JP3932225B2 - Vehicle door and manufacturing method thereof - Google Patents

Description

[0001]
【Technical field】
The present invention relates to a vehicle door and a method for manufacturing the same.
[0002]
[Prior art and its problems]
Various types of vehicle doors and manufacturing methods thereof are known for each component. Among them, focusing on the inner panel having the door part insertion hole and the modular panel fixed to the periphery of the door part insertion hole of the inner panel after assembling the door part, the inner panel and the modular panel have conventionally been separated. It is stamped and formed by pressing. And the knocked-down part which arises when forming a component insertion hole in an inner panel was discarded as scrap. However, as the door parts become more complex and functional, the part insertion holes tend to be larger, and the material cost of the part insertion hole part to be punched out cannot be ignored.
[0003]
Further, a conventional vehicle door is usually provided with a window regulator on the modular panel, and a guide rail serving as a slide guide for the door glass is provided on a door side member different from the modular panel. For this reason, there is a problem that not only the assemblability is bad but it is difficult to smoothly engage the door glass with the guide rail.
[0004]
Yet another problem is the processing of wiring within the modular panel. As door parts become more functional and more powerful, the number of wirings for doors tends to increase, and a structure capable of neatly storing these wirings is desired.
[0005]
OBJECT OF THE INVENTION
An object of the present invention is to provide a vehicle door and a method of manufacturing the same that can reduce waste of material obtained by punching a door part insertion hole of an inner panel based on the above problem awareness.
Another object of the present invention is to provide a vehicle door that is excellent in assemblability between a window regulator and a door glass and can smoothly operate the door glass.
A further object of the present invention is to provide a vehicle door that can neatly store wiring around a modular panel and hardly interfere with other parts.
[0006]
SUMMARY OF THE INVENTION
The present invention has been completed based on the viewpoint that, when a plate material is punched to form an inner panel, a conventionally discarded material corresponding to a door part insertion hole is used as a modular panel, so that waste of the material can be eliminated. It is a thing.
That is, the present invention, according to one aspect thereof, the plate member from the non-circular door parts insertion hole inner panel is formed by punching a; and from the plate above the door parts insertion hole of non-circular formed when punched It consists of a panel , spans the door part insertion hole in one direction in a state of relative rotation in a front view from a punched state, and is fixed in a state where a pair of end portions separated in the one direction overlap with the side surface of the inner panel. A modular panel.
[0007]
Of course, if the modular panel is made of a plate material that has been punched out of the door part insertion hole, it will fall into the door part insertion hole. It is possible to fix to the periphery of the component insertion hole.
[0008]
The modular panel preferably supports a window regulator and a guide rail of door glass that is raised and lowered by the window regulator. Further, the wiring around the modular panel can be made clear by forming a wiring storing groove for storing the wiring for the door in the modular panel.
[0009]
The window regulator is preferably an X-arm type having a glass bracket that is fixed to the lower end of the glass and moves up and down substantially horizontally, and is slidable on a pair of front and rear guide rails fixed to the modular panel at both ends of the glass bracket. By providing the sliding guide to be fitted, the door glass lifting mechanism can be unitized and held on the modular panel.
[0010]
In an aspect in which the present invention focuses on unitizing a door glass lifting mechanism to a modular panel, an inner panel formed by punching a non-circular door component insertion hole from a plate material; and the door component insertion hole punched from the plate material A pair of end portions that cross over the door part insertion hole in one direction in a state of relative rotation in a front view from a punched state and are spaced apart in the one direction. A vehicle panel provided with a modular panel fixed in a state of being overlapped on a side surface of the panel ; a window regulator for raising and lowering a glass bracket fixed to the lower end of the glass on the modular panel ; and at both ends of the glass bracket A fixed slide guide and a pair of front and rear guide rails on which the slide guide is slidably fitted are supported. It is characterized in that.
[0011]
Further, according to the present invention, in an aspect focusing on the wiring structure around the modular panel, an inner panel formed by punching a non-circular door component insertion hole from a plate material; and formed when the door component insertion hole is punched from the plate material A pair of end portions that cross over the door part insertion hole in one direction in a state of relative rotation in a front view from a punched state and are spaced apart in the one direction on the side surface of the inner panel. A vehicle door provided with a modular panel fixed in an overlapped state is characterized in that a wiring storage groove for storing wiring for the door is formed in the modular panel.
Further, in any aspect, the pair of end portions of the modular panel are corner portions of the modular panel, and the edge portions of the pair of side edges sandwiching the corner portions are overlapped with the side surfaces of the inner panel. It is preferable to fix with.
