JP6318977B2 - Manufacturing method of component assembly - Google Patents

Description

  The present invention relates to a method for manufacturing a component assembly.

  Patent Document 1 below discloses a component manufacturing technique. In this component manufacturing technology, a carbon fiber reinforced resin sheet is polymerized on a metal plate, and the metal plate and the carbon fiber reinforced resin sheet are integrally formed by pressing.

JP 2013-212603 A

  In the component manufacturing technology, since the metal plate and the carbon fiber reinforced resin sheet are simply bonded together by pressing, there is room for improvement in terms of the bonding strength between the two.

  In view of the above facts, an object of the present invention is to obtain a method of manufacturing a component assembly that can improve the bonding strength between components including resin components provided with fibers.

Method for producing a component conjugate according to the invention described in claim 1, the first part holes are formed, the fiber is a sheet-like resin material oriented in one direction by changing the direction of orientation of the fibers A process of overlapping a plurality of second parts formed by overlapping a plurality of sheets, and press molding the second part to the first part side allows the resin material to flow in the hole and has a retaining shape on the inner wall of the hole. Forming a boss portion and joining the first part and the second part.

In the method of manufacturing the component assembly according to the first aspect, first, the second component is superposed on the first component. A hole is formed in the first component. The second component fiber is a sheet-like resin material oriented in one direction are formed by a plurality heavy combined by changing the direction of orientation of the fibers. Next, the second part is pressure-molded to the first part side. As a result, the resin material of the second part flows into the hole and a boss portion having a retaining shape is formed in the hole, so that the first part and the second part are joined.

Here, the second component fiber is a sheet-like resin material oriented in one direction are formed by a plurality heavy combined by changing the direction of orientation of the fibers. When the resin material is flowed into the hole by pressure molding, a boss portion in which fibers are oriented in multiple directions is formed. For this reason, a boss part with small strength anisotropy can be formed, and a boss part with improved strength can be formed.

  The method for manufacturing a component assembly according to the first aspect of the present invention has an excellent effect that the bonding strength between components including resin components provided with fibers can be improved.

It is the side view which looked at the front side door of the vehicle to which the component coupling body which concerns on 1st Embodiment was applied from the vehicle interior side. FIG. 2 is a cross-sectional view (a cross-sectional view in region A, region B, or region C in FIG. 1) of the component assembly shown in FIG. It is 1st process sectional drawing explaining the manufacturing method of the component coupling body which concerns on 1st Embodiment. It is 2nd process sectional drawing. It is process sectional drawing explaining the manufacturing method of the component coupling body which concerns on a comparative example. It is sectional drawing corresponding to FIG. 2 of the component coupling body which concerns on 2nd Embodiment.

[First Embodiment]
Hereinafter, the manufacturing method of the component assembly according to the first embodiment of the present invention will be described with reference to FIGS. 1 to 5 together with the component assembly. In the drawings, an arrow FR appropriately shown indicates the front direction of the vehicle to which the present embodiment is applied, and an arrow IN indicates the inner side in the vehicle width direction. An arrow UP indicates the upward direction of the vehicle. In addition, the application method of the coupling | bonding method of components with respect to vehicle bodies, such as a motor vehicle, and the coupling | bonding structure of components is not limited by this Embodiment.

(Side door configuration)
As shown in FIG. 1, a front side door 10 of a four-door type (or two-door type) automobile to which a component assembly 30 according to the present embodiment is applied includes a door main body 12 and an upper portion of the door main body 12. The door frame 14 is provided. The front side door 10 constitutes a vehicle body side portion.

  The door body 12 includes a door outer panel 20 and a door inner panel 22 provided on the inner side in the vehicle width direction than the door outer panel 20. A window regulator (not shown) for raising and lowering the door glass 16 is accommodated inside the door body 12 between the door outer panel 20 and the door inner panel 22. The front side door 10 is formed with a window opening 18 surrounded by an upper edge (door belt molding) 12A of the door body 12 and an inner peripheral edge 14A of the door frame 14. The window opening 18 can be opened and closed by raising and lowering the door glass 16. The door inner panel 22 is provided with an opening 28A and an opening 28B on the upper and lower sides on the vehicle front side, and an opening 28C and an opening 28D on the upper and lower sides on the vehicle rear side.

