JP2015229391A - Door sash and method for manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a door sash that can prevent the occurrence of a defective shape such as a wrinkle and can reduce a load required for bending and shorten the weld length even if the curvature of bending is increased when forming an upper part and a pillar part by bending.SOLUTION: In a door sash 10 where an upper part 11 and a pillar part 12 are formed of a member partially continuing in the longitudinal direction, a continuous part 19 is formed which continues on an outer peripheral side of a corner part 13 extending from the upper part 11 to the pillar part 12, and a welded part 20 is formed which is welded in a state where an edge 103 of a cut-off part 102 is substantially abutted on an inner peripheral side of the corner part 13.

Description

  The present invention relates to a door sash used for a vehicle door and a manufacturing method thereof.

  Conventionally, as a door sash used for a vehicle door, a door sash having a structure in which an upper part and a pillar part of separate members are welded at a corner portion is known. The door sash is formed by bending the upper part and the pillar part separately and separately welding the end part of the upper part and the end part of the pillar part.

  In addition, in order to eliminate the process of welding the upper part and the pillar part of separate members, the upper and pillar parts are formed by bending an elongated intermediate material having a basic sectional shape of the door sash at a predetermined position in the longitudinal direction. By forming, a door sash is proposed in which the upper part and the pillar part are formed of the same member (see Patent Document 1).

  Further, after bending an elongated intermediate material having a cross-sectional shape having a basic cylindrical portion of the door sash at a predetermined position in the longitudinal direction to form an upper portion and a pillar portion, the corner portion is more than the cylindrical portion. A door sash has also been proposed in which a portion in the direction corresponding to the outer surface of the vehicle body is partially cut from the intermediate material and the cylindrical portion is continuous from the upper portion to the pillar portion, and the corner patch is fixed so as to fill the cut portion. (See Patent Documents 2 and 3). This door sash can cut off a part of a defective shape such as a wrinkle generated by bending by cutting a part of the corner part to some extent.

JP-A-8-142777 JP 2011-84129 A JP2013-23131A

  By the way, the door sashes of Patent Documents 2 and 3 leave the inner peripheral side of the bending direction in the bending process such as the cylindrical part of the intermediate material in a continuous manner. Most of them occur at the part where the inner circumference is left over. Therefore, as the curvature of the bending process is increased, a defective shape such as a wrinkle is remarkably generated in a portion on the inner peripheral side in the bending direction, and the cross-sectional shape having the cylindrical portion becomes a cross-sectional shape in which the cylindrical portion is crushed. (See Patent Document 3, paragraph [0018]).

  Moreover, since the door sash of patent documents 1-3 is a thing which bends the elongate intermediate material which formed the basic cross-sectional shape of the door sash as it is, a big load is needed for a bending process, and bending Processing equipment for processing is also limited to expensive ones.

  On the other hand, in a door sash that welds the end of the upper part and the end of the pillar part over the whole part, the weld length becomes long. However, if the weld length becomes long, the welding operation becomes longer and the weld bead becomes longer. The increase in the number of man-hours for cutting causes an increase in the amount of electricity used and the deterioration of the working environment, so it is required to make the welding length as short as possible.

  The present invention is proposed in view of the above problems, and when forming the upper portion and the pillar portion by bending, it is possible to prevent occurrence of defective shapes such as wrinkles even if the bending curvature is increased. An object of the present invention is to provide a door sash capable of reducing a load required for bending and shortening a welding length and a method for manufacturing the door sash.

The door sash of the present invention is a door sash formed of a member in which an upper portion and a pillar portion are partially continuous in the longitudinal direction, and is continuous on the outer peripheral side of a corner portion extending from the upper portion to the pillar portion. A continuous portion is formed, and a welded portion is formed on the inner peripheral side of the corner portion, the welded portion being welded by substantially abutting the edge of the cut portion.
According to this, when the upper portion and the pillar portion of the door sash formed by a member in which the upper portion and the pillar portion are partially continuous in the longitudinal direction are formed by bending, the cut portion on the inner peripheral side Even if the curvature of bending is increased, it is possible to prevent occurrence of defective shapes such as wrinkles. Further, since the occurrence of a defective shape can be prevented even if the curvature is increased, the degree of freedom in the corner portion and the degree of design can be greatly improved. In addition, since bending can be performed with the inner peripheral side cut away, the load required for bending can be reduced, the range of usable bending devices can be expanded, and device costs can be reduced. You can also Further, since welding is unnecessary at the portion where the outer peripheral side of the corner portion extending from the upper portion to the pillar portion is continuous, the welding length can be shortened. Therefore, the amount of electricity used can be reduced and the working environment can be improved by shortening the welding work and reducing the number of welding beads.

