JP5406762B2 - Body structure manufacturing method and body structure - Google Patents

Description

  The present invention relates to a vehicle body structure manufacturing method and a vehicle body structure, and more particularly to a vehicle body structure manufacturing method and a vehicle body structure in which a hollow closed cross-section structure is filled with a foaming material and stiffened.

  A vehicle body structure such as a front pillar, a center pillar, a side sill, and a subframe having a hollow closed cross-sectional structure such as an automobile generally functions as a skeleton member, but stiffening that further increases rigidity is required.

  Various techniques are disclosed in Patent Document 1 as a method for stiffening such a hollow closed cross-sectional structure serving as a skeleton member. For example, when attaching a door hinge that supports a door to a center pillar with a closed outer cross-section structure that includes an outer panel and an inner panel, a plate-shaped phosphorus hose is sandwiched between the outer panel and the inner panel, and a reinforcing plate is attached to the phosphorus hose. The door hinge is disposed on the outer panel, and the bolt is passed through the through holes of the door hinge, the outer panel, the phosphorus hose, and the reinforcing plate, and screwed into the nut attached to the reinforcing plate.

  In addition, a reinforcing block made of hard resin for reinforcement is placed in the hollow closed cross-section structure formed by the outer panel and inner panel of the center pillar, and the closed space around the reinforcing block is filled with a filler and stiffened. Then, the door hinge is disposed on the outer panel, and the bolt is passed through the door hinge, the outer panel, the reinforcing block, and the inner panel and screwed into the nut.

  Further, in Patent Document 2 and Patent Document 3, a phosphorus reinforcement is provided between the outer panel and the inner panel of the front pillar, and the foamed resin material is in a closed space between the outer panel and the phosphorus hose and between the inner panel and the phosphorus hose. To increase the rigidity of the front pillar.

JP 2001-163055 A JP 2005-233891 A JP 2009-96439 A

  As described above, the rigidity of the vehicle body structure can be improved by arranging the phosphorus hose, the hard block, the foamed resin material, or the like in the hollow closed cross-sectional structure such as a pillar that requires the rigidity of the vehicle body. However, since the phosphorus hose, the hard block, the foamed resin material, and the like are disposed in the vehicle body structure, the number of components increases, the manufacturing cost increases, and the vehicle body mass may increase.

  On the other hand, the hollow closed cross-sectional structure includes a portion that requires further improvement in rigidity and a portion that requires a sound insulation function.

  An object of the present invention made in view of such points is to provide a manufacturing method of a vehicle body structure and a vehicle body structure that can obtain efficient rigidity and a sound insulation effect without incurring an increase in components, manufacturing cost, and mass of a hollow closed cross-sectional structure. There is to do.

  The vehicle body structure manufacturing method according to claim 1, which achieves the above object, comprises a foamed resin material obtained by foaming and expanding a foamed resin material in a hollow closed cross-sectional structure, and a vehicle body structure stiffened by filling a hollow metal sphere with a granular shape. The hollow closed cross-section structure is filled with a foam material by a hollow metal sphere movement restricting member that prevents passage of the hollow metal sphere and allows passage of an uncured foamed resin material having fluidity. And the hollow metal sphere filling portion, the hollow metal sphere filling portion is filled with the hollow metal sphere, and the foamed resin material is foamed and expanded in the hollow closed cross-sectional structure. The inside of the hollow metal sphere filling portion including the gap and the inside of the foam material filling portion are filled with a foamed resin material.

  According to this, for example, sound insulation or the like is required by the hollow metal sphere movement restricting member that prevents the passage of the hollow metal sphere through the hollow closed cross-sectional structure of the vehicle body and allows the passage of the uncured foamed resin material having fluidity. The foamed material filling part and the hollow metal sphere filling part are divided according to the part to be processed and the part requiring rigidity, and the hollow metal sphere filling part is filled with a rigid and lightweight granular hollow metal sphere. By expanding and expanding the foamed resin material in the hollow closed cross-sectional structure, the hollow metal sphere filling portion is filled with the hollow metal sphere and the foamed resin material, and the foam material filling portion is filled with the foamed resin material. As a result, the hollow metal sphere filling portion is stiffened by the hollow metal sphere and the foamed resin material to improve the rigidity, and the inside of the foam material filling portion is filled with the foamed resin material to obtain the vibration damping and sound insulation functions in the foam material filling portion. . Accordingly, it is possible to reduce or omit stiffening members and the like in the hollow closed cross-section structure, and the simplification of the hollow closed cross-section structure and the restriction on the shape are alleviated without incurring an increase in the number of structural components. Thus, an efficient rigidity and sound insulation effect of the vehicle body structure can be obtained.

  The vehicle body structure manufacturing method according to claim 2, which achieves the above object, is a vehicle body that stiffens by filling a foamed resin material obtained by foaming and expanding a foamed resin material and granular hollow metal spheres in a hollow closed cross-sectional structure. A method of manufacturing a structure, wherein the hollow closed cross-sectional structure is filled with a foam material by a hollow metal sphere movement regulating member that prevents passage of the hollow metal sphere and allows passage of an uncured foamed resin material having fluidity. And the hollow metal sphere filling part, the inside of the hollow metal sphere filling part is filled with the hollow metal sphere, and the foamed resin material is expanded and expanded in the foaming material filling part. The inside of the hollow metal sphere filling portion including the gap and the foam filling portion are filled with a foamed resin material.

  According to this, the foam filling part and the hollow metal sphere are filled in the hollow closed cross-section structure of the vehicle body by the hollow metal sphere movement restricting member, for example, a part requiring vibration suppression and sound insulation and a part requiring rigidity. The hollow metal sphere filling portion is filled with a lightweight, granular hollow metal sphere having rigidity, and the foamed resin material is foamed and expanded in the foam filling portion so that the inside of the foam filling portion is a foamed resin material. It is efficiently filled, and the hollow metal sphere filling portion is filled with the hollow metal sphere and the foamed resin material. As a result, the hollow metal sphere filling portion is stiffened by the hollow metal sphere and the foamed resin material to improve the rigidity, and the inside of the foam material filling portion is filled with the foamed resin material to obtain the vibration damping and sound insulation functions in the foam material filling portion. . Accordingly, it is possible to reduce or omit stiffening members and the like in the hollow closed cross-section structure, and the simplification of the hollow closed cross-section structure and the restriction on the shape are alleviated without incurring an increase in the number of structural components. Thus, an efficient rigidity and sound insulation effect of the vehicle body structure can be obtained.