[0012]
Next, according to an aspect of the vehicle door manufacturing method of the present invention, a step of punching a non-circular door part insertion hole from a plate material to form an inner panel ; formed when the door part insertion hole is punched from the plate material Processing a non-circular panel into a modular panel fixed to the periphery of the door part insertion hole ; incorporating a required door part into the modular panel; The step of overlapping the modular panel in a state of relative rotation on the inner panel in a manner straddling the door part insertion hole in one direction, and a pair of end portions spaced apart in the one direction of the modular panel, And a step of fixing in a state of being overlapped on the side surface.
[0013]
The step of processing the modular panel preferably includes a step of pressing a wiring storage groove for storing the wiring for the door. The step of incorporating the door part into the modular panel includes the step of incorporating a window regulator and the step of fixing a pair of front and rear guide rails that serve as raising and lowering guides for the door glass raised and lowered by the window regulator to the modular panel. Further, it is possible to further include a step of slidably fitting slide guides at both ends of the glass bracket fixed to the lower end of the glass, which are lifted and lowered by the window regulator, to the pair of front and rear guide rails.
Further, each of the pair of end portions of the modular panel is a corner portion of the modular panel, and the step of fixing the pair of end portions of the modular panel to the side surface of the inner panel includes a pair of sides sandwiching the corner portion. It is preferable that the step is to fix the edge of the side in a state where it is overlapped on the side surface of the inner panel .
[0014]
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows an example of a punching shape for making a modular panel 20 as a punching material when punching an inner panel 10 having a door part insertion hole 11 from a plate material t. The modular panel 20 has, on its outer periphery, an upper edge 21 and a lower edge 22 that are parallel to each other, a pair of parallel vertical edges 23 and 24 that are substantially orthogonal to the upper edge 21 and the lower edge 22, and a door part insertion hole. 11 has side portions 25 and 26 corresponding to the upper edge 12 and the lower edge 13, and the distance W between the upper edge 21 and the lower edge 22 is larger than the vertical width w of the door part insertion hole 11. Such a shape makes the upper edge 21 and the lower edge 22 and the vertical edges 23 and 24 of the modular panel 20 an angle α with respect to the upper edge 12 and the lower edge 13 and the vertical edge 14 of the door part insertion hole 11. This is possible by setting the shape after tilting.
[0015]
The modular panel 20 is rotated by an angle α after punching, and as shown by a chain line in FIG. 1 and as indicated by a solid line in FIG. It is located outside the door part insertion hole 11 and can be fixed to the inner panel 10. The side portions 25 and 26 of the modular panel 20 are inclined with respect to the upper edge 12 and the lower edge 13 of the door part insertion hole 11 in this fixed state.
[0016]
The inner panel 10 is cut along the cutting line 15 and the front end of the door part insertion hole 11 is opened. In the illustrated example, a pair of inner panel 10 and modular panel 20 are taken out from a single plate material t symmetrically on both sides of the center line tc, and the hatched portion in the figure is discarded. When the inner panel 10 and the modular panel 20 are punched, the fixing screw hole 27 and the like can be processed on the modular panel 20 at the same time.
[0017]
Next, the inner panel 10 is subjected to necessary processing, and is combined with the front inner panel 28, the door sash 29, the outer panel 30, and the like to complete the door base 31.
[0018]
On the other hand, the modular panel 20 is subjected to processing such as necessary press processing in a separate process from the inner panel 10. At this time, the modular panel 20 is formed with a wiring housing groove 32 having a predetermined depth and a predetermined depth along with various component mounting portions and fixing holes.
[0019]
The modular panel 20 is mounted with door-related parts before being assembled into the door base 31. As shown in FIG. 3, these include at least a pair of front and rear guide rails 41, 42, an X arm type window regulator 50, a drive motor unit 51, a door lock related component 43, an inside handle 44, and a wiring cord bundle 45. It is out. Reference numeral 46 denotes a door trim that is finally put on the modular panel 20 after the modular panel 20 is fixed to the inner panel 10.
[0020]
Among the above elements, one of the characteristic portions of the present invention is related to the guide rails 41 and 42 and the X arm type window regulator 50. As is apparent from FIG. 4, the guide rails 41 and 42 are made of a channel material and are given a curvature that matches the curvature of the door (glass). The guide rails 41 and 42 are fixed to the modular panel 20 through fixing bolt holes 41b and 42b.