(Component assembly)
In the door inner panel 22 of the door body 12 shown in FIG. 1, the component assembly 30 according to the present embodiment is at least one of the hinge mounting portion in the region A, the insert molding portion in the region B, and the door lock portion in the region C. It is applied to the place. As shown in FIG. 2, the door inner panel 22 includes a first part 24 and a second part 26 that is provided so as to be superimposed on the inner side in the vehicle width direction than the first part 24. And the 1st component 24 and the 2nd component 26 are couple | bonded, and the component coupling body 30 which concerns on this Embodiment is applied to this coupling | bonding.

  As shown in FIG. 2, the first component 24 includes a plate-shaped component main body 24 </ b> A that extends in the vehicle front-rear direction and the vehicle vertical direction, although the shape varies depending on the location where it is applied. For example, in the hinge mounting portion in the area A shown in FIG. 1, a hinge or the like that opens and closes the front side door 10 with respect to a front pillar (A pillar) (not shown) is mounted on the first component 24. The first component 24 is made of a metal material such as iron, a light metal material such as aluminum, or an alloy material thereof.

  In the first component 24, a hole 24 </ b> B is provided at a portion where the components of the component main body 24 </ b> A are coupled to each other. The hole 24B is penetrated from the surface on the second component 26 side (surface on the vehicle interior side) of the component main body 24A to the opposite back surface (surface on the vehicle exterior side), and the hole width (or hole inner diameter) is that of the component main body 24A. It is formed by through holes that are the same in the thickness direction. Although not shown in the side view of the vehicle, the hole 24B extends along the vehicle vertical direction. A plurality of holes 24B may be provided at regular intervals along the vehicle vertical direction.

  The second component 26 includes a plate-shaped component body 26A that extends along the vehicle longitudinal direction and the vehicle vertical direction. In the component main body 26A, a position corresponding to the hole 24B is a portion where the components are coupled to each other, and the boss portion 26B is integrally provided at this portion. The boss portion 26B protrudes from the surface of the component body 26A on the first component 24 side into the hole 24B, is in close contact with the inner wall of the hole 24B, and is embedded in the hole 24B. Furthermore, in the present embodiment, the tip end portion 26C in the protruding direction of the boss portion 26B is configured to protrude at least in the vehicle front-rear direction along the back surface of the component main body 24A of the first component 24. In other words, the boss portion 26B has a T-shape when viewed from the bottom, and has a removal prevention shape that prevents the boss portion 26B from coming off from the hole 24B. The second component 26 is coupled to the first component 24 by coupling the boss portion 26B to the hole 24B.

  The component body 26A of the second component 26 is formed of a resin material 26R in which the fibers 26F are oriented in multiple directions and the density of the fibers 26F is uniform. The entire boss portion 26B is formed of a resin material 26R in which the fibers 26F are oriented in multiple directions and the density of the fibers 26F is uniform. Here, that the fibers 26F are oriented in multiple directions means that the orientation of the fibers 26F is oriented in a plurality of directions in three dimensions rather than in one direction, and the orientation of the fibers 26F does not have directionality. Also, the density of the fibers 26F is uniform means that the variation in the content of the fibers 26F provided per unit volume of the resin material 26R is within a range of 10% at any part, and the content of the fibers 26F The variation of is small. Here, if the variation in the content of the fiber 26F is within 20%, the density can be treated as an equal category.

  The resin material 26R provided with the fibers 26F is generally called a composite material. More specifically, the composite material is a carbon fiber reinforced plastic (CFRP: Carbon Fiber) in which a thermoplastic resin material is used as the resin material 26R, and carbon fiber (CF: Carbon Fiber) is provided as the fiber 26F on the thermoplastic resin material. Reinforced Plastic). The carbon fiber reinforced plastic has high strength and is lighter than, for example, a metal material, and is optimal as a material for the door inner panel 22. The carbon fiber reinforced plastic can also be used as a design surface (decorative surface) in the vehicle interior. In the present embodiment, short fibers having a length of 10 mm or less, preferably 5 mm or less are used for the carbon fibers.

  More specifically, thermoplastic resin materials include polypropylene resin, polyamide resin (for example, abbreviations PA6, PA66, PA610, PA10T, etc.), aromatic polyamide resin, semi-aromatic polyamide resin, polyphenylene sulfide (PPS) resin, polyethylene terephthalate. Any resin material such as a tarate (PET) resin, a polybutylene terephthalate (PBT) resin, a polycarbonate resin (PC), an acrylic (PMMA) resin, an ABS resin, or a thermoplastic epoxy resin can be used. As the fiber 26F provided in the thermoplastic resin material, in addition to carbon fiber, metal fiber such as glass fiber (GF: Glass fiber), aramid fiber, basalt fiber, bamboo fiber, iron, cellulose fiber, polypropylene fiber (self-reinforced type) ) Any of the fibers can be used.

