JP2013067236A - Method for manufacturing vehicle body frame - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a vehicle body frame capable of controlling corrosion of a base material which composes a reinforcing member while restricting increase in manufacturing cost.SOLUTION: When manufacturing a vehicle body frame provided with the reinforcing member inside a frame member, the reinforcing member 60 is formed by applying an electrodeposition coating on a surface of a frame member 24a including a base material 62 while an unfoamed filler 100 and the base material 62 are positioned inside the frame member 24a with a clearance secured between them, and then foaming the unfoamed filler 100 and filling a filling member 61 between the frame member 24a and the base material 62.

Description

  The present invention relates to a method for manufacturing a vehicle body frame provided under a vehicle floor.

  Since the body frame provided under the floor of a vehicle such as an automobile forms a skeleton of the vehicle, it is necessary to ensure a sufficiently high strength. Conventionally, for example, the strength of the body frame has been increased by joining a reinforcing member to a predetermined position of the body frame by spot welding or the like. Although this can improve the strength of the body frame, there is a problem that the weight of the vehicle increases.

  Further, in order to suppress deformation of the body frame, there is one in which a closed cross-sectional space between an outer panel constituting the body frame and a reinforcing member disposed inside the outer panel is filled with a foamed resin material (for example, , See Patent Documents 1 and 2).

  By filling the inside of the body frame with the foam filler (foamed resin material) in this way, deformation of the body frame can be suppressed.

Japanese Patent No. 3525890 JP 2009-120161 A

  By the way, there may be a large number of pores due to foaming inside the foam filler, which may absorb moisture. For this reason, when the base material which consists of a metal board | plate material is used as a reinforcement member, there exists a possibility that a base material may corrode gradually by the water | moisture content absorbed by the foaming filler. For this reason, it is preferable that the contact surface of the base material with the foam filler is preliminarily subjected to rust prevention treatment, for example, coating.

  However, individually applying a rust-proofing treatment to each base material has poor work efficiency and may increase manufacturing costs.

  The present invention has been made in view of such circumstances, and an object of the present invention is to provide a method for manufacturing a vehicle body frame that can suppress corrosion of a base material constituting a reinforcing member while suppressing an increase in manufacturing cost. To do.

  A first aspect of the present invention that solves the above-described problems is a base material made of a metal material, which is arranged under a vehicle floor and formed between a plurality of frame members, and is filled between the base material and the frame member. A vehicle body frame manufacturing method comprising a reinforcing member constituted by a filled member made of a foamed filler in the frame member, wherein the unfoamed filler and the base material are interposed between the two. A step of performing electrodeposition coating on the surface of the frame member including the base material in a state where a gap is secured in the frame member, and then the filler is foamed to form the frame member and the base. And a step of filling the filler member with the material.

  According to a second aspect of the present invention, there is provided a method of manufacturing a vehicle body frame according to the first aspect, wherein a protrusion is formed on a contact surface with one of the base material and the filler, and the protrusion In the manufacturing method of the vehicle body frame, the base material and the filling member are brought into contact with each other through a portion to secure a space therebetween.

  According to a third aspect of the present invention, there is provided a method for manufacturing a vehicle body frame according to the second aspect, wherein the protrusion is provided on the filler.

  According to the present invention, when electrodeposition coating is performed on the frame member, the contact surface of the base material with the filling member can be simultaneously subjected to rust prevention treatment. Therefore, corrosion of the base material can be suppressed while suppressing an increase in manufacturing cost.

1 is a schematic view showing a vehicle body structure of a vehicle according to an embodiment. It is the schematic which shows an example of the rear suspension which comprises a vehicle. It is a side view which shows the frame member which concerns on one Embodiment. It is a schematic perspective view which shows the frame member which concerns on one Embodiment. It is sectional drawing which shows the structure of the frame member which concerns on one Embodiment. It is a perspective view which shows the manufacturing process of the vehicle body frame which concerns on one Embodiment. It is sectional drawing which shows the manufacturing process of the vehicle body frame which concerns on one Embodiment. It is sectional drawing which shows the structure of the frame member which concerns on one Embodiment.