[0021]
The X arm type window regulator 50 includes a lift arm 54 that is integral with a shaft 53 that is rotatably supported by a base member 52 that is fixed to the modular panel 20. The lift arm 54 is integrally provided with a sector gear 55 that is coaxial with the shaft 53, and the drive pinion 56 of the drive motor unit 51 meshes with the sector gear 55 as is apparent from FIG. 6.
[0022]
On the other hand, a sub arm 58 is pivotally attached to the lift arm 54 by a shaft 57 in an X shape. A roller 59 provided at the lower end portion of the sub arm 58 and a roller (not shown) provided at the lower end portion of the lift arm 54 are fitted in a glass bracket 60 made of a channel material so as to be freely rollable. The slider 61 provided at the upper end portion of the sub arm 58 is slidably fitted to a horizontal guide member 62 fixed to the modular panel 20. When the lift arm 54 is driven forward and reversely together with the shaft 53 via the drive motor unit 51, the drive pinion 56, and the sector gear 55 by this guide mechanism, the glass bracket 60 moves up and down while maintaining the level. Such an X-arm type window regulator itself is well known. As shown in FIG. 7, a spiral spring 64 for balancing is provided between the base member 52 and the shaft 53 to urge the shaft 53 (lift arm 54) in the direction in which the glass bracket 60 is raised. Yes.
[0023]
As shown in FIG. 3, slide guides 65 that are slidably inserted into guide rails 41 and 42 that are fixed to the modular panel 20 are provided at both ends of the glass bracket 60. FIG. 5 shows the details, and the slide guide 65 is made of a synthetic resin block matched to the cross-sectional shape and curvature of the guide rails 41 and 42, and is fixed to both ends of the glass bracket 60. Further, both ends of the glass bracket 60 are provided with fixtures 67 for fixing the door glass 66. The fixture 67 includes an opening / closing leg 70 having a protrusion 69 that fits into a fixing hole 68 that is formed in the front and back of the lower end of the door glass 66. The fixing tool 67 is placed on the glass bracket 60, and the opening / closing leg 70 is attached. The door glass 66 can be supported and fixed on the glass bracket 60 by closing and fitting the projection 69 into the fixing hole 68.
[0024]
As is apparent from the above description, according to this embodiment, the guide rails 41 and 42 for guiding the door glass 66 and the X-arm type window regulator 50 for raising and lowering the door glass 66 are integrated with the modular panel 20 in advance. It has become. Therefore, the door glass 66 can be easily assembled and the door glass 66 can be smoothly guided as compared with the conventional apparatus in which the guide rail is provided on the door base 31 side. The actual incorporation of the door glass 66 is practically performed after the modular panel 20 is fixed to the inner panel 10.
[0025]
Accordingly, the vehicle door having the above-described configuration is thus constructed by incorporating the above-described elements into the modular panel 20 and then connecting each connector of the wiring cord bundle 45 to the corresponding connector so that the wiring cord bundle 45 is formed on the modular panel 20. Store in the storage groove 32. By forming the wiring housing groove 32 in the modular panel 20, wiring can be easily and clearly performed, and interference with other components can be prevented. Then, as shown in FIG. 8, the modular panel 20 is attached to a door base 31 formed using the inner panel 10, and a door trim 46 is placed thereon to complete the modular panel 20.
[0026]
【The invention's effect】
ADVANTAGE OF THE INVENTION According to this invention, the vehicle door which can reduce the waste of the material which pierce | punched the door component insertion hole of the inner panel, and its manufacturing method are obtained. Moreover, according to this invention, the door for vehicles which is excellent in the assembly property of a window regulator and a door glass, and can operate a door glass smoothly is obtained. Furthermore, the wiring around the modular panel can be stored cleanly, and a vehicle door that does not easily interfere with other components can be obtained.
[Brief description of the drawings]
FIG. 1 is a plan view showing an example of a shape in which an inner panel and a modular panel are formed by punching from a plate material, showing a vehicle door and a manufacturing method thereof according to the present invention.
FIG. 2 is a front view showing a state in which the modular panel punched out in FIG. 1 is fixed to the periphery of the door part insertion hole of the inner panel.
FIG. 3 is an exploded perspective view showing a state before the door part to be attached to the modular panel is assembled.
FIG. 4 is an exploded perspective view showing a coupling relationship between a guide rail fixed to a modular panel and slide members at both ends of a glass bracket of an X-arm type wind regulator.
FIG. 5 is a front view of a driving portion of an X arm type window regulator.
FIG. 6 is a cross-sectional view showing a mechanism around a guide rail and a glass bracket that supports a window glass.
7 is a cross-sectional view taken along line VII-VII in FIG.
FIG. 8 is a perspective view showing a state in which the modular panel to which the door part is attached is attached to the inner panel.
