JP2015189092A - panel member - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a panel member which realizes higher strength and rigidity and excellent productivity by applying a combination of a press-moldable shape and a layered member structure.SOLUTION: A planar panel member is composed of three members consisting of an upper layer member forming the upper surface, a lower layer member forming the lower surface and a middle layer member intervening between the upper and lower layer members or a joint structure of two members consisting of a middle layer member forming the upper surface and a lower layer member forming the lower surface; the upper and lower layer members are composed of a surface structure having a flat surface; and the middle layer member consists of an irregular press structure formed with a structure having a continuous irregular shape by press-molding a stampable base material consisting of a planar base material.

Description

  The present invention relates to a planar panel member, and more particularly to a panel member in which a plurality of layered members having high strength, rigidity, and excellent productivity are combined.

  Resin panel members have been widely applied to meet demands for planar panel members in various fields. Use of fiber reinforced resin panel members is particularly required when high strength and rigidity are required. Is known to be suitable. However, since many of the conventional fiber reinforced resin members are formed by injection molding (for example, Patent Document 1), the fiber length of the reinforced fiber used is relatively short, and is adopted as a panel member for a vehicle, for example. Therefore, the strength and rigidity may be insufficient.

  Therefore, the present inventors have used a stampable base material in which the fiber length of the reinforcing fiber is relatively long and the molded article can exhibit high strength and rigidity in order to solve the above-described lack of strength and rigidity. The study started. However, since the stampable base material is formed by press forming, in-plane flow is a prerequisite for the forming. However, in press molding using a stampable base material, it is difficult to form a reinforcing rib on the surface of the planar body (that is, molding requiring an out-of-plane flow), and therefore a substantially planar structure. However, it was difficult to exhibit high rigidity in terms of shape. Therefore, the high strength and rigidity inherent in the fiber reinforced resin material constituting the stampable base material cannot be effectively used.

JP 2012-94476 A

  Therefore, in view of the current situation as described above, the object of the present invention is to apply a combination of a press-formable shape and a layered member structure while paying attention to excellent properties that can exhibit high strength and rigidity of a stampable base material. Accordingly, an object of the present invention is to provide a panel member suitable for use in various fields that can realize excellent productivity.

  In order to solve the above problems, a panel member according to the present invention is a planar panel member, and is interposed between an upper layer member that forms an upper surface, a lower layer member that forms a lower surface, and an upper layer member and a lower layer member. A surface structure in which three types of members of the middle layer member, or a middle layer member that forms the upper surface, and a lower layer member that forms the lower surface are joined to each other, and the upper layer member and the lower layer member have a flat surface. The intermediate layer member is composed of a concavo-convex press structure in which a structure having a continuous concavo-convex shape is formed by press molding of a stampable substrate made of a planar substrate.

  In such a panel member according to the present invention, since it is configured in a laminated joining structure of a plurality of layered members, the panel member is structurally composed of an upper layer member and a lower layer member that form an outer surface having a flat surface. It is possible to easily separate the functions from the middle layer member that bears strength and rigidity. Among these, the middle layer member is composed of a concavo-convex press structure having a continuous concavo-convex shape, and therefore can exhibit high strength and rigidity structurally. This structure with continuous unevenness capable of developing high strength and rigidity is formed by press molding of a stampable substrate made of a planar substrate. In other words, it can be formed by press molding of a stampable substrate. As the uneven shape is adopted as the uneven shape of the middle layer member, it is not necessary to stand up ribs etc. that are difficult to form by press forming of stampable base material, so it can be easily formed into the desired shape without problems And excellent productivity is secured. As a result, a panel member that can be manufactured with excellent productivity and can exhibit high strength and rigidity is realized.

  In the panel member according to the present invention, it is preferable that at least the middle layer member is made of a fiber reinforced resin. Since the fiber reinforced resin is a material that is lightweight and can exhibit high strength and rigidity, at least the middle layer member is made of fiber reinforced resin to achieve the desired strength and rigidity while reducing the weight of the entire panel member. Can be expressed.

  Further, when at least the middle layer member is made of a fiber reinforced resin, it is possible to adopt a form in which the reinforcing fiber constituting the fiber reinforced resin is made of a mat in which the reinforcing fibers cut discontinuously are mixed. By including such a mat, it becomes possible to flow the reinforcing fibers together with the resin while maintaining an appropriate distribution state of the reinforcing fibers when press forming the stampable base material for forming the middle layer member. It becomes possible to promote the uniformity of the strength and rigidity of the intermediate layer member after press molding, and thus the entire panel member.

