JP6381435B2 - Roof rail material and manufacturing method thereof - Google Patents

Description

  The present invention relates to a roof rail material constituting a roof rail attached to a roof panel of a vehicle and a manufacturing method thereof.

  Vehicle roof rails have been used exclusively for loading luggage, but in recent years they may be mounted primarily for decoration purposes. For this reason, the appearance of the roof rail tends to be emphasized as an element that affects the product value.

  As the roof rail material, an aluminum hollow extruded material is used because it is lightweight and has good moldability (see Patent Document 1). Moreover, since aluminum has a beautiful metallic luster, the hollow extruded material is used by polishing the surface to increase the glossiness and revealing the aluminum base in appearance.

  The hollow extruded material is produced using a holrodice such as a porthole die (see Patent Document 2).

JP 2007-253928 A Japanese Patent Laid-Open No. 9-271834

  In the port hole die, since the material divided into a plurality of metal holes is welded in the welding chamber to form a hollow portion, it is inevitable that the trace of welding is formed in a line shape along the extrusion direction.

  As shown in FIG. 1A, since the roof rail 2 is attached to the left and right side edge portions of the roof panel 1 along the front-rear direction, the welded portion formed along the extrusion direction can be seen well from the side of the vehicle. In addition, the welded portion is emphasized by bending or polishing and becomes easily noticeable, and this is a factor that affects the appearance quality of the roof rail material in which the aluminum base is exposed.

  The port hole die described in the cited document 2 is provided with a protruding portion in a bad portion of the metal flow in the welding chamber, and increases the amount of metal flowing toward the welding portion of the extruded material, thereby making the welding portion inconspicuous. Yes. However, it is insufficient for the production of a roof rail material in which appearance is important.

  In view of the background art described above, an object of the present invention is to provide a roof rail material made of a hollow extruded material in which an aluminum base appears in appearance, and the quality of appearance is not impaired by the welded portion of the extrusion, and a method for manufacturing the same.

  That is, this invention has the structure as described in following [1]-[6].

[1] A roof rail material that is made of an aluminum hollow extruded material and is attached to the left and right edges of the outer surface of the roof panel of the vehicle so as to extend in the longitudinal direction of the vehicle.
When the region facing upward and to the side of the vehicle is the main appearance region when the roof rail material is attached, the welded portion of the hollow extruded material is formed at the corner outside the main appearance region and / or inside the main appearance region. The welded portion is not formed in the main appearance area excluding the corner,
A roof rail material in which at least a part of the surface of the main appearance region is polished.

  [2] The roof rail material according to item 1 above, wherein the glossiness after polishing in the main appearance region is 250 or more.

  [3] The roof rail material according to item 1 above, wherein an anodized film is formed in the polished main appearance region, and the glossiness in the main appearance region is 200 or more.

[4] When the roof rail material to be attached to the outer surface of the roof panel of the vehicle is made of an aluminum hollow extruded material, and the region facing upward and to the side of the vehicle in the attached state of the roof rail material is a main appearance region,
A female die having a bearing hole for molding the outer surface of the hollow extruded material, a mandrel for molding the inner surface of the hollow extruded material, and a leg portion supporting the mandrel corresponding to a portion other than the main appearance region and / or Extruded aluminum and hollowed using a horodice that is formed in a part corresponding to the corner in the main appearance area and combined with a male mold that does not have legs in the part corresponding to the main appearance area excluding the corner. An extrusion process for forming the extruded material;
A method for producing a roof rail material, comprising performing a polishing step of polishing at least a main appearance surface of the hollow extruded material formed by the extrusion step.

  [5] The method for manufacturing a roof rail material according to the item 4, wherein the main appearance region is polished so that the glossiness is 250 or more in the polishing step.

  [6] The method for producing a roof rail material according to item 4 or 5, wherein the hollow extruded material after the polishing step is anodized to form an anodized film having a glossiness of 200 or more in the main appearance region.