  In addition to the thermoplastic resin material, a thermosetting resin material can be used as the resin material 26R. As the thermosetting resin material, any one of epoxy resin, urethane resin, vinyl ester resin, unsaturated polyester resin, and phenol resin can be used. As the fibers 26 </ b> F provided in the thermosetting resin material, the same fibers as those provided in the thermoplastic resin material can be used.

(How to connect parts)
The method for joining parts according to the present embodiment is as follows. First, as shown in FIG. 3, the first component 24 and the second component are overlapped between the first press die (upper die) 32A and the second press die (lower die) 32B of the press die 32. Arranged together. More specifically, the first component 24 is placed on the second press die 32B. The first component 24 is formed by a plate-shaped component main body 24A, and a hole 24B is formed at a portion where the components of the component main body 24A are coupled to each other. A bottomed recess 32D is provided at a position corresponding to the hole 24B of the second press die 32B. A plate-like second component 26 is placed on the first component 24. As described above, the second component 26 is formed of the resin material 26R in which the fibers 26F are oriented in multiple directions and the density of the fibers 26F is uniform. Here, a carbon fiber reinforced plastic is used as the second component 26, and the thermoplastic resin material as the resin material 26R contains 20% by volume to 40% by volume of carbon fiber as the fiber 26F. More specifically, the carbon fiber reinforced plastic is a sheet-like resin material having a thickness of 0.1 mm to 0.2 mm in which the fibers 26F are oriented in one direction, and the orientation direction of the fibers 26F is changed. It is formed by overlapping one to several dozen sheets.

  Next, preheating is performed, and the second component 26 (resin material 26R) is preheated and softened. The heating temperature for preheating is 300 ° C., and the heating time is 5 minutes. Note that, in the method for joining parts according to the present embodiment, preheating is performed on the entire second component 26, but preheating may be performed on a part of the joining portion of the second component 26.

  Next, as shown in FIG. 4, the first part 24 and the softened second part 26 are sandwiched between the press dies 32 using a press machine (not shown), and the first dies are further pressed by the press dies 32. The second part 26 is pressure-formed to the part 24 side. This pressure molding is generally referred to as sheet stamping molding. As pressure molding conditions (processing conditions for sheet stamping molding), the heating temperature of the press die 32 is 150 ° C., the pressure P is 9800 kN, and the mold holding time is 2 minutes. When the second component 26 is pressurized by the pressing force P by the pressure molding, the resin material 26R of the second component 26 flows into the hole 24B of the first component 24, and further passes through the hole 24B and passes through the hole 24B. It flows into the bottomed recess 32D of the two-press mold 32B. As the resin material 26R flows, the fibers 26F flow. The resin material 26R and the fibers 26F flow around firmly along the inner wall shape of the hole 24B and the contour shape of the bottomed recess 32D of the second press die 32B. The boss portion 26B in which the fibers 26F are oriented in multiple directions and the density of the fibers 26F is uniform is integrally formed with the second component 26 by the resin material 26R that has flowed into the holes 24B. Further, the resin material 26R is formed integrally with the boss portion 26B with the tip portion 26C in which the fibers 26F are oriented in multiple directions and the density of the fibers 26F is uniform.

  And since the boss | hub part 26B is couple | bonded with the hole 24B, the 1st component 24 and the 2nd component 26 are couple | bonded. Thereby, the manufacturing method of the component assembly 30 according to the present embodiment is completed, and the component assembly 30 is completed.

(Operation and effect of the present embodiment)
In the method for manufacturing the component assembly 30 according to the present embodiment, as shown in FIG. 3, first, the second component 26 is superposed on the first component 24. The first component 24 is formed with a hole 24B that couples the components. The second component 26 is formed of a resin material 26R in which fibers 26F are oriented in multiple directions. Next, as shown in FIG. 4, the second component 26 is pressure-molded toward the first component 24 side. As a result, the resin material 26R of the second component 26 flows into the hole 24B, and the boss portion 26B having a retaining shape is formed in the hole 24B, so that the first component 24 and the second component 26 are coupled. The

