding die) 52 are clamped. At this time, since the cavity 58 corresponding to the resin outer plate having a shape to be molded is provided at the time of mold clamping, the outer wall member 11A is arranged in a part thereof, and the remaining part corresponds to the inner wall part 15. A cavity is formed.

  Then, the inner wall portion 15 is integrated with the outer wall member 11A by injecting the second resin material R2 having a linear expansion coefficient lower than that of the first resin material R1 into the mold (cavity) clamped. Mold. Specifically, for the second resin material R2, a resin composed of short fiber reinforcing fibers and the same kind of matrix resin as the resin material R1 is used.

  As shown in FIG. 7, in the second molding step, the second resin material R2 is made so that the reinforcing fibers 25a flow in the direction L along the parting line with the surrounding vehicle parts (adjacent parts). Eject. Such a flow of the resin can be achieved by arranging the introduction port 55 and the discharge port 56 of the second resin material R2 upstream and downstream in the direction of flow as shown in FIG. it can. In this way, the reinforcing fibers 25a contained in the fiber reinforced resin material can be oriented at least in the direction L along the parting line.

  In the first molding step, an outer wall member 11A corresponding to the outer wall portion 11 of the vehicle resin outer plate 10 is molded, and then the inner wall portion 15 made of a fiber reinforced resin material is continuously formed on the outer wall member 11A. Can be integrally molded.

  Furthermore, as shown in FIG. 7, the reinforcing fiber of the fiber reinforced resin material, which is a low linear expansion material, can be oriented in the direction L along the parting line, so the expansion of the outer plate in the direction along the parting line Can be reliably suppressed.

  Furthermore, in order to attach the vehicle resin outer plate 10 to the vehicle body by a fastening member such as a bolt, a mounting hole is formed in the inner wall portion after the second molding step. In the second injection step, after the second resin material R2 is injected and the inner wall portion 15 is molded so that the reinforcing fibers contained in the second resin material R2 flow along the parting line, mounting hole processing is performed. Therefore, the resin flow during the injection of the second resin material can be stabilized, and the reinforcing fibers of the fiber reinforced resin material, which is a low linear expansion material, can be preferably oriented in the direction along the parting line.

  Although the embodiments of the present invention have been described in detail above, the present invention is not limited to the above-described embodiments, and various designs can be made without departing from the spirit of the present invention described in the claims. It can be changed. For example, as the present embodiment, a fender panel in front of the vehicle, a door outer panel on the side of the vehicle, and the like are illustrated, but the present invention may be applied to resin outer plates such as a hood panel and a back door panel.

  Moreover, as long as the extension of the outer wall portion can be suppressed, all portions between the parting line below the attachment portion and the peripheral edge of the panel may be made of fiber reinforced resin material, for example, in the first embodiment. Only the vertical wall portion 26A and the folded wall portion 28A of the second embodiment may be made of a reinforced fiber resin material.

  Furthermore, in this embodiment, the resin outer plate is manufactured by injection molding. For example, a resin outer plate is formed by insert molding using a prepreg tape (so-called UD tape or the like) in which reinforcing fibers are aligned in one direction as an insert material. In addition to glass fiber and carbon fiber, organic fiber or natural fiber may be used as the fiber.

  1A to 1C: vehicle, 2: vehicle outer surface, 10: resin outer plate for vehicle, 11: outer wall portion, 11A: outer wall member, 15: inner wall portion, 20A, 20B: fender panel, 21: outer wall portion , 23, 23B: parting line, 25A, 25B: inner wall part, 25a: reinforcing fiber, 26B: attachment part, 27B: attachment hole, 28B: attachment part, 30A: door outer panel, 31: outer wall part, 33: parting line Line, 50: Mold, 51: Upper mold, 52: Lower mold

Claims (10)

A resin outer plate for a vehicle in which an outer wall portion constituting an outer surface of a vehicle and an inner wall portion bent toward the inside of the vehicle from a parting line between vehicle parts arranged around the outer wall portion are integrally formed. And
The resin outer plate for a vehicle, wherein the inner wall portion includes a low linear expansion material having a lower linear expansion coefficient than the outer wall portion.   The vehicle resin outer plate according to claim 1, wherein the low linear expansion material is a fiber-reinforced resin material.   The resin outer plate for a vehicle according to claim 2, wherein the reinforcing fibers contained in the fiber reinforced resin material are oriented at least in a direction along the parting line.   4. The vehicle resin outer plate according to claim 2, wherein a portion of the inner wall portion including the fiber reinforced resin material has an attachment portion for attachment to a main body of the vehicle.   The resin outer plate for a vehicle according to any one of claims 1 to 4, wherein the resin constituting the outer wall portion and the matrix resin contained in the fiber reinforced resin material are the same type of resin. A method for manufacturing a resin outer plate for a vehicle, in which an outer wall portion constituting an outer surface of a vehicle and an inner wall portion bent inward from the parting line between parts arranged around the outer wall portion are integrally formed. There,
The manufacturing method includes a first molding step of molding an outer wall member corresponding to the outer wall portion by injecting a first resin material into a pair of molding dies,
A mold opening step of opening the mold in a state where the outer wall member is held in one of the molds;
A mold holding the outer wall member and a second mold having a cavity corresponding to the inner wall portion are clamped, and the mold is clamped in a line more than the first resin material. And a second molding step of integrally molding the inner wall portion on the outer wall member by injecting a second resin material having a low expansion coefficient.   The method of manufacturing a resin outer plate for a vehicle according to claim 6, wherein a resin material containing reinforcing fibers is used for the second resin material.   8. The vehicle resin outer plate according to claim 7, wherein in the second molding step, the second resin material is injected so that the reinforcing fiber flows in a direction along a parting line. Production method.   9. The vehicle resin according to claim 8, wherein after the second molding step, a mounting hole for mounting on the vehicle main body is formed in a portion made of the second resin material in the inner wall portion. Manufacturing method of the outer plate.   The method for producing a resin outer plate for a vehicle according to any one of claims 6 to 9, wherein the same kind of resin is used as the resin constituting the first and second resin materials.

Images