  In the roof rail material according to the above [1], the welded portion is formed outside the main appearance region and / or the corner portion inside the main appearance region, and the welded portion is not formed in the main appearance region excluding the corner portion. Since the outside of the main appearance area is a portion that is difficult to see, the appearance quality is not impaired even if the welded portion is formed. In addition, since the corner portion is originally a portion in which the linear change is seen in the extrusion direction in the main appearance region, the presence or absence of the welded portion does not affect the quality of the appearance so much, and the welded portion is present in the corner portion. Even if formed, the appearance quality is not impaired. That is, the welded portion is formed only in a portion where the appearance quality is not impaired even if the welded portion is formed, and the welded portion that is inevitably formed in the hollow extruded material does not deteriorate the appearance quality. In addition, the welded portion is easily noticeable by polishing, but since the welded portion does not exist in a portion where the appearance quality is important, the appearance quality is not deteriorated by polishing, and an appearance utilizing the metallic luster of aluminum is obtained.

  The roof rail material according to the above [2] has a good appearance quality exhibiting a metallic luster because the gloss after polishing is 250 or more.

  The roof rail material according to the above [3] has a glossiness of 200 or more in a state where an anodized film is formed, and thus has excellent corrosion resistance while maintaining appearance quality.

  According to the method for manufacturing a roof rail material described in [4] above, in the horodice used in the extrusion process, the leg portion supporting the male mandrel corresponds to a portion corresponding to a region other than the main appearance region of the hollow extruded material and / or the main portion. It is formed in a portion corresponding to the corner portion in the appearance area, and no leg portion is formed in a portion corresponding to the main appearance area excluding the corner portion. The extruded hollow extruded material has a welded portion formed at a portion corresponding to the position of the leg portion. Furthermore, the glossiness of the main external appearance area | region of a hollow extruded material can be raised in a grinding | polishing process. The roof rail material manufactured by these processes has a welded part formed only in the part where the appearance quality is not impaired even if there is a welded part, so the welded part inevitably formed in extrusion deteriorates the appearance quality. I will not let you. In addition, the welded part is easily noticeable by polishing, but since there is no welded part in the part where appearance quality is important, the appearance of the roof rail that makes use of the metallic luster of aluminum without impairing the appearance quality by polishing is manufactured. Can do.

  According to the method for producing a roof rail material described in [5] above, it is possible to produce a roof rail material having an appearance quality exhibiting a metallic luster having a glossiness of 250 or more.

  According to the method for producing a roof rail material described in [6] above, it is possible to produce a roof rail material exhibiting a metallic luster having a glossiness of 200 or more and high corrosion resistance by an anodized film.

It is a side view of the vehicle which attached the roof rail. It is a front view of FIG. 1A. It is a perspective view of the roof rail material which is one Embodiment of this invention. It is a disassembled perspective view of the porthole die which shape | molds the roof rail material of FIG. It is sectional drawing of the porthole die of FIG. 3A. It is the figure which showed the position of the leg part of the die | dye of FIG. 3A on the cross section of the roof rail material of FIG. It is the figure which showed the position of the leg part of the die | dye of another aspect on the cross section of the roof rail material of FIG. It is sectional drawing which shows the other corner | angular part shape in a roof rail material. It is sectional drawing which shows other corner | angular part shape in a roof rail material. It is a side view which shows the other attachment aspect of a roof rail material. It is sectional drawing which shows the other shape and main external appearance area | region of a roof rail material. It is sectional drawing which shows another shape and main external appearance area | region of a roof rail material. It is sectional drawing which shows another shape and main external appearance area | region of a roof rail material. It is the figure which showed the position of the leg part of die | dye on sectional drawing of the roof rail material of a comparative example. It is. It is a side view of the roof rail material bent.

  1A and 1B show a state in which a pair of roof rails 2 are attached to the left and right edges of the outer surface of the roof panel 1 of the vehicle along the front-rear direction of the vehicle. The roof rail 2 is a hollow body that has been processed to close both ends of a roof rail member 10 made of an aluminum hollow extruded material.