  According to a third aspect of the present invention, in the method for manufacturing a vehicle body structure according to the first or second aspect, the foamed resin material is a heat-foamable foamed resin material, and is heated and foamed by a heat source in a paint drying process. It is characterized by.

  According to this, the foamed resin material is heated and foamed by the heat source in the paint drying process, so that it is possible to suppress equipment and manufacturing costs that do not require a dedicated heating means for heating and foaming the foamed resin material.

  According to a fourth aspect of the present invention, in the method for manufacturing a vehicle body structure according to any one of the first to third aspects, the foamed resin material and the hollow metal sphere are hollowed from the material supply port that opens to the hollow metal sphere filling portion. It supplies in a cross-sectional structure.

  According to this, simplification of the vehicle body structure can be obtained by supplying the foamed resin material and the hollow metal sphere from a single material supply port.

  According to a fifth aspect of the present invention, in the method for manufacturing a vehicle body structure according to any one of the first to third aspects, the hollow metal sphere is inserted into the hollow metal sphere filling portion from the material supply port opened to the hollow metal sphere filling portion. The foamed resin material is supplied into the foaming material filling part from a material supply port that opens to the foaming material filling part.

  According to this, the hollow metal sphere is supplied into the hollow metal sphere filling portion from the material supply port opening to the hollow metal sphere filling portion, and the foamed resin material is supplied into the foam filling portion from the material supply port opening to the foam filling portion. By doing so, the hollow metal sphere can be efficiently supplied into the metal sphere filling part, and the foamed resin material can be supplied to the foaming material filling part.

  The invention of a vehicle body structure according to claim 6 that achieves the above object is a vehicle body structure that stiffens by filling a foamed resin material obtained by foaming and expanding a foamed resin material and a granular hollow metal sphere in a hollow closed cross-sectional structure. The hollow metal sphere movement restricting member that prevents the passage of the hollow metal sphere and allows the passage of the uncured foamed resin material having fluidity is filled with the foam filling portion and the hollow metal sphere in the hollow closed cross-sectional structure. And the foamed resin material filling the hollow metal sphere filling portion including the gap between the filled hollow metal spheres and the foaming material filling portion. It is characterized by comprising.

  According to this, the hollow metal sphere filling part divided in the hollow closed cross-section structure of the vehicle body by a hollow metal sphere movement restricting member, for example, a part requiring vibration suppression and sound insulation and a part requiring rigidity is provided. Stiffening is achieved by the filled hollow metal spheres and the foamed resin material to improve the rigidity, and the foamed material filling portion is filled with the foamed resin material to obtain the vibration damping and sound insulation functions in the foamed material filling portion. Furthermore, it is possible to reduce or omit stiffening members in the hollow closed cross-section structure, and the simplification of the hollow closed cross-section structure and the restriction on the shape are alleviated without incurring an increase in structural components. Thus, an efficient rigidity and sound insulation effect of the vehicle body structure can be obtained without incurring an increase in the noise.

  The invention according to claim 7 is the vehicle body structure according to claim 6, wherein the hollow closed cross-sectional structure has a hollow closed cross-sectional shape and extends in the longitudinal direction of the vehicle body, and a hollow closed cross-section having a lower end connected to the side sill. A pillar having a shape, wherein the foam filling portion is a connecting portion between a side sill and a pillar connected in a hollow shape, and the hollow metal sphere filling portion is a pillar continuous with the connecting portion. And

  According to this, it is possible to ensure the vibration suppression and sound insulation of the connecting portion between the side sill and the pillar, which require vibration suppression and sound insulation, and the rigidity is required, the pillar is stiffened, and the rigidity of the pillar can be ensured.

  According to an eighth aspect of the present invention, in the vehicle body structure of the sixth aspect, a rear frame member that extends in the vehicle width direction and has both ends attached to the vehicle body frame, and is separated from the rear frame member in the vehicle width direction. The rear end is connected to the rear frame member and the longitudinal frame member extending in the front-rear direction is joined to the side end range with the rear differential attachment part supporting the differential device in the central range. A sub-frame having a front frame member attached to the body frame, the hollow closed cross-sectional structure is the front frame member, and the foam filling portion is a central region of the front frame member, filled with metal balls The portion is a side end portion range.

  According to this, the rigidity of the side end part range of the front frame member that requires rigidity in the sub-frame is improved, and the vibration control and sound insulation effect in the central part range where vibration suppression and sound insulation are required by supporting the differential device is expected. it can.

  According to the present invention, in the hollow closed cross-section structure of the vehicle body, the foam metal filler and the hollow metal sphere filler according to the hollow metal sphere movement restricting member, for example, the part where sound insulation is required and the part where rigidity is required The hollow metal sphere filling portion is filled with the hollow metal sphere and the foamed resin material, and the foam material filling portion is filled with the foamed resin material. As a result, the hollow metal sphere filling portion is stiffened by the hollow metal sphere and the foamed resin material to improve the rigidity, and the inside of the foam material filling portion is filled with the foamed resin material to obtain the vibration damping and sound insulation functions in the foam material filling portion. . The reduction or omission of stiffening members in the hollow closed cross-section structure is possible, and the simplification of the hollow closed cross-section structure and the restriction on the shape, etc. are eased without incurring an increase in structural components, and the manufacturing cost and mass are increased. In this way, an efficient rigidity and sound insulation effect of the vehicle body structure can be obtained.

It is a principal part perspective view of the motor vehicle concerning one embodiment of the present invention. It is II section sectional drawing in FIG. It is the III-III sectional view taken on the line of FIG. It is the IV-IV sectional view taken on the line of FIG. It is the V section enlarged view of FIG. It is the VI-VI sectional view taken on the line of FIG. It is work process explanatory drawing. It is work process explanatory drawing. It is sectional drawing of a hollow metal sphere. It is a perspective view of the sub-frame which concerns on 2nd Embodiment of this invention. It is the perspective view which fractured | ruptured a part of subframe. It is work process explanatory drawing.