  Here, FIG. 5 shows a cross section in a resin molding process for explaining a method of manufacturing a component assembly according to a comparative example. In the resin injection molding (RTM) method or the injection molding method, the first part 24 is disposed between the upper mold 36A and the lower mold 36B of the molding die 36, and the upper mold 36A, the lower mold 36B, and the first part 24 are used. A resin material 34R is injected into the formed cavity to mold the second component 34. The configuration of the first component 24 of the comparative example is the same as the configuration of the first component 24 of the present embodiment. The first component 24 includes a component main body 24A, and a hole 24B is provided in the component main body 24A. On the other hand, the second component 34 of the comparative example includes a component main body 34A formed of a resin material 34R provided with fibers 34F, and a boss portion 34B is formed in the hole 24B in the component main body 34A. The front end portion 34D of the boss portion 34B is configured to protrude along the back surface of the first component 24, and the boss portion 34B has a shape that prevents it from coming off.

  In the manufacturing method according to the comparative example, the upper die 36A is provided with an injection gate 36C. When the resin material 34R having fluidity and provided with the fibers 34F is injected into the cavity from the injection gate 36C, and the resin material 34R is cured after being injected, the boss portion 34B is formed in the hole 24B of the first component 24. The joined second part 34 is molded. Since the resin material 34R immediately after being injected into the cavity flows along the contour shape in the cavity, the fibers 34F flow along with the flow of the resin material 34R, and the fibers 34F are oriented in the flow direction of the resin material 34R. For this reason, in the second component 34, since the fibers 34F of the component main body 34A and the boss portion 34B are oriented in a certain direction, anisotropy occurs in the strength of the component main body 34A and the boss portion 34B. Here, the strength anisotropy is a property in which the strength in a certain direction is strong and the strength in a certain direction is weak.

  In contrast to the manufacturing method according to the comparative example, in the manufacturing method of the component assembly 30 according to the present embodiment, the second component 26 is formed of a resin material 26R in which fibers 26F are oriented in multiple directions. By the pressure molding, the resin material 26R flows in the holes 24B, and the fibers 26F flow to form the boss portions 26B. For this reason, since the boss part 26B is formed by the resin material 26R in which the fibers 26F are oriented in multiple directions, the boss part 26B having low strength anisotropy can be formed, and the boss part 26B having improved strength. Can be formed. Therefore, in the component assembly 30 formed by the manufacturing method according to the present embodiment, the bonding strength between the first component 24 and the second component 26 can be improved.

  In addition, as shown in FIGS. 3 and 4, in the boss portion 26B, resin is firmly formed by pressure molding along the shape of the inner wall of the hole 24B and the contour shape of the bottomed recess 32D of the second press die 32B. Material 26R and fibers 26F can be wrapped. More specifically, the resin material 26 </ b> R and the fibers 26 </ b> F can be drawn to every corner of the boss portion 26 </ b> B that protrudes into the hole 24 </ b> B and has a tip portion 26 </ b> C that protrudes along the back surface of the first component 24. In the resin injection molding method according to the comparative example shown in FIG. 5, the resin material 34 </ b> R flows in a certain direction, and the resin material 34 </ b> R is insufficiently wound in a complicated shape portion, so that a void (nest) is likely to occur. For example, a missing part may be formed at the tip 34C of the boss 34B. On the other hand, in the manufacturing method of the component assembly 30 according to the present embodiment, the generation of voids can be effectively suppressed, and the boss portion 26B can be formed with a desired shape. For this reason, in the component assembly 30 according to the present embodiment, the strength of the boss portion 26B can be further improved.

  Further, in the method of manufacturing the component assembly 30 according to the present embodiment, as shown in FIGS. 3 and 4, the resin material 26 </ b> R flows in the holes 24 </ b> B and the fibers 26 </ b> F flow by pressure molding. Thus, the boss portion 26B having a uniform density of the fibers 26F is formed. For this reason, the boss | hub part 26B which reduced the intensity spot can be formed. More specifically, in the boss portion 26B, since the variation in the content of the fiber 26F provided per unit volume of the resin material 26R is small, there is no partial weak portion of strength. For this reason, the quality of the strength of the boss portion 26B can be improved. Therefore, in the component assembly 30 according to the present embodiment, the coupling strength between the first component 24 and the second component 26 can be further improved.

  Furthermore, in the component assembly 30 according to the present embodiment, as shown in FIG. 2, the tip end portion 26C of the boss portion 26B projects along the back surface of the first component 24 to have a shape that prevents it from coming off. For this reason, the effect of preventing the second component 26 from coming off from the first component 24 can be enhanced.