The door sash of the present invention has a cross-sectional shape having a cylindrical portion, and the cylindrical portion located on the inner peripheral side of the corner portion is formed by welding at least a part of the edge of the cut portion. It is characterized by.
According to this, about the door sash of the cross-sectional shape which has a cylindrical part, it can prevent that the cylindrical part becomes the cross-sectional shape which was crushed, or becomes a cylindrical part with a wrinkle.

The door sash manufacturing method of the present invention is a method of manufacturing the door sash of the present invention, wherein a first step of forming an elongated intermediate material having a cross-sectional shape corresponding to the cross-sectional shape of the door sash, and the intermediate material A second step of partially cutting the intermediate material at a predetermined position in the longitudinal direction to form a cut portion, and bending the inner cut side of the cut portion to form shapes corresponding to the upper portion and the pillar portion And a fourth step of welding at least a part of the abutted edge by arranging to abut the edge of the cut portion.
According to this, the door sash of this invention can be manufactured efficiently and correctly. In addition, when bending and welding the upper part and pillar part of separate members, it is necessary to form the shape by bending the upper part and pillar part in separate processes and equipment, respectively. By forming the upper part and the pillar part with a continuous intermediate material, the bending process and equipment can be integrated into one, and the working space can be reduced.

In the door sash manufacturing method of the present invention, the intermediate material is bent between the first step and the second step, and the intermediate material bent in the bending step in the second step The cut portion is formed on the circumferential side.
According to this, it is possible to easily form an appropriate excised portion so that the abutted portion has an accurate and beautiful finish. Further, even when wrinkles or the like are generated in the inner peripheral side portion of the corner portion by bending before excision, it can be removed by a partial excision step.

The door sash manufacturing method of the present invention is characterized in that, in the second step, a substantially chevron-shaped cut portion having a rounded top portion or a substantially flat top portion is formed in the intermediate material.
According to this, the part which abutted the edge of the excision part by the bending process can be abutted more accurately, and the finish can be made more accurate and beautiful.

  According to the present invention, when the upper portion and the pillar portion of the door sash formed by a member in which the upper portion and the pillar portion are partially continuous in the longitudinal direction are formed by bending, the bending curvature is increased. Even so, it is possible to prevent occurrence of defective shapes such as wrinkles. In addition, since bending can be performed with the inner peripheral side cut away, the load required for bending can be reduced, the range of usable bending devices can be expanded, and device costs can be reduced. You can also Further, since welding is unnecessary at the portion where the outer peripheral side of the corner portion extending from the upper portion to the pillar portion is continuous, the door sash can be obtained with a short welding length.

The perspective view which shows the door sash of 1st Embodiment by this invention. The perspective view which shows the corner part vicinity of the door sash of 1st Embodiment. Sectional drawing of the corner part of the door sash of 1st Embodiment. (A)-(d) is sectional explanatory drawing which shows the process of forming the intermediate material used as the door sash of 1st Embodiment by bending molding. (A)-(c) is explanatory drawing explaining the process of bending and partial excision to the intermediate material used as the door sash of 1st Embodiment. The fragmentary perspective view which shows the state which formed the cut part in the intermediate material used as the door sash of 1st Embodiment. (A)-(c) is sectional explanatory drawing explaining the process of partially excising the intermediate material used as the door sash of 1st Embodiment. The perspective view which shows the corner part vicinity of the door sash of 2nd Embodiment. Sectional drawing of the corner part of the door sash of 2nd Embodiment. The fragmentary perspective view which shows the state which formed the cut part in the intermediate material used as the door sash of 2nd Embodiment. (A)-(c) is sectional explanatory drawing explaining the process of partially excising the intermediate material used as the door sash of 1st Embodiment.

[Door Sash of First Embodiment and Manufacturing Method Thereof]
As shown in FIGS. 1 and 2, the door sash 10 of the first embodiment is formed by a member in which an upper portion 11 and a pillar portion 12 are partially continuous in the longitudinal direction. A portion reaching the pillar portion 12 is a corner portion 13 having a bent shape. As shown in the cross-sectional shape of FIG. 3, the door sash 10 includes a cylindrical portion 14, a concave glass run channel accommodating portion 15, a concave weather strip accommodating portion 16, and a substantially plate-shaped exterior portion 17. A single metal plate is formed by bending and is joined at the joint 18 by spot welding or the like. The cross-sectional shape including the cylindrical portion 14, the glass run channel accommodating portion 15, the weather strip accommodating portion 16, and the exterior portion 17 is common to the upper portion 11, the pillar portion 12, and the corner portion 13.