  Embodiments of a vehicle body structure and a method of manufacturing the vehicle body structure according to the present invention will be described with reference to the drawings.

(First embodiment)
1 is a perspective view of a main part of a vehicle body 1. FIG. 2 is a sectional view taken along a line II in FIG. 1, FIG. 3 is a sectional view taken along a line III-III in FIG. 5 is an enlarged view of a portion V in FIG. 4, and FIG. 6 is a sectional view taken along line VI-VI in FIG.

  A front door opening 2 and a rear door opening 3 are formed on the side of the vehicle body 1. A side sill 10 extends along the longitudinal direction of the vehicle body below the front door opening 2 and the rear door opening 3, and a center pillar 20 extending vertically between the front door opening 2 and the rear door opening 3. The front pillar 30 is disposed along the front edge of the front door opening 2, the lower end of the center pillar 20 is coupled to the middle part of the side sill 10 in the longitudinal direction of the vehicle body, and the lower end of the front pillar 30 is the front end of the side sill 10. Combined with

  The left and right side sills 10 are connected by a cross member extending in the vehicle width direction, and the floor panel 5 is bridged. The left and right side sills 10 are joined along the front end of the floor panel 5 between the left and right front pillars 30 and extend in the vehicle width direction. A toe board that divides the passenger compartment from the engine compartment is installed. Further, the side rail 6 extends along the upper edges of the front door opening 2 and the rear door opening 3, and the upper part of the center pillar 20 and the upper part of the front pillar 30 are joined to the side rail 6. A roof panel 7 is installed between them.

  The side sill 10, the center pillar 20, and the front pillar 30 have a hollow closed cross-sectional structure, and the side sill 10 is formed by a side sill outer panel 11 and a side sill inner panel 12 in a hollow closed cross-sectional shape extending in the longitudinal direction of the vehicle body. The center pillar outer panel 21 and the center pillar inner panel 22 are formed in a hollow closed cross section extending in the vertical direction, and the front pillar 30 is a hollow closed cross section extending in the vertical direction by the front pillar outer panel 31 and the front pillar inner panel 32. It is formed in a shape.

  As shown in FIG. 3, the connecting portion 20 </ b> A between the side sill 10 and the center pillar 20 joins the upper edge of the side sill outer panel 11 and the lower end of the center pillar outer panel 21, and the upper edge of the side sill inner panel 12 and the center pillar inner panel 22. The lower ends are joined to form a hollow and continuous T-shape. The connecting portion 30A between the side sill 10 and the front pillar 30 is hollow, with the front end of the side sill outer panel 11 and the lower end of the front pillar outer panel 31 joined, and the front end of the side sill inner panel 12 and the lower end of the front pillar inner panel 32 joined. It is formed in a continuous L shape.

  Here, the connecting portion 20A between the side sill 10 and the center pillar 20 and the connecting portion 30A between the side sill 10 and the front pillar 30 are required to have rigidity, and to have vibration damping and sound insulation functions. On the other hand, the lower range of the center pillar 20 having a hollow closed cross-section having a lower end connected to the side sill 10 and an upper end connected to the side rail 6 and extending in the vertical direction, that is, a range 20B in the vicinity of the lower end from the center in the vertical direction is a door hinge. Is provided, a load accompanying opening and closing of the door is repeatedly input, and a relatively large rigidity is required to cope with a load input at the time of a collision or the like. Similarly, in the range 30B near the lower end of the front pillar 30 from the center in the vertical direction, a door hinge is provided, a load accompanying opening and closing of the door is repeatedly input, and a relatively large rigidity is required to cope with a load input at the time of collision. Is done.

  In particular, in the connecting portion 20A between the side sill 10 and the center pillar 20, which is a sound insulating requirement range where vibration damping and sound insulating functions are required, the side sill 10 across the connecting portion 20A is made liquid-tight by the opposing separators 41 and 42. The inside of the vicinity of the lower end of the center pillar 20 serving as the upper end of the connecting portion 20A is divided into the side sill 10 side and the center pillar 20 side by the hollow metal ball movement restricting member 43 in the vertical direction. As a result, the connecting portion 20A has a hollow closed cross-section structure defined by the side sill outer panel 11, the side sill lure inner panel 12, the center pillar outer panel 21, the center pillar inner panel 22, the separators 41 and 42, and the hollow metal ball movement restricting member 43. A foam filling portion 45 is formed. Here, the hollow metal sphere movement restricting members 43 and 44 prevent passage of a hollow metal sphere 61 having a diameter of, for example, 1 to 5 m, which will be described later. It is constituted by a perforated plate or a mesh that allows passage of the foamed resin material 63 of the mold and passage of the uncured foamed resin material having fluidity.

  A hollow metal ball movement restricting member 44 that divides the center pillar 20 vertically is provided corresponding to a range 20B near the lower end of the center pillar 20 having a relatively large required rigidity, that is, an upper end of the required rigidity range 20B.

  Thereby, the hollow metal sphere filling portion 46 having a hollow closed cross-section structure defined by the center pillar outer panel 21, the center pillar inner panel 22, and the hollow metal sphere movement restricting members 43 and 44 is formed in the rigidity required range 20B. A material supply hole 47 for supplying the granular hollow metal sphere 61 and the unfoamed foamed resin material 63 is opened slightly above the hollow metal filling portion 46 in the center pillar inner panel 22.

  Here, the hollow metal sphere movement restricting members 43 and 44 prevent passage of a hollow metal sphere 61 having a diameter of, for example, 1 to 5 m, which will be described later. It is constituted by a perforated plate or a mesh that allows passage of the foamed resin material 63 of the mold and passage of the uncured foamed resin material having fluidity.