[Second Embodiment]
Next, with reference to FIG. 6, a method for manufacturing a component assembly according to the second embodiment of the present invention will be described together with the component assembly. In the present embodiment, the same or equivalent components as those in the first embodiment are denoted by the same reference numerals, and redundant description is omitted.

(Component assembly)
In the component assembly 40 according to the present embodiment shown in FIG. 6, the boss portion 26D of the second component 26 is coupled to the hole 24C of the first component 24 in the same manner as the component assembly 30 according to the first embodiment. The first component 24 and the second component 26 are coupled. The hole 24C is tapered when viewed from the bottom, and the opening width (or opening diameter) on the back surface side is larger than the opening width (or opening diameter) on the front surface side (second component 26 side) of the hole 24C. . The boss portion 26D is in close contact with the inner wall of the hole 24C and is formed in an inverted shape with respect to the shape of the hole 24C. In other words, the boss portion 26D has a shape that prevents the boss portion 26D from slipping out and has a larger width (or outer diameter) on the front end side in the protruding direction than the width (or outer diameter) on the component body 26A side.

(Manufacturing method of component assembly)
The manufacturing method of the component assembly 40 according to the present embodiment is the same as the manufacturing method according to the first embodiment. That is, as shown in FIG. 3, the second part 26 is superposed on the first part 24. Then, as shown in FIG. 4, the first part 24 and the second part 26 are sandwiched between the press molds 32 and are pressure-formed by a press machine (not shown). Due to the pressure molding, a part of the resin material 26R of the second component 26 flows into the hole 24C of the first component 24, and the boss portion 26D having a removal preventing shape is formed by the flowed resin material 26R. In the boss portion 26D, with the flow of the resin material 26R, the fibers 26F are oriented in multiple directions, and the density of the fibers 26F is made uniform.

  When the boss portion 26D is formed, the boss portion 26D is coupled to the hole 24C, so that the first component 24 and the second component 26 are coupled. Thereby, the manufacturing method according to the present embodiment is completed, and the component assembly 40 is completed.

(Operation and effect of the present embodiment)
In the component coupling body 40 and the manufacturing method thereof according to the present embodiment, it is possible to obtain the same operational effects as the operational effects obtained by the component coupling body 30 according to the first embodiment and the manufacturing method thereof.

  Moreover, in the component coupling body 40 and the manufacturing method thereof according to the present embodiment, the hole 24C of the first component 24 is tapered, and the boss portion 26D is inverted with respect to the hole 24C. 26D has a shape that prevents it from coming off, and the boss portion 26D is locked in the hole 24C. For this reason, the effect of preventing the second component 26 from coming off from the first component 24 can be enhanced. Furthermore, in the boss portion 26D, the structure of the tip end portion 26C (see FIG. 2) protruding along the back surface of the first component 24 is eliminated, so that the structure can be simplified. Furthermore, in the manufacturing method of the component assembly 40, the bottomed concave portion 32D of the second press die 32B is eliminated, so that the structure of the press die 32 can be simplified.

[Supplementary explanation of the above embodiment]
The present invention is not limited to the above-described embodiment, and various modifications can be made without departing from the scope of the invention. For example, in the above embodiment, the first component is a metal material, a light metal material, or an alloy material, but the present invention is formed of a resin material harder than the second component or a resin material provided with fibers. Alternatively, the first part may be used.

  Further, in the first embodiment, a counterbore portion connected to the hole may be provided on the back surface side of the first component, and the tip end portion of the boss portion of the second component may be formed as a slip-off preventing shape that fits in the counterbore portion. Furthermore, in the present invention, the first component and the second component are not limited to plate shapes, but may be block shapes.

  Further, in the above embodiment, the component combination and the manufacturing method thereof are applied to the front side door of the automobile. However, the present invention relates to the component combination such as the rear side door, back door, hood, luggage, and roof of the automobile. And the manufacturing method thereof.

  Furthermore, the present invention may be applied to a component combination of vehicles other than automobiles or a building or a method of manufacturing a component combination.

30, 40 Component assembly 24 First component 24B, 24C Hole 26 Second component 26B, 26D Boss portion 26R Resin material 26F Fiber

Claims (1)

A step of superimposing a second part formed by overlapping a plurality of sheets of resin material in which the fibers are oriented in one direction on a first part in which holes are formed;
By press-molding the second part toward the first part, the resin material is caused to flow in the hole to form a retaining boss on the inner wall of the hole. Combining the two parts;
The manufacturing method of the component coupling body provided with.