  First, a vehicle body frame structure of a vehicle according to the present invention will be described with reference to the drawings.

  As shown in FIG. 1, a vehicle 10, which is an automobile, includes a vehicle body frame 20 that forms a skeleton of a lower body of a vehicle body 11 below the floor (below the passenger compartment). The vehicle body frame 20 is composed of a plurality of frame members. For example, in the present embodiment, the vehicle body frame 20 includes a pair of side members 21 extending in the front-rear direction of the vehicle 10 and a plurality of cross members 22 extending in the vehicle width direction of the vehicle 10. Yes. Each side member 21 is formed by, for example, connecting a plurality of members, and in this embodiment, a front side member 23 that forms the front side of the vehicle 10 and a rear side member 24 that forms the rear side of the vehicle 10. It consists of and. Each cross member 22 is fixed to a predetermined position of the side member 21 by spot welding or the like.

  The structure of the vehicle body frame 20 is not particularly limited. However, since it forms a skeleton of the vehicle 10, it is preferable that its rigidity is relatively high. The vehicle body frame 20 preferably has a high overall rigidity, and in particular, it is desirable that the rigidity of the portion to which other members are connected is high.

  For example, in the present embodiment, the front wheel 30 (see FIG. 1) of the vehicle 10 is supported on the vehicle body 11 (vehicle body frame 20) by a front suspension (not shown). The rear wheel 31 of the vehicle 10 is supported on the vehicle body 11 (vehicle body frame 20) by a rear suspension. As shown in FIG. 2, as the rear suspension 40, for example, a multi-link type rear suspension can be cited. The rear suspension 40 extends in the front-rear direction of the vehicle 10 to determine the front-rear position of the rear wheel 31 and swings in the up-down direction, and includes a plurality of links extending in the vehicle width direction. 42, 43, 44, a shock absorber 45 extending in the vertical direction of the vehicle 10, and a strut 47, etc., that sheathes the coil spring 46. Each link 42, 43, 44 is attached to a suspension cross member (not shown in FIG. 2) that forms the skeleton of the rear suspension 40. The suspension cross member is attached to the vehicle body frame 20.

  Specifically, as shown in FIG. 3, the rear side member 24 constituting the vehicle body frame 20 is inclined at a portion facing the rear wheel 31 of the vehicle 10 so that the rear end side is positioned above the front end side. It has a kick-up portion 24a. The kick-up portion 24a is provided to avoid interference with the rear suspension 40 and the like. A suspension cross member 48 constituting the rear suspension 40 is coupled to the kick-up portion 24a of the rear side member 24 via a suspension bracket 50. That is, a part of the rear suspension 40 is connected to the kick-up portion 24 a of the rear side member 24. In the present embodiment, the suspension cross member 48 is formed of a cross-shaped pipe frame, and is fixed to the rear side member 24 and the suspension bracket 50 by fastening members 51 such as bolts.

  As shown in FIGS. 4 and 5, the kick-up portion 24a of the rear side member 24 is filled with a filling member 61 formed of a heat-curing foam filling material and provided on the filling member 61. A reinforcing member 60 composed of a base member 62 fixed to the rear side member 24 by a member 61 is provided. The rear side member 24 according to the present embodiment is formed in a substantially U-shaped cross section to define a groove portion 25, and a reinforcing member 60 is provided in the groove portion 25. On the rear side member 24, a rear side member upper 70 which is another frame member constituting the vehicle body frame 20 is joined by spot welding or the like, and the groove portion 25 is closed by the rear side member upper 70.

  Here, as the foaming filler that is the material of the filling member 61, for example, an epoxy-based thermosetting foaming filler is used. The base material 62 is for temporarily holding the unfoamed (before heating and foaming) filler and guiding the foamed area, and is formed of a relatively hard plate material such as a metal material or a resin material. Yes.

  In this embodiment, the filling member 61 constituting the reinforcing member 60 is formed by heating and foaming a thermosetting foaming filler. Specifically, the reinforcing member 60 is formed by the following procedure. First, an unfoamed filler is placed in the rear side member 24, and a base material 62 is placed on the filler. In this state, the filler is heated and foamed. Thereby, the filling member 61 made of the foamed filler is formed into a desired shape, and the filling member 61 is firmly joined to the rear side member 24 and the base material 62. That is, the rear side member 24 and the base material 62 are joined by the filling member 61 to form the reinforcing member 60.