  Similarly, the inside of the front end of the side sill 10 adjacent to the connecting portion 30A, which is a sound insulation request range where vibration suppression and sound insulation are required, is partitioned in a liquid-tight manner by the separator 51, and the lower end of the front pillar 30 above the connecting portion 30A. The vicinity is partitioned into a side sill 10 side and a front pillar 30 side by a hollow metal ball movement restricting member 53 in the vertical direction. As a result, the foam filling material having a hollow closed cross-section structure defined by the side sill outer panel 11, the side sill lure inner panel 12, the front pillar outer panel 31, the front pillar inner panel 32, the separator 51, and the hollow metal ball movement restriction member 53 in the connecting portion 30 </ b> A. A portion 55 is formed. The hollow metal sphere movement restricting member 53 prevents the passage of the hollow metal sphere 61 in the same manner as the hollow metal sphere movement restricting member 43, while the uncured foamed resin material 63 is in an uncured state having movement and fluidity. It is constituted by a perforated plate or a mesh that allows passage of the foamed resin material.

  A hollow metal ball movement restricting member 54 that divides the front pillar 30 vertically is provided corresponding to the range 30B near the lower end of the front pillar 30 having a relatively large required rigidity, that is, the upper end of the required rigidity range 30B. The hollow metal sphere movement restricting member 54 prevents the passage of the hollow metal sphere 61 in the same manner as the hollow metal sphere movement restricting member 43, while the uncured foamed resin material 63 is in a non-cured state having movement and fluidity. It is constituted by a perforated plate or a mesh that allows passage of the foamed resin material.

  Thus, the hollow metal sphere filling portion 56 having a hollow closed cross-section structure defined by the front pillar outer panel 31, the front pillar inner panel 32, and the hollow metal sphere movement restricting members 53 and 54 is formed in the rigidity required range 30B. A material supply hole 57 for supplying the granular hollow metal sphere 61 and the foamed resin material 63 is opened slightly above the hollow metal sphere filling portion 56 in the front pillar inner panel 32.

  Then, the hollow metal sphere movement restricting member 44 arranged in the center pillar 20 and the hollow metal sphere movement restricting member 54 arranged in the front pillar 30 are not attached, and FIG. 2 and FIG. As shown in the corresponding operation explanatory diagram, an unfoamed foamed resin material 63 is supplied into the center pillar 20 by a preset amount from a material supply hole 47 opened in the center pillar inner panel 22 of the center pillar 20. The unfoamed foamed resin material 63 supplied from the material supply hole 47 flows down and drops along the inner surfaces of the center pillar outer panel 21 and the center pillar inner panel 22 formed in a cylindrical shape, thereby forming the hollow metal ball movement regulating member 43. It passes through and stays in the foam filling portion 45 formed in a hollow T shape by the side sill 10 partitioned by the lower part of the center pillar 20 and the separators 41 and 42.

  Following the supply of the foamed resin material 63, the hollow metal sphere 61 is supplied into the center pillar 20 from the material supply hole 47, and a partition is formed by the center pillar outer panel 21, the center pillar inner panel 22, and the hollow metal sphere movement regulating member 43. The hollow metal sphere filling portion 46 is filled. A hollow metal sphere movement restricting member 44 closes the upper part of the hollow metal sphere filling portion 46 filled with the granular hollow metal sphere 61. In addition, since the hollow metal sphere 61 and the foamed resin material 63 are supplied from the single material supply port 47 as described above, the material supply ports for supplying the hollow metal sphere 61 and the foamed resin material 63 are individually formed. As compared with the above, the shape of the center pillar inner panel 22 and the like can be simplified.

The hollow hollow metal sphere 61 is hollow and has a reduced specific gravity. As shown in a cross section in FIG. 9, for example, the diameter d is 1 to 5 mm and the wall thickness t is 70 to 100 μm. It is constituted by a lightweight hollow iron ball having a density of 0.8 to 0.9 g / cm ³ . For example, as disclosed in Japanese Patent Application Laid-Open No. 2009-121599, the hollow iron sphere is formed by spraying a slurry containing iron oxide on the surface of the foamed resin sphere to form a film, and coating the obtained foamed resin material with a film. Obtained by sintering.

  Similarly, an unfoamed foamed resin material 63 is supplied into the front pillar 30 by a preset amount from a material supply hole 57 that opens to the front pillar inner panel 32 of the front pillar 30. The foamed resin material 63 supplied from the material supply hole 57 flows down and drops along the inner surface of the front pillar 30 formed in a cylindrical shape by the front pillar outer panel 31 and the front pillar inner panel 32, and the hollow metal ball movement restricting member 53. Passes through the front pillar 30, the side sill 10, the separator 51, and the front part of the side sill 10 defined by the hollow metal ball movement restricting member 53, and stays in the foam filling portion 55 that is partitioned and formed in an L shape. Further, since the hollow metal sphere 61 and the foamed resin material 63 are supplied from a single material supply port 57, compared to the case where the material supply ports for supplying the hollow metal sphere 61 and the foamed resin material 63 are separately formed, the front is provided. Simplification of the shape of the pillar inner panel 32 is obtained.

  Subsequent to the supply of the foamed resin material 63, the hollow metal sphere 61 is supplied into the front pillar 30 from the material supply hole 57, and is partitioned by the front pillar outer panel 31, the front pillar inner panel 32, and the hollow metal sphere movement restricting member 53. The hollow metal sphere filling portion 56 is filled. The upper part of the hollow metal sphere filling portion 56 filled with the hollow metal sphere 61 is closed by the hollow metal sphere movement restricting member 53.

  Thereafter, the assembled vehicle body is painted, and the foamed resin material 63 supplied to the foam filling parts 45 and 55 is heated and foamed by a heat source in the paint drying process. In this way, by heating and foaming the foamed resin material 63 supplied to the foam filling parts 45 and 55 by the heat source in the paint drying process, a dedicated heating means for heating and foaming is not required, and the manufacturing cost is suppressed. Is obtained.