  In addition, when at least the middle layer member is made of a fiber reinforced resin, carbon fiber, glass fiber, aramid fiber, or a combination thereof can be used as the reinforcing fiber constituting the fiber reinforced resin, but particularly high strength. In addition, it is preferable to include carbon fibers that can exhibit rigidity and are easy to design their properties.

  In the panel member according to the present invention, the stampable base material is not particularly limited as long as it is a stampable base material capable of forming an intermediate layer member composed of the uneven press structure as described above by press molding. From the viewpoint of properties, etc., it is preferably made of a stampable base material composed of a thermoplastic resin and reinforcing fibers.

  Moreover, as the uneven | corrugated press structure which comprises the said intermediate | middle layer member, any form of the structure where the uneven | corrugated shape was connected in both the vertical and horizontal directions, or the structure where the uneven | corrugated shape was connected in any one of the vertical and horizontal directions can be taken. Furthermore, any irregular shape can be adopted as long as it is a continuous irregular shape that can be formed by press molding of a stampable substrate made of a planar substrate.

  Moreover, in the panel member which concerns on this invention, the said intermediate | middle layer member can also provide only one layer, and can also provide multiple layers. In the case where the uneven shape of the uneven press structure constituting the middle layer member is connected in the vertical and horizontal directions as described above, high strength and rigidity can be expressed in both the vertical and horizontal directions even if the intermediate layer member is only one layer. is there. Further, in the case where the uneven shape of the uneven press structure constituting the middle layer member is connected in any one of the vertical and horizontal directions, the laminated structure of two or more middle layer members so that the uneven shape is in a different direction By doing so, high strength and rigidity can be expressed in all different directions. Here, in the case of the latter form, it is possible to facilitate the press forming of each intermediate layer member as compared to the former case.

  In the panel member according to the present invention, the upper layer member and the lower layer member can also be configured from members obtained by press-molding the stampable base material as described above. The upper layer member and the lower layer member are composed of a surface structure having a flat surface at least partially. However, when considering the peripheral portion of the upper layer member and the lower layer member, the upper layer member and the lower layer member are not necessarily configured as a surface structure having a flat surface throughout. Is not limited. Therefore, even in such a case, if the upper layer member or the lower layer member is configured from the press molded member of the stampable base material, the molding of the upper layer member or the lower layer member is facilitated, and the productivity of the entire panel member is greatly increased. It is done.

  In the present invention, the stampable substrate is preferably composed of a substrate exhibiting isotropic physical properties (for example, isotropic mechanical properties). If the intermediate layer member is formed using such a stampable base material, and if the upper layer member and the lower layer member are also formed using such a stampable base material, the strength and rigidity of the entire panel member are made uniform. Can be further promoted.

  Further, if the stampable base material is configured as a laminate in which a plurality of sheet-like base materials are laminated, the physical properties of the intermediate layer member, and further, the upper layer member and the lower layer member formed by using the stampable base material, depending on the desired physical properties. It becomes easy to control easily and by extension, it becomes easier to control the physical property of the whole panel member to a desired physical property. Also when using the sheet-like base material for comprising such a laminated body, it is preferable that this sheet-like base material consists of a base material which shows an isotropic physical property. If a stampable base material composed of the laminate is configured using such a sheet-like base material, the strength and rigidity of the intermediate layer member formed using the stampable base material, and further, the upper layer member and the lower layer member are improved. It becomes possible to further promote the homogenization, and consequently to further promote the homogenization of the strength and rigidity of the entire panel member.

  Such a panel member according to the present invention can be applied to virtually any application, and is particularly suitable as a vehicle panel member that is required to be lighter, stronger, and more rigid.

  As described above, according to the panel member of the present invention, high strength and rigidity can be realized by providing an intermediate layer member made of a concavo-convex press structure that can be formed by press molding of a stampable base material while reducing weight. A panel member can be realized, and the panel member can be manufactured with excellent productivity.

  In particular, even for applications that require mass production, it becomes possible to meet the requirements reliably and easily.

1 is a schematic configuration diagram of a vehicle to which a panel member according to an embodiment of the present invention is applied. It is the disassembled perspective view (A) of the panel member which concerns on one embodiment of this invention, and the perspective view (B) after an assembly. It is the disassembled perspective view (A) of the panel member which concerns on another embodiment of this invention, and the perspective view (B) after an assembly. It is the disassembled perspective view (A) of the panel member which concerns on another embodiment of this invention, and the perspective view (B) after an assembly. It is a schematic block diagram which shows the example of the input load to the panel member which concerns on one embodiment of this invention.