  By the way, the filling member 61 formed of the foam filler may absorb moisture. For this reason, it is preferable that the contact surface of the base material 62 with the filling member 61 is subjected to rust prevention treatment in advance.

  In the present invention, when the vehicle body frame 20 is manufactured, the reinforcing member 60 is provided in the rear side member 24 in the procedure described below, so that the contact surface of the base material 62 with the filling member 61 is reduced. Efficient rust prevention treatment is applied.

  As shown in FIGS. 6 and 7, in the rear side member 24, which is a frame member, in this embodiment, the unfoamed filler 100 and the base material 62 are placed between the two in the groove portion 25 of the kick-up portion 24a. In a state where a gap is secured. In the present embodiment, a plurality of projecting portions 101 projecting toward the base material 62 side are provided on the surface of the filler 100 on the base material 62 side, and these projecting portions 101 abut on the base material 62. Thus, a gap is secured between the filler 100 and the base material 62. A gap is also secured between the unfoamed filler 100 and the rear side member 24. In order to ensure this gap, one of the filler 100 or the rear side member 24 may be provided with a plurality of protrusions that protrude toward the other side.

  And the electrodeposition coating with respect to the rear side member 24 is performed in the state which ensured the clearance gap between the filler 100 and the base material 62 in this way. Since a gap is secured between the filler 100 and the base material 62, electrodeposition coating as a rust-proofing treatment is applied to the surface of the base material 62 on the side of the filler 100 together with the surface of the rear side member 24. Will be.

  Thereafter, the filler 100 is foamed to fill the filling member 61 between the rear side member 24 and the base material 62. Thereby, the rear side member 24 and the base material 62 are joined by the filling member 61 to form the reinforcing member 60 (see FIG. 5).

  As described above, according to the present invention, when the electrodeposition coating is performed on the rear side member 24, the contact surface of the base member 62 with the filling member 61 can be simultaneously subjected to rust prevention treatment. That is, the rust prevention treatment can be performed very efficiently on the contact surface of the base material 62 with the filling member 61. Therefore, even when the filling member 61 absorbs moisture, corrosion of the base material 62 due to the moisture can be suppressed. Further, an increase in manufacturing cost can be suppressed.

  Further, in the present embodiment, since the protruding portion 101 is provided on the filler 100 that becomes the filling member 61, the protruding portion 101 disappears by foaming the filler 100, and the gap between the rear side member 24 and the base material 62 is eliminated. The filling member 61 can be filled particularly well. The number and size of the protrusions 101 are not particularly limited, but it is preferable that the area of the protrusions 101 that contacts the base material 62 be as small as possible. Thereby, the area of the base material 62 which can perform a rust prevention process spreads, and corrosion of the base material 62 can be suppressed more reliably.

  The method for securing the gap between the filler 100 and the substrate 62 is not particularly limited. For example, a protrusion may be provided on the surface of the substrate 62 on the filler 100 side. In addition, a member different from the filler 100 may be interposed between them. In any case, if a gap can be secured between the filler 100 and the base material 62, the contact surface of the base material 62 with the filling member 61 can be efficiently subjected to rust prevention.

  Further, since the reinforcing member 60 composed of the filling member 61 and the base material 62 is provided in the kick-up portion 24a of the rear side member 24, the collision performance of the kick-up portion 24a is greatly improved. . That is, even when a collision from the rear of the vehicle (rear collision) occurs, the energy of the collision is absorbed by the filling member 61 and deformation of the body frame 20 is suppressed, and the safety of the vehicle 10 is improved.

  The shape of the filling member 61 is not particularly limited, and may be appropriately determined according to the shape of the rear side member 24 and the like. In this embodiment, the filling member 61 is provided so as to cover the bottom surface portion of the groove portion 25 of the rear side member 24. For example, the filling member 61 is provided only at two corners of the groove portion 25 defined by the rear side member 24. May be. Each corner of the groove 25 has a large load (energy) load in the event of a collision from the rear of the vehicle. For this reason, by providing the filling member 61 at each corner, the energy at the time of the collision can be absorbed by the filling member 61 and the deformation of the vehicle body frame 20 can be effectively suppressed.