  2 and 3, due to the expansion of the foamed resin material 63, the lower portion of the center pillar 20, the side sill outer panel 11, the side sill inner panel 12, the opposing separators 41 and 42, and the metal ball movement restricting member 43 cause The inside of the foam filling portion 45 partitioned in a letter shape is filled with the foamed foamed resin material 62, and further, the uncured foamed resin material having fluidity passes through the metal ball movement regulating member 43 and is shown in FIGS. As shown in FIG. 5, an enlarged view of the V part 4 is shown in FIG. 5. Each hollow filled in the hollow metal sphere filling part 46 defined by the center pillar outer 21, the center pillar inner panel 22, and the metal ball movement restricting members 43 and 44. The hollow metal sphere filling portion 46 penetrates into the gaps between the metal spheres 61 and between the hollow metal spheres 61 and the inner surface of the center pillar 20, and the hollow metal spheres 61 and the foamed trees are granular. It is filled with wood 62.

  Air and foam gas remaining in the foam filling portion 45 and the hollow metal sphere filling portion 46 accompanying this foam filling or surplus foam resin material 62 are discharged through the hollow metal sphere movement restricting member 44 to fill the foam. Residual gas is prevented from staying in the portion 45 and the hollow metal sphere filling portion 46, generation of voids is suppressed, and smooth foam filling can be secured.

  Similarly, as the foamed resin material 63 in the foam filling portion 55 formed at the front end of the side sill 10 expands and expands, the lower part of the front pillar 30 formed by the front pillar outer panel 31 and the front pillar inner panel 32, the side sill outer panel. 11, the inside of the foam material filling portion 55 defined by the side sill inner panel 12, the separator 51, and the hollow metal ball movement restricting member 53 is filled with the foamed resin material 62, and is further hollow as shown in FIGS. Between the hollow metal spheres 61 filled in the hollow metal sphere filling part 56 that passes through the metal sphere movement restriction member 53 and is partitioned by the front pillar outer panel 31, the front pillar inner panel 32, and the metal sphere movement restriction members 53, 54. And enters the gap between the hollow metal sphere 61 and the inner surface of the front pillar 30. Filling the hollow metal spheres filled portion 56 and the hollow metal ball 61 by the foam resin material 62 Te.

  The air and foam gas in the foam filling portion 55 and the hollow metal filling portion 56 accompanying the foam filling or the surplus foam material 52 are discharged through the metal ball movement restricting member 54, and the foam filling portion 55 and the hollow filling material 55 are hollow. Residual gas does not stay in the metal filling portion 56, and generation of voids is suppressed, so that smooth foam filling can be secured.

  In this way, in the connecting portion 20A between the side sill 10 and the center pillar 20, the foam filling portion partitioned into a hollow T shape by the side sill 10, the separators 41 and 42, the lower portion of the center pillar 20, and the metal ball movement restricting member 43. By providing the foamed resin material 62 filled in 45, the side sill outer panel 11, the side sill inner panel 12, the center pillar outer panel 21, and the center pillar inner panel 22 are connected to the side sill 10 and the center pillar 20 connecting portion 20A. Cross-sectional deformation is suppressed, rigidity is ensured, and crushing is difficult. Thus, when a load is applied to the connecting portion 20A between the side sill 10 and the center pillar 20, the input load can be received and absorbed. Further, the foamed resin material 62 is filled into the foamed material filling portion 45 defined in a hollow T shape by the side sill outer panel 11, the side sill inner panel 12, the opposing separators 41 and 42, and the lower part of the center pillar 20, The vibration damping and sound insulation effects can be obtained at the connecting portion 20A between the center pillar 20 and the center pillar 20.

  On the other hand, the hollow metal sphere filling portion 46 defined by the center pillar outer panel 21, the center pillar inner panel 22, and the metal ball movement restricting members 43 and 44 is filled with a relatively rigid hollow metal sphere 61, and each hollow metal The hollow metal balls 61 and the foamed resin material 62 are filled in the hollow metal ball filling portion 46 by entering the gaps between the balls 61 and between the hollow metal balls 61 and the inner surface of the center pillar 20. Cross-sectional deformation of the center pillar 20 formed in a hollow cylindrical shape by the pillar inner panel 22 is suppressed, and relatively large rigidity is ensured. Further, sound insulation and vibration suppression in the partial range can be obtained.

  Further, when a load is applied to the center pillar 20 from the door hinge or the outside, if a load is input, for example, a load indicated by an arrow P in FIGS. 4 and 5 is input to the center pillar outer panel 21, the center pillar outer panel 21 is bent or deformed, and with this bending or deformation, the hollow metal sphere 61 in contact with the bending or deformation occurrence range of the center pillar outer panel 21 is pressed against the adjacent hollow metal sphere 61 to absorb and disperse the load due to the frictional force, The individual hollow metal spheres 61 are successively pressed against the adjacent hollow metal spheres 61 to absorb and disperse the load and distribute the load over a wide range of the center pillar outer panel 21 and the center pillar inner panel 22. In addition, the load is absorbed by the deformation of the foamed resin material 62 interposed in the gap between the hollow metal sphere 61 and the inner surface of the center pillar 20. Is a large drag force due to the deformation of the center pillar 20 is secured.

  Further, the hollow metal sphere 61 is filled in the hollow metal sphere filling portion 46 defined by the center pillar outer panel 21, the center pillar inner panel 22, and the hollow metal sphere movement restricting members 43, 44, and between the hollow metal spheres 61 and Since the hollow metal sphere 61 and the foamed resin material 62 are filled in the hollow metal sphere filling portion 46 because it enters the gap between the hollow metal sphere 61 and the inner surface of the center pillar 20, The movement of the hollow metal sphere 61 is restricted, and each hollow metal sphere 61 is held in a stable state.

  Similarly, in the joint portion 30A between the side sill 10 and the front pillar 30, the foam material is filled in a hollow L-shape by the front portion of the side sill 10, the separator 51, the lower portion of the front pillar 30, and the metal ball movement restriction member 53. By providing the foamed resin material 62 filled in the portion 55, the cross-sectional deformation of the connecting portion 30A between the side sill 10 and the front pillar 20 is suppressed, and rigidity is ensured. Thereby, when a load is applied to the joint portion 30A between the side sill 10 and the front pillar 30, the input load can be received and absorbed. Furthermore, the foamed resin material 62 is filled into the foam material filling portion 55 partitioned into a hollow L shape by the side sill 10, the front pillar 30, the separator 51, and the hollow metal ball movement restricting member 53, and sound insulation and Vibration suppression can be obtained.