Embodiments of the present invention will be described below with reference to the drawings.
FIG. 1 shows an application example of a panel member according to the present invention. In this example, a panel member 2 provided at the lower part of a vehicle 1 is illustrated. Such a panel member 2 is configured as shown in FIGS.

  In the embodiment shown in FIG. 2 as an exploded perspective view (A) of the panel member and a perspective view (B) after assembly, the planar panel member 3 includes an upper layer member 4 forming an upper surface and a lower layer member forming a lower surface. 5, a layered and joined structure of three types of members, the middle layer member 6 interposed between the upper layer member 4 and the lower layer member 5. The upper layer member 4 and the lower layer member 5 are composed of a plane structure having flat surfaces 7 and 8. The middle layer member 6 is composed of a concavo-convex press structure 9 formed by press molding a stampable base material (sheet-like stampable base material) made of a planar base material with a structure having a continuous concavo-convex shape. In the aspect, the uneven press structure 9 is configured in a structure in which the uneven shape is connected in both the vertical and horizontal directions. Each concavo-convex shape portion has a hat-shaped cross-sectional shape. In this embodiment, the middle layer member 6, the upper layer member 4 and the lower layer member 5 are all made of a fiber reinforced resin containing carbon fiber, and the upper layer member 4 and the lower layer member 5 are also formed by press molding of a stampable base material. Has been. The carbon fiber as the reinforcing fiber is composed of a mat formed by blending discontinuously cut carbon fibers, and the fiber length is, for example, in the range of 1 to 50 mm and at the stage of a stampable base material, a conventional injection molded product. Is set longer than the fiber length.

  In such a panel member 3, the upper layer member 4 and the lower layer member 5 having the flat surfaces 7 and 8 form a desired outer surface with respect to the surroundings and the mounted component, and the uneven press structure interposed therebetween. The middle layer member 6 formed of the body 9 mainly develops the strength and rigidity required for the panel member 3. Therefore, both the outer surface shape, strength, and rigidity required for the panel member 3 are satisfied by the laminated configuration of these members. Moreover, in this embodiment, since the middle layer member 6, the upper layer member 4, and the lower layer member 5 are all comprised from the fiber reinforced resin containing carbon fiber, the intensity | strength and rigidity as the panel member 3 whole are ensured highly. Lightweight is also secured. The middle layer member 6 that expresses structurally high strength and rigidity is formed on the concave and convex press structure 9 in which the hat-shaped cross-sections are connected while maintaining the planar shape as a whole. It is not necessary to stand upright, and it is easily formed without any problems by using a stampable base material made of a sheet-like planar base material as a material and press-molding it. In other words, it is formed as a concavo-convex structure that can be formed without problems by press forming a stampable substrate. Therefore, the panel member 3 capable of expressing high strength and rigidity while realizing excellent productivity is realized.

  As described above, if the intermediate layer member 6 and further the upper layer member 4 and the lower layer member 5 are formed using a base material having isotropic properties as the stampable base material, the entire panel member 3 is formed. It is possible to promote uniform strength and rigidity. Further, if a laminate in which a plurality of sheet-like base materials are laminated as a stampable base material, the middle layer member 6, and further, the upper layer member 4 and the lower layer member 5 can be easily controlled to have desired physical properties. As a result, the physical properties of the entire panel member 3 can be easily controlled to the desired physical properties. Furthermore, if a base material showing isotropic properties is used as a sheet-like base material for constituting such a laminate, the intermediate layer member 6 formed using the stampable base material, and further the upper layer member It becomes possible to further promote the homogenization of the strength and rigidity of the lower member 4 and the lower layer member 5, and to further promote the homogenization of the overall strength and rigidity of the panel member 3.

  FIG. 3 shows a panel member 11 according to another embodiment of the present invention as an exploded perspective view (A) of the panel member and a perspective view (B) after assembly. In the present embodiment, the middle layer member is composed of two middle layer members 12 and 13 formed on the concave and convex press structures 14 and 15 having a structure in which the concave and convex shapes are connected in any one of vertical and horizontal directions. The extending directions of the ridges and the ridges of the uneven press structures 14 and 15 constituting the middle layer members 12 and 13 are set to intersect with each other, in particular perpendicularly to each other. Since the other configuration conforms to the embodiment shown in FIG. 2, the same reference numerals as those in FIG.