  Further, the base material 62 constituting the reinforcing member 60 is not directly fixed (joined) to the rear side member 24, and is fixed only by the filling member 61. By setting it as such a structure, the energy at the time of a collision can be efficiently absorbed by the filling member 61, and a deformation | transformation of the vehicle body frame 20 can be suppressed.

  The material of the base material 62 is not particularly limited, and as described above, for example, a relatively hard material such as a metal material or a resin material can be used. In particular, a relatively light resin material is used. Is preferred. Since the energy at the time of the collision is efficiently absorbed by the filling member 61, deformation of the vehicle body frame 20 can be suppressed even if the base material 62 is formed of a resin material. Therefore, by forming the base material 62 from a resin material, the vehicle body frame 20 can be reduced in weight and fuel efficiency can be improved while improving the collision performance.

  However, when the thermosetting foam filler is heated and foamed, it is preferable to temporarily fix the base material 62 to the rear side member 24 to restrict the movement of the base material 62. Although the method of temporary fixing is not particularly limited, for example, in the present embodiment, the base material 62 is temporarily fixed to the rear side member 24 by a clip member. Specifically, as shown in FIG. 8, a protrusion 63 that protrudes toward the rear side member 24 with the thickness of the filling member 61 is provided at a predetermined position of the base material 62. Is provided with a through hole 64. On the other hand, the rear side member 24 is also provided with a communication hole 26 communicating with the through hole 64. For example, the base member 62 is temporarily fixed to the rear side member 24 by attaching the clip member 80 made of an elastic material such as a resin material or a rubber material to the through hole 64 and the communication hole 26.

  Thereby, the filling member 61 can be satisfactorily formed into a predetermined shape by heating and foaming the thermosetting foam filler into a desired shape. The clip member 80 may be removed after the filling member 61 is formed, or may be left as it is.

  As mentioned above, although one Embodiment of this invention was described, Of course, this invention is not limited to such Embodiment. The present invention can be modified as appropriate without departing from the spirit of the present invention.

  For example, in the above-described embodiment, the rear side member is exemplified as the frame member on which the reinforcing member is provided. However, the reinforcing member may be provided on any frame member constituting the vehicle body frame.

  In the above-described embodiment, the multi-link type rear suspension is illustrated as an example of the rear suspension coupled to the kick-up portion. However, the type of the rear suspension is not particularly limited.

DESCRIPTION OF SYMBOLS 10 Vehicle 11 Car body 20 Body frame 21 Side member 22 Cross member 23 Front side member 24 Rear side member 24a Kick-up part 25 Groove part 26 Communication hole 30 Front wheel 31 Rear wheel 40 Rear suspension 41 Trailing arm 42, 43, 44 Link 45 Shock absorber Zober 46 Coil spring 47 Strut 48 Suspension cross member 50 Suspension bracket 51 Fastening member 60 Reinforcement member 61 Filling member 62 Base member 63 Projection part 64 Through hole 70 Rear side member upper 80 Clip member 100 Filler 101 Protrusion part

Claims (3)

It is arranged under the floor of the vehicle and is formed with a plurality of frame members,
A method of manufacturing a vehicle body frame comprising a reinforcing member formed of a base material made of a metal material and a filling member made of a foamed filler filled between the base material and the frame member. Because
A step of performing electrodeposition coating on the surface of the frame member including the base material in a state in which the unfoamed filler and the base material are arranged in the frame member with a gap between them; ,
Then, filling the filler between the frame member and the base material by foaming the filler, and
A method of manufacturing a vehicle body frame, comprising: It is a manufacturing method of the body frame according to claim 1,
A protrusion is formed on the contact surface with the other of the base material or the filler, and the base material and the filling member are brought into contact with each other via the protrusion, so that A method of manufacturing a vehicle body frame characterized by securing a space. A method of manufacturing a vehicle body frame according to claim 2,
A method of manufacturing a vehicle body frame, wherein the protrusion is provided on the filler.

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