  On the other hand, the hollow metal sphere filling portion 56 defined by the front pillar 30 and the metal ball movement restricting members 53 and 54 is filled with the hollow metal sphere 61 having relatively high rigidity, and between the hollow metal spheres 61 and between the hollow metal spheres 61. When the foamed resin material 62 enters the gap between 61 and the inner surface of the front pillar 30 and the hollow metal sphere filling portion 56 is filled with the hollow metal sphere 61 and the foamed resin material 62, the front pillar outer panel 31 and The front pillar inner panel 32 suppresses the cross-sectional deformation of the center pillar 20 formed in a hollow cylindrical shape, and ensures rigidity. Further, sound insulation and vibration suppression in the partial range can be obtained.

  Further, when a load is applied to the front pillar 30 from a door hinge or from the outside, the front pillar outer panel 31 bends or deforms when it acts on a portion to which the load acts, for example, the front pillar outer panel 31, and comes into contact with this bending or deformation occurrence range. The hollow metal spheres 61 are pressed against the adjacent hollow metal spheres 61 to absorb and disperse the load due to the frictional force, and the individual hollow metal spheres 61 are pressed against the adjacent hollow metal spheres 61 one after another to absorb and disperse the load. The load is distributed over a wide range of the pillar outer panel 31 and the front pillar inner panel 32, and the foamed resin material 62 is interposed between the hollow metal balls 61 and between the hollow metal balls 61 and the inner surface of the center pillar 20. The load is absorbed, and a large drag accompanying the deformation of the front pillar 30 is ensured.

  Therefore, the inside of the connecting portion 20A between the side sill 10 and the center pillar 20 where vibration suppression and sound insulation are required is partitioned by the separators 41, 42 and the metal ball movement regulating member 43 such as a mesh, and the foam filling material 45 is provided in the connecting portion 20A. The hollow metal sphere filling portion 46 is formed in the lower range of the center pillar 20, the foamed resin material 63 is supplied into the foam material filling portion 45, and the hollow metal sphere filling portion 46 is filled with the hollow metal sphere 61. The inside of the connecting portion 30A between the side sill 10 and the front pillar 30 that requires vibration and sound insulation is partitioned by a separator 51 and a metal ball movement regulating member 53 such as a mesh, and the foam filling material 55 and the front pillar 30 are formed in the connecting portion 30A. The hollow metal sphere filling portion 56 is formed in the lower range of the resin, the foamed resin material 63 is supplied into the foam material filling portion 55, and the hollow metal sphere filling portion 56 is By filling the metal sphere 61 and expanding and expanding the foamed resin material 63 with the drying heat at the time of coating and drying, the foamed resin filling material 45 is filled in the foamed material filling parts 45 and 55, and the hollow metal sphere filling part 46, 56 is filled with the hollow metal sphere 61 and the foamed resin material 62, so that the connecting portion 20 </ b> A between the side sill 10 and the center pillar 20 and the connecting portion 30 </ b> A between the side sill 10 and the front pillar 30 can be efficiently configured with a simple configuration and operation. A sound insulation effect can be obtained, and the rigidity of the center pillar 20 and the front pillar 30 can be secured.

  Further, in the side sill 10, the center pillar 20, the front pillar 30, and the like including the side sill 10, the center pillar 20, the front pillar 30, the connecting portion 20 </ b> A of the side sill 10 and the center pillar 20, and the connecting portion 30 of the side sill 10 and the front pillar 30. The reduction and omission of stiffening members such as phosphorus hoses is possible, and the simplification of the vehicle body structure and restrictions on the shape and the like are eased without incurring an increase in structural components, and the manufacturing cost and mass are increased. Therefore, efficient rigidity and sound insulation effect of the vehicle body structure can be obtained.

  In the above description, the case where the foamed resin material 63 supplied from the material supply hole 47 opened to the center pillar 20 is supplied to the foam material filling portion 45 via the hollow metal sphere filling portion 46 has been described as an example. However, as shown by 47a in FIGS. 2 and 7, a material supply hole is formed in the side sill inner panel 12, and the foamed resin material 63 is supplied to the foam material filling portion 55 without going through the hollow metal filling portion 46. It can also be. As a result, the hollow metal sphere 61 is supplied from the material supply port 47 to the hollow metal sphere filling unit 46 and the foamed resin material 62 is supplied from the material supply port 47a to the foam material filling unit 45. 61 can be supplied into the metal ball filling portion 46, and the foamed resin material 63 can be supplied to the foaming material filling portion 45.

  Further, the connecting portion 20A and the center pillar 20 between the side sill 10 and the center pillar 20 and the connecting portion 30A and the front pillar 30 between the side sill 10 and the front pillar 30 have been described, but other hollows such as the side rail 6 and the vehicle body frame are described. It can be applied to a cross-sectional structure. Furthermore, the hollow metal sphere 61 is hollow and has a reduced specific gravity, and is not limited to a sphere, and may have a shape similar to a sphere such as a cube. The material may be iron, carbon steel, stainless steel, or the like. It can be comprised with an iron-type metal and another metal.

(Second Embodiment)
FIG. 10 is a perspective view of the subframe 70 disposed on the lower surface of the vehicle body and supporting the differential device and the rear suspension, and FIG. 11 is a partially broken explanatory view of the subframe 70.

  The sub-frame 70 has a hollow front frame member 71 that is curved and extends in the vehicle body width direction so that the central area 72 is raised and both side areas 73 and 74 extend horizontally, and the front frame member 71. With respect to the rear frame member 75 extending in the vehicle body width direction, a support member 76 coupled to the front side of the rear frame member 75 and extending in the vehicle body width direction, and extending in the vehicle body longitudinal direction. The front frame member 71 is integrally formed in a cross beam shape having side end ranges 73 and 74 and a vertical frame member 77 coupled to each end of the support member 76. Attachment members 71a are attached to both ends of the front frame member 71 and sealed. Similarly, attachment members 75a are attached to both ends of the rear frame member 75 and sealed.