  A continuous portion 19 that is continuous with the upper portion 11 and the pillar portion 12 in a bent or curved state is formed on the outer peripheral side of the corner portion 13, and the edge 103 of the cut portion 102 is formed on the inner peripheral side of the corner portion 13. Are arranged so as to be substantially in contact with each other, and a part of the substantially contact portion is welded to form a welded portion 20 (see FIGS. 2, 3, 6, and 7). The welded portion 20 in the first embodiment partially cuts the inner peripheral side portion of the exterior portion 17 and the cylindrical portion 14 disposed on the inner peripheral side into a substantially chevron shape, and the edge 103 of the cut portion 102 is removed. It is made to abut by bending, and a part is welded in this abutted state. That is, the exterior portion 17 of the corner portion 13 is formed by joining the inner peripheral side with the welded portion 20, and the cylindrical portion 14 of the corner portion 13 is welded with a part of the edge 103 of the cut portion 102 at the welded portion 20. It is formed like this.

  When manufacturing the door sash 10 of the first embodiment, as shown in FIG. 4, one elongated metal plate 101 is sequentially bent and formed by roll forming, press forming or the like, and the cylindrical portion 14 and the glass run are formed. A cross-sectional shape having a channel accommodating portion 15, a weather strip accommodating portion 16, and an exterior portion 17 is formed. Then, by joining at the joining portion 18, the cross-sectional elongated intermediate material 100 having the cylindrical portion 14, the glass run channel accommodating portion 15, the weather strip accommodating portion 16, and the exterior portion 17, in other words, the cross section of the door sash 10. An elongated and substantially straight intermediate member 100 having a cross-sectional shape corresponding to the shape in the longitudinal direction is formed.

  Thereafter, as shown in FIG. 5, the intermediate material 100 is bent to form the intermediate material 100 that is gently curved by a certain amount of preliminary bending. Then, as shown in FIGS. 5 to 7, at a predetermined position in the longitudinal direction of the substantially arc-shaped intermediate material 100, the intermediate material 100 is partially cut to form a cut portion 102. In this cutting process, cutting is performed by partially forming a substantially chevron-shaped cutting part 102 having a rounded top part or a substantially flat top part on the inner peripheral side of the intermediate material 100 bent by bending. In FIG. 7, reference numeral 104 denotes a removal portion that is removed by excision.

  Next, from the state of FIG. 5C and FIG. 6, the intermediate member 100 is bent with the cut portion 102 as the inner peripheral side, and shapes corresponding to the upper portion 11 and the pillar portion 12 are formed in the intermediate member 100. . And the door sash 10 is obtained by arrange | positioning so that the edge 103 of the cut | disconnected part 102 of the intermediate material 100 may be faced | matched, and welding the part of edge 103 * 103 which faced and arranged, and forming the welding part 20. FIG. The welded portion 20 is formed at a location shown in FIG. 3 corresponding to a part of the abutted portion of the edge 103 of the cut portion 102. In FIG. 3, CW is a welded portion having a conventional structure when the upper portion 11 and the pillar portion 12 are welded as separate members, and the weld length of the welded portion 20 of the first embodiment is a welded portion having a conventional structure. It is shorter than CW.

  According to the door sash 10 of the first embodiment or the manufacturing method thereof, the upper portion 11 and the pillar portion 12 of the door sash 10 formed of a member in which the upper portion 11 and the pillar portion 12 are partially continuous in the longitudinal direction. When forming by bending, it is possible to prevent the occurrence of defective shapes such as wrinkles even if the bending curvature is increased by the cut portion 102 on the inner peripheral side. Therefore, in the case of the door sash 10 having a cross-sectional shape having the cylindrical portion 14, it is possible to prevent the cylindrical portion 14 from being crushed in cross section or becoming a wrinkled cylindrical portion 14. In addition, since the occurrence of a defective shape can be prevented even if the curvature is increased, the degree of freedom in the curvature and design of the corner portion 13 can be greatly improved.