9 is a cross-sectional view taken along line IX-IX in FIG.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 Inner panel 11 Door component insertion hole 20 Modular panel 28 Front inner panel 29 Door sash door sash 30 Outer panel 31 Door base 32 Wiring storage groove 41 42 Guide rail 45 Wiring cord bundle 50 X arm type window regulator 51 Drive motor unit 52 Base member 53 Shaft 54 Lift arm 55 Sector gear 56 Drive pinion 60 Glass bracket 65 Slide guide 66 Door glass 67 Fixing tool

Claims (12)

An inner panel formed by punching a non-circular door part insertion hole from the plate material; and
It consists of a non-circular panel formed when the door part insertion hole is punched from the plate material , straddling the door part insertion hole in one direction in a state of relative rotation in a front view from the punched state, the one direction A vehicle door comprising: a modular panel fixed in a state where a pair of end portions spaced apart from each other are overlapped on a side surface of the inner panel . 2. The vehicle door according to claim 1, wherein the modular panel supports a window regulator and a guide rail of door glass that is lifted and lowered by the window regulator.  3. The vehicle door according to claim 1, wherein the modular panel is formed with a wiring storage groove for storing the wiring for the door. The vehicle door according to claim 2 or 3, wherein the window regulator includes a glass bracket fixed to the lower end of the glass and moving up and down substantially horizontally, and a pair of front and rear fixed to the modular panel at both ends of the glass bracket. A vehicle door provided with a slide guide slidably fitted on the guide rail. An inner panel formed by punching a non-circular door part insertion hole from the plate material ; and
It consists of a non-circular panel formed when the door part insertion hole is punched from the plate material, straddling the door part insertion hole in one direction in a state of relative rotation in a front view from the punched state, the one direction A modular panel that is fixed in a state where a pair of end portions that are spaced apart from each other are overlapped on a side surface of the inner panel;
A window regulator that raises and lowers a glass bracket fixed to the lower end of the glass on the modular panel; a slide guide fixed to each end of the glass bracket; a pair of front and rear guides on which the slide guide fits slidably; A vehicle door characterized in that a rail is supported. An inner panel formed by punching a non-circular door part insertion hole from the plate material ; and
It consists of a non-circular panel formed when the door part insertion hole is punched from the plate material, straddling the door part insertion hole in one direction in a state of relative rotation in a front view from the punched state, the one direction A modular panel that is fixed in a state where a pair of end portions that are spaced apart from each other are overlapped on a side surface of the inner panel;
A vehicle door characterized in that a wiring storage groove for storing wiring for a door is formed in the modular panel. The vehicle door according to any one of claims 1 to 6,
  The pair of end portions of the modular panel are corner portions of the modular panel, respectively, and the vehicle door is fixed in a state where the edge portions of the pair of side edges sandwiching the corner portions are overlapped with the side surfaces of the inner panel. Punching a non-circular door part insertion hole from the plate material to form an inner panel ;
Processing a non-circular panel formed when the door part insertion hole is punched out of a plate material into a modular panel fixed to the periphery of the door part insertion hole;
Incorporating the required door parts into this modular panel;
Overlaying the modular panel in a state of relative rotation in a front view from a state punched out of the door part insertion hole on the inner panel in a manner straddling the door part insertion hole in one direction; and
A method of manufacturing a vehicle door, comprising : fixing a pair of end portions of the modular panel spaced apart in the one direction on the side surface of the inner panel . 9. The method of manufacturing a vehicle door according to claim 8 , wherein the step of processing the modular panel includes a step of pressing a wiring storage groove for storing the wiring for the door. 10. The manufacturing method according to claim 8 , wherein the step of incorporating the door part into the modular panel includes a step of incorporating a window regulator, and a pair of front and rear guide rails serving as raising and lowering guides for the door glass raised and lowered by the window regulator. A vehicle door manufacturing method including the step of fixing to the modular panel. 11. The manufacturing method according to claim 10 , wherein the step of incorporating the door part into the modular panel includes sliding the both ends of the glass bracket fixed to the lower end of the glass, which is raised and lowered by the window regulator on the pair of front and rear guide rails. A method for manufacturing a vehicle door, the method including a step of slidably fitting a guide. The manufacturing method according to any one of claims 8 to 11,
  The pair of end portions of the modular panel are corner portions of the modular panel,
  For the vehicle, the step of fixing the pair of end portions of the modular panel to the side surface of the inner panel is a step of fixing the edge portions of the pair of side edges sandwiching the corner portion on the side surface of the inner panel. Door manufacturing method.

Images