  Rear differential attachment portions 78 a and 78 b are attached to the lower surfaces of both ends of the raised central portion range 72 of the front frame member 71, and a rear differential support portion 78 c is provided in the central portion of the support member 76. A differential device (not shown) is attached to the rear differential attachment portions 78a and 78b, and the rear end of the differential device is supported by the rear differential support portion 78c. A suspension support bracket 79 that supports the suspension device is attached to each vertical frame member 77.

  The sub-frame 70 configured as described above has an attachment portion 71a attached to both ends of the front frame member 71 and attachment portions 75a attached to both ends of the rear frame member 75. It is attached to a vehicle body frame 91 extending in the longitudinal direction of the vehicle body along both sides of the lower surface.

  Here, a load is repeatedly input from the suspension device to the connecting portion 77A of the vertical frame member 77 of the front frame member 71 through the vertical frame member 77, and a relatively large load is input to the end of the front frame member 71. Therefore, the front frame member 71 is required to have a large rigidity in order to ensure the support rigidity of the suspension device in the side end ranges 73 and 74 continuing from the end portion to the coupling portion 77A. Damping and sound insulation are required for the central range 72 where vibrations are input via the rear differential attachment portions 78a and 78b.

  Between the front frame member 71, a hollow metal is provided between the central portion range 72, which is a sound insulation requirement range where vibration suppression and sound insulation are required, and the side end portions 73, 74, which are rigidity requirement ranges having relatively large required rigidity. Comparted by the ball movement restricting members 81 and 82. Thereby, the front frame member 71 is formed with the foam filling portion 83 and the hollow metal sphere filling portions 84 and 85 having a hollow cross-sectional structure. The hollow metal sphere movement restricting members 81 and 82 are, for example, the same as the hollow metal sphere movement restricting members 43, 44, 53, and 54 in the first embodiment, and block the passage of the hollow metal sphere 61 having a diameter of 1 to 5 m, for example. Further, it is constituted by a perforated plate or a mesh that allows passage of the unfoamed foamed resin material 62 and passage of the uncured foamed resin material having fluidity. Further, material supply holes 86 and 87 for supplying the hollow metal sphere 61 and the unfoamed foamed resin material 63 into the front frame member 71 are opened on the lower surfaces of the side end portions 73 and 74 in the front frame member 71.

  Then, as shown in the operation explanatory diagram in FIG. 12, in the state where the subframe 70 is turned upside down, the unfoamed foamed resin material 63 is transferred from the material supply 86, 87 opened to the front frame member 71 into the front frame member 71. Is supplied in a preset amount. The unfoamed foamed resin material 63 supplied from the material supply holes 86 and 87 flows down along the inner surface of the front frame member 71, passes through the hollow metal ball movement restricting members 81 and 82, and is bent downward. It stays in the bottom of the range, that is, in the foam filling portion 83.

  Following the supply of the foamed resin material 63, the hollow metal sphere 61 is supplied from the material supply holes 86 and 87, respectively, and the hollow metal sphere filling portions 84 and 85 are filled with the hollow metal sphere 61.

  Thereafter, the subframe 70 is subjected to electrodeposition coating and drying, and the foamed resin material 63 in the foam material filling portion 83 is expanded and expanded by this drying heat.

  The foamed resin material 63 is foamed in the foamed material filling portion 83 defined by the hollow metal sphere movement restricting members 81, 82 due to the expansion of the foamed resin material 63, in other words, the foamed resin material 62 is foamed in the central region 72 of the front frame member 71. Between the hollow metal spheres 61 that are filled and further pass through the hollow metal sphere movement restricting members 81, 82 and are filled in the hollow metal sphere filling portions 84, 85, and between the hollow metal sphere 61 and the inner surface of the front frame member 71. The hollow metal sphere filling portions 84 and 85 are filled with the hollow metal sphere 61 and the foamed resin material 62 by entering the gap therebetween. The foam filling portion 83 and the air and foam gas remaining in the hollow metal filling portions 84 and 85 accompanying the foam filling or the surplus foam material 62 are discharged from the material supply holes 86 and 87, and the foam filling portion 83. In addition, the residual gas does not stay in the hollow metal filling portions 86 and 87, and the generation of voids is suppressed to ensure smooth foam filling.

  Thus, by including the foamed resin material 62 filled in the foam material filling portion 83 defined by the hollow metal ball movement restricting members 81 and 82 in the front frame member 71, the cross-sectional deformation of the central region 72 is suppressed. The hollow metal sphere filling portions 86 and 87 partitioned by the hollow metal sphere movement restricting members 81 and 82 are filled with the hollow metal spheres 61 having relatively high rigidity, and between the hollow metal spheres 61. And into the gap between the hollow metal sphere 61 and the inner surface of the front frame member 71, and the side end portion areas 73 and 74 are filled with the hollow metal sphere 61 and the foamed resin material 62 to form a hollow cylinder. The cross-sectional deformation of the side end regions 73 and 74 is suppressed to ensure the rigidity, the rigidity of the front frame member 71 is improved, and the rigidity of the entire subframe 70 is improved.

  In particular, the side end range 73 is filled with the hollow metal sphere 61 and the foamed resin material 62 between the end portion of the front frame member 71 connected to the vehicle body frame 91 and the connecting portion 77A to which the vertical frame 77 is connected. The rigidity of the suspension 74 is ensured and the suspension support rigidity is improved. On the other hand, in the central area 72 where the vibration is input via the rear differential attachment parts 78a and 78b from the differential device, the foamed resin material 62 is filled in the part. Vibration is suppressed and sound insulation is provided.

  Accordingly, the foamed material is formed by partitioning the metal frame movement restricting members 81 and 82 between the central range 72 of the front frame member 71 that requires vibration suppression and sound insulation and the side end ranges 73 and 74 that require rigidity. The filling portion 83 and the hollow metal sphere filling portions 84 and 85 are formed, the foamed resin material 63 is supplied into the foam material filling portion 83, and the hollow metal sphere filling portions 84 and 85 are filled with the hollow metal sphere 61 and painted. By expanding and expanding the foamed resin material 63 with the drying heat at the time of drying, the foamed material filling portion 83 is filled with the foamed resin material 62, and the hollow metal sphere filling portions 84 and 85 are filled with the hollow metal sphere 61 and the foamed resin material. Since 62 is filled, it is possible to obtain the vibration damping and sound insulation effects in the central region 72 with a simple configuration and operation, and to secure the rigidity of the side end regions 73 and 74. Further, coupled with the fact that the hollow metal sphere 61 is light and inexpensive, an increase in manufacturing cost and mass can be avoided.