  In addition, since bending can be performed in a state where the cut portion 102 on the inner peripheral side is formed, it is possible to reduce the load necessary for bending, thereby expanding the range of usable bending apparatuses, and reducing the apparatus cost. Can also be reduced. Further, since welding is unnecessary at the portion where the outer peripheral side of the corner portion 13 extending from the upper portion 11 to the pillar portion 12 is continuous, the welding length can be shortened. Therefore, the amount of electricity used can be reduced and the working environment can be improved by shortening the welding work and reducing the number of welding beads.

  Moreover, the door sash 10 can be manufactured efficiently and accurately by manufacturing the door sash 10 in the manufacturing process. Further, by bending the intermediate material 100 before the partial excision step, it is possible to easily form an appropriate excision portion 102 so that the abutted portion has an accurate and clean finish. At the same time, even when wrinkles or the like are generated in the inner peripheral side portion of the corner portion 13 by bending before excision, the removal portion 104 can be removed by a partial excision step. Further, by making the shape of the cut portion 102 a rounded top portion or a substantially chevron shape having a substantially flat top portion, the portion where the edge 103 of the cut portion 102 is abutted by bending can be more accurately abutted. The finish can be made more accurate and beautiful.

  In addition, when bending and welding the upper part and pillar part of separate members, it is necessary to form the shape by bending the upper part and pillar part in separate processes and equipment, respectively. By forming the upper part 11 and the pillar part 12 of the door sash 10 from the continuous intermediate material 100, the bending process and the equipment can be unified, and the work space can be reduced.

[Door Sash of Second Embodiment and Manufacturing Method Thereof]
As shown in FIG. 8, the door sash 30 of the second embodiment is also formed by a member in which the upper portion 31 and the pillar portion 32 are partially continuous in the longitudinal direction, and the upper portion 31 to the pillar portion 32. The part which reaches is a corner portion 33 having a bent shape. The door sash 30 is a hidden-type door sash having a cylindrical portion 34 and a substantially plate-shaped protruding portion 35 provided so as to protrude from the cylindrical portion 34, as shown in the cross-sectional shape of FIG. It is formed by bending a single metal plate, and is fixed by caulking or the like and joined and fixed by a joint portion 36 by spot welding or the like. In FIG. 9, a molding is provided on the tip side of the protrusion 35, a weather strip is provided on the upper surface side of the protrusion 35, and a glass run channel is provided on the lower surface side of the protrusion 35 (not shown). The cross-sectional shape having the cylindrical portion 34 and the protruding portion 35 is common to the upper portion 31, the pillar portion 32, and the corner portion 33.

  A continuous portion 37 that is continuous with the upper portion 31 and the pillar portion 32 in a bent or curved state is formed on the outer peripheral side of the corner portion 33, and the edge 302 of the cut portion 301 is formed on the inner peripheral side of the corner portion 33. Are arranged so as to be substantially in contact with each other, and a part of the substantially contact portion is welded to form a welded portion 38 (see FIGS. 8 to 11). The welded portion 38 in the second embodiment is obtained by partially cutting the cylindrical portion 34 disposed on the inner peripheral side into a substantially mountain shape, and matching the edge 302 of the cut portion 301 by bending. It is formed by welding a part in the state. That is, the cylindrical portion 34 of the corner portion 33 is formed so that a part of the edge 302 of the cut portion 301 is welded by the welding portion 38.

  When manufacturing the door sash 30 of the second embodiment, as in the first embodiment, a single thin metal plate is sequentially bent and formed by roll forming, press forming, etc. A cross-sectional shape having a portion 35 is formed, fixed by caulking and the like, and joined and fixed by a joint portion 36, whereby a cross-sectionally elongated intermediate material 300 having a protruding portion 35, in other words, a door. An elongated and substantially straight intermediate member 300 having a cross-sectional shape corresponding to the cross-sectional shape of the sash 30 in the longitudinal direction is formed. Thereafter, similarly to the first embodiment, the intermediate material 300 is bent, and the intermediate material 300 that is gently curved is formed by a certain degree of preliminary bending.

  Then, as shown in FIGS. 10 and 11, a cut portion 301 is formed by partially cutting the intermediate material 300 at a predetermined position in the longitudinal direction of the substantially arc-shaped intermediate material 300. In this cutting process, cutting is performed by partially forming a substantially chevron-shaped cutting portion 301 having a rounded top portion or a substantially flat top portion on the inner peripheral side of the intermediate member 300 bent by bending. In FIG. 11, reference numeral 303 denotes a removal portion that is removed by excision.