  Even in such a configuration, by using a stampable base material made of a sheet-like planar base material as a material and press-molding it, the middle layer members 12 and 13 made of the uneven press structures 14 and 15 are problematic. Easily molded. In the present embodiment, each of the uneven press structures 14 and 15 only needs to be formed in a structure in which the uneven shapes are connected in one direction, so that it is molded more than the form shown in FIG. Has been made easier. Then, by laminating the middle layer members 12 and 13 composed of the two uneven pressing structures 14 and 15 so that the extending direction of the unevenness is different, the same strength and rigidity as the form shown in FIG. 2 are obtained. It can be expressed. Other actions and effects are in accordance with the embodiment shown in FIG.

  FIG. 4 shows a panel member 21 according to still another embodiment of the present invention as an exploded perspective view (A) of the panel member and a perspective view (B) after assembly. In the present embodiment, no upper layer member is provided, and a laminated and bonded structure of two types of members, a lower layer member 5 and an intermediate layer member 6, equivalent to those shown in FIG. When the uneven structure may be exposed on the upper surface, the panel member 21 having such a two-layer structure can be obtained. Since the other configuration conforms to the embodiment shown in FIG. 2, the same reference numerals as those in FIG.

  Even in such a configuration, the strength and rigidity required mainly for the panel member 21 are expressed by the middle layer member 6 made of the uneven press structure 9, so that the same high strength and rigidity as the panel member 3 shown in FIG. Is obtained. Other actions and effects are in accordance with the embodiment shown in FIG.

  In the panel member which concerns on this invention which can be comprised in the above various forms, high intensity | strength and rigidity can be expressed with respect to the load from the outside as shown, for example in FIG. FIG. 5 illustrates the panel member 3 shown in FIG. 2 among the above embodiments, but the panel members 11 and 21 according to the embodiments shown in FIGS. 3 and 4 similarly exhibit high strength and rigidity. it can. In FIG. 5, the panel member 3 is higher than a load 31 from the front (for example, a front collision load in a vehicle), a load 32 from the side (for example, a side collision load in a vehicle), and a bending load 33. Strength and rigidity can be expressed.

  The panel member according to the present invention can be applied to all fields and is excellent in productivity. Therefore, the panel member is particularly suitable as a panel member (for example, a vehicle panel member) in a field requiring mass production.

DESCRIPTION OF SYMBOLS 1 Vehicle 2, 3, 11, 21 Panel member 4 Upper layer member 5 Lower layer member 6, 12, 13 Middle layer member 7, 8 Flat surface 9, 14, 15 Concave press structure 31 Load 32 from the front 32 Load 33 from the side Bending load

Claims (12)

  3 types of planar panel members, an upper layer member forming the upper surface, a lower layer member forming the lower surface, an intermediate layer member interposed between the upper layer member and the lower layer member, or an intermediate layer member forming the upper surface A structure in which two types of members of the lower layer member forming the lower surface are joined, the upper layer member and the lower layer member are composed of a plane structure having a flat surface, and the middle layer member has a continuous uneven shape A panel member comprising a concavo-convex press structure formed by press molding a stampable base material made of a planar base material.   The panel member according to claim 1, wherein at least the middle layer member is made of a fiber reinforced resin.   The panel member according to claim 1 or 2, wherein at least the intermediate layer member is made of a fiber reinforced resin, and the reinforcing fibers constituting the fiber reinforced resin are made of a mat mixed with discontinuously cut reinforcing fibers.   The panel member according to any one of claims 1 to 3, wherein at least the intermediate layer member is made of a fiber reinforced resin, and carbon fibers are included as the reinforcing fibers constituting the fiber reinforced resin.   The panel member in any one of Claims 1-4 in which the said stampable base material consists of a base material comprised with the thermoplastic resin and the reinforced fiber.   The panel member according to claim 1, wherein the concavo-convex press structure has a structure in which the concavo-convex shape is connected in both the vertical and horizontal directions, or a structure in which the concavo-convex shape is connected in any one of the vertical and horizontal directions. .   The panel member according to any one of claims 1 to 6, wherein the intermediate layer member is provided with only one layer or a plurality of layers.   The panel member according to claim 1, wherein both the upper layer member and the lower layer member are members formed by press-molding the stampable base material.   The panel member according to any one of claims 1 to 8, wherein the stampable substrate is made of a substrate exhibiting isotropic physical properties.   The panel member according to any one of claims 1 to 9, wherein the stampable base material comprises a laminate in which a plurality of sheet-like base materials are laminated.   The panel member according to claim 10, wherein the sheet-like substrate is made of a substrate exhibiting isotropic physical properties.   The panel member according to claim 1, comprising a vehicle panel member.

Images