  In the above description, the foamed resin material 63 supplied from the material supply holes 86 or 87 opened to the side end ranges 73 and 74 of the front frame member 71 is foamed through the hollow metal sphere filling portions 84 and 85. Although the case where it supplies to the material filling part 83 was demonstrated to the example, as shown by 86a in FIG. 12, a material supply hole is formed in the center part area | region 72, and it does not go through the hollow metal filling parts 84 and 85, but a foaming material It is also possible to supply the foamed resin material 63 to the filling portion 83.

1 Body 10 Side sill (hollow closed section structure)
11 Side sill outer panel 12 Side sill inner panel 20 Center pillar (hollow closed section structure)
20A Connection between side sill and center pillar (sound insulation requirement range)
20B Rigid requirement range 21 Center pillar outer panel 22 Center pillar inner panel 30 Front pillar (hollow closed section structure)
30A Side sill and front pillar connection (sound insulation requirement range)
31 Front pillar outer panel 32 Front pillar inner panel 41, 42 Separator 43 Hollow metal sphere movement regulating member 44 Hollow metal sphere movement regulating member 45 Foam filling part 46 Hollow metal sphere filling part 47 Material supply hole 51 Separator 53 Hollow metal sphere movement restriction Member 54 Hollow metal sphere movement restricting member 55 Foam filling portion 56 Hollow metal sphere filling portion 57 Material supply hole 61 Hollow metal sphere 62 Foamed resin material 63 Foamed resin material 70 Subframe 71 Front frame member (hollow closed cross-section structure)
72 Central part range 73, 74 Side end range 75 Rear frame member 76 Support member 77 Vertical frame member 77A Joint part 91 of front frame member and vertical frame member Body frame 78a, 78b Rear differential attachment part 81, 82 Restriction of movement of hollow metal ball Member 83 Foam filling part 84, 85 Hollow metal sphere filling part 86, 87, 86a Material supply hole

Claims (8)

A foamed resin material obtained by foaming and expanding a foamed resin material in a hollow closed cross-sectional structure and a method for manufacturing a vehicle body structure stiffened by filling a hollow metal sphere with a granular shape,
A foam filling portion and a hollow metal sphere filling portion are formed in the hollow closed cross section by a hollow metal sphere movement restricting member that prevents passage of the hollow metal sphere and allows passage of an uncured foamed resin material having fluidity. Partition
Filling the hollow metal sphere filling portion with the hollow metal sphere,
A vehicle body structure characterized by foaming and expanding a foamed resin material in the hollow cross-sectional structure to fill a hollow metal sphere filling portion including a gap between the filled hollow metal spheres and a foam material filling portion with a foamed resin material. Manufacturing method. A method for manufacturing a vehicle body structure for stiffening by filling a foamed resin material obtained by foaming and expanding a foamed resin material in a hollow closed cross-sectional structure and a granular hollow metal sphere,
A foam filling portion and a hollow metal sphere filling portion are formed in the hollow closed cross section by a hollow metal sphere movement restricting member that prevents passage of the hollow metal sphere and allows passage of an uncured foamed resin material having fluidity. Partition
Filling the hollow metal sphere filling portion with the hollow metal sphere,
A vehicle body structure characterized in that a foamed resin material is foamed and expanded in the foamed material filling portion, and the inside of the hollow metal sphere filling portion including the gap between the filled hollow metal spheres and the foamed material filling portion are filled with the foamed resin material. Manufacturing method. The foamed resin material is a heat-foamable foamed resin material,
The method for manufacturing a vehicle body structure according to claim 1 or 2, wherein foaming is performed by heating with a heat source in the paint drying process.   The method for manufacturing a vehicle body structure according to any one of claims 1 to 3, wherein the foamed resin material and the hollow metal sphere are supplied into the hollow cross-sectional structure from a material supply port that opens to the hollow metal sphere filling portion. .   A hollow metal sphere is supplied into the hollow metal sphere filling portion from a material supply port that opens to the hollow metal sphere filling portion, and a foamed resin material is supplied into the foam filling portion from the material supply port that opens to the foam filling portion. The method for manufacturing a vehicle body structure according to any one of claims 1 to 3. A vehicle body structure that stiffens by filling a foamed resin material obtained by foaming and expanding a foamed resin material in a hollow closed cross-sectional structure and a granular hollow metal sphere,
A foam filling portion and a hollow metal sphere filling portion are formed in the hollow closed cross section by a hollow metal sphere movement restricting member that prevents passage of the hollow metal sphere and allows passage of an uncured foamed resin material having fluidity. Partition
The hollow metal sphere filling the hollow metal sphere filling portion;
A vehicle body structure comprising: a hollow metal sphere filling portion including a gap between the filled hollow metal spheres and a foamed resin material filling the foam material filling portion. The hollow closed cross-sectional structure has a hollow closed cross-sectional shape and a side sill extending in the longitudinal direction of the vehicle body, and a hollow closed cross-sectional pillar having a lower end connected to the side sill,
The foam filling portion is a connecting portion between the side sill and the pillar connected in a hollow shape,
7. The vehicle body structure according to claim 6, wherein the hollow metal sphere filling portion is a pillar continuous with the connecting portion. A rear frame member that extends in the vehicle width direction and has both ends attached to the vehicle body frame, and a rear differential attachment portion that supports the differential device in a hollow central portion that is spaced apart from the rear frame member and extends in the vehicle width direction. A vertical frame member connected to the rear frame member with the rear end connected to the rear frame member in the side end range, and a front frame member having both ends attached to the vehicle body frame.
The hollow cross-sectional structure is the front frame member,
7. The vehicle body structure according to claim 6, wherein the foam filling portion is a central range of the front frame member, and the metal ball filling portion is a side end range.

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