  Next, from the state of FIG. 10, the intermediate member 300 is bent with the cut portion 301 as the inner peripheral side, and shapes corresponding to the upper portion 31 and the pillar portion 32 are formed in the intermediate member 300. And the door sash 30 is obtained by arrange | positioning so that the edge 302 of the cut part 301 of the intermediate material 300 may be faced | butted, and welding the part of edge 302 * 302 which faced and arranged, and forming the welding part 38. FIG. The weld 38 is formed at a location shown in FIG. 9 corresponding to a part of the abutted portion of the edge 302 of the cut portion 301. In FIG. 9, CW is a welded portion having a conventional structure when the upper portion 31 and the pillar portion 32 are welded as separate members, and the weld length of the welded portion 38 in the second embodiment is a welded portion having a conventional structure. It is shorter than CW.

  According to the door sash 30 of the second embodiment or the manufacturing method thereof, a corresponding effect can be obtained by the configuration corresponding to the first embodiment.

[Modifications of Embodiment, etc.]
The invention disclosed in this specification is specified by changing these partial configurations to other configurations disclosed in this specification within the applicable range in addition to the configurations of each invention and each embodiment, or It includes those specified by adding other configurations disclosed in this specification to these configurations, or those obtained by deleting these partial configurations to the extent that partial effects can be obtained and specifying them as superordinate concepts. . The following modifications are also included.

  For example, the door sashes 10 and 30 formed continuously in the longitudinal direction in the present invention, the intermediate materials 100 and 300 formed continuously in the longitudinal direction, etc. are formed of a single metal plate 101 or the like. For example, a portion corresponding to the exterior portion 17 or a portion forming a recess of the weather strip housing portion 16 is formed as a separate member. It is also possible to use a member formed continuously in a part or a member formed continuously in the longitudinal direction.

  In the first and second embodiments, the case where the substantially linear intermediate members 100 and 300 are bent into a substantially arc shape and then partially cut away from the substantially arc-shaped intermediate members 100 and 300 has been described. In the present invention, it is possible to omit the bending process performed before the step of partially cutting, for example, the step of partially cutting the substantially straight intermediate members 100 and 300 is performed. It is also possible.

  Further, the welded portion in the present invention can be appropriately formed at a required location, and for example, as in the first and second embodiments, the edge 103 of the cut portion 102 or the edge 302 of the cut portion 301 is abutted and arranged. In addition to forming at a required portion of the place, it is also possible to adopt a configuration in which it is formed over the entire length of the place where the edge 103 of the cut portion 102 or the edge 302 of the cut portion 301 is abutted.

  The present invention can be used for a door sash installed on a door of a vehicle.

DESCRIPTION OF SYMBOLS 10, 30 ... Door sash 11, 31 ... Upper part 12, 32 ... Pillar part 13, 33 ... Corner part 14, 34 ... Cylindrical part 15 ... Glass run channel accommodation part 35 ... Projection part 16 ... Weather strip accommodation part 17 ... Exterior Part 18, 36 ... Joint part 19, 37 ... Continuous part 20, 38 ... Welded part 100, 300 ... Intermediate material 101 ... Metal plate 102, 301 ... Cut part 103, 302 ... Edge 104, 303 ... Removal part CW ... Conventional structure Welded parts

Claims (5)

A door sash formed of a member in which an upper part and a pillar part are partially continuous in the longitudinal direction,
A continuous part that is continuous on the outer peripheral side of the corner part from the upper part to the pillar part is formed,
The door sash is characterized in that a welded portion is formed on the inner peripheral side of the corner portion and welded by substantially contacting the edge of the cut portion. It has a cross-sectional shape with a cylindrical part,
The door sash according to claim 1, wherein the cylindrical portion located on the inner peripheral side of the corner portion is formed by welding at least a part of an edge of the cut portion. It is a manufacturing method of the door sash of Claim 1 or 2,
A first step of forming an elongated intermediate material having a cross-sectional shape corresponding to the cross-sectional shape of the door sash;
A second step of partially cutting the intermediate material at a predetermined position in the longitudinal direction of the intermediate material to form a cut portion;
A third step of bending the cut portion on the inner peripheral side to form a shape corresponding to the upper portion and the pillar portion;
And a fourth step of welding at least a part of the abutted edge by arranging to abut the edge of the cut portion. Bending the intermediate material between the first step and the second step,
4. The method of manufacturing a door sash according to claim 3, wherein in the second step, the cut portion is formed on an inner peripheral side of the intermediate material bent by the bending process. 5. The method of manufacturing a door sash according to claim 3, wherein, in the second step, a substantially chevron-shaped cut portion having a rounded top portion or a substantially flat top portion is formed in the intermediate material.

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