  As shown in FIG. 2, the roof rail member 10 has a bottom surface 11 and a top surface 12 that are parallel to each other, an outer side surface 13 that is positioned on the side surface of the vehicle is inclined downward, and an inner side surface 14 that is positioned on the center side of the vehicle. Has a trapezoidal cross section perpendicular to the bottom surface 11. The roof rail member 10 is attached so that the bottom surface 11 is in contact with the roof panel 1 of the vehicle.

  The roof rail material 10 is manufactured by extrusion molding using a holrodice. FIG. 3A and FIG. 3B show a porthole die 20 that is a kind of horodice. The port hole die 20 is a die in which a female die 21 having a bearing hole 22 for molding the outer peripheral surface of a hollow extruded material and a male die 31 having a mandrel 32 for molding the inner surface of the hollow extruded material are combined. The female die 21 has a circular recess 24 on the mating surface 23 with the male die 31, and a bearing hole 22 is formed in the bottom surface of the recess 24. In the male mold 31, a mandrel 32 protruding from a mating surface 33 with the female mold 21 is supported by two leg portions 34, and the port hole 35 is divided into two by the leg portions 34. When the female mold 21 and the male mold 31 are assembled and their mating surfaces 23 and 33 are brought into contact with each other, a male mandrel 32 is inserted into the bearing hole 22 of the female mold 21 and the cross section of the hollow extruded material 10 is between them. A molding gap 40 corresponding to the shape is formed, and the recess 24 of the female die 21 is closed in communication with the two port holes 35 to form a welding chamber 41.

  In the extrusion of aluminum using the port hole die 20, the aluminum flows into the welding chamber 41 from the two port holes 35 of the male die 31, and the two metal flows are welded together to form a hollow material from the forming gap 40. Extruded. The welded portions of the two metal flows are positions corresponding to the two leg portions 34 of the male mold 31 and appear as two line-shaped welded portions on the molded hollow extruded material 10. Since the welded portion is different in the degree of processing, metal temperature, and the like from the other portions, a metal structure different from the other portions is formed, and the difference in the metal structures may be visible.

  In general, extruded materials have fine irregularities on the surface and low gloss, so in products in which an aluminum substrate appears in appearance, the appearance quality is improved by polishing the surface and increasing the gloss. However, when the glossiness of the surface is increased by polishing, the welded portion is emphasized and becomes easily noticeable. Further, when the roof panel is formed with a curved surface, the roof rail material is bent along the curve of the roof panel, but the welded portion is easily noticeable even by bending. Note that the roof panel 1 of FIG. 1A has a gently curved surface, and the roof rail member 10 is bent along the roof panel.

  The present invention defines the position of a welded portion that is inevitably formed in a roof rail material made of a hollow extruded material and is emphasized by bending or polishing, and lowers the appearance quality by forming the welded portion at a specific position. Avoid.

  In the present invention, in a state where the roof rail member 10 is attached to the left and right edges of the outer surface of the roof panel 1 so as to extend in the front-rear direction of the vehicle, the region facing the upper side and the side of the vehicle is defined as the main appearance region of the roof rail member 10 A is defined. The portions where the welded portion is allowed to be formed are corners outside the main appearance area A and inside the main appearance area A. The portion where the formation of the welded portion is not allowed is in the main appearance region A excluding the corner portion.

  The main appearance area A is a part that is visually recognized from the side of the vehicle or is easily visible and easily noticeable, and is an area where appearance quality is important. However, since the corner portion is originally a portion where a linear change is seen in the extrusion direction, the presence or absence of the welded portion does not greatly affect the quality of the appearance quality, and the welded portion is present at the corner portion in the main appearance area A. Even if it is formed, it can be determined that the appearance quality is not impaired. On the other hand, the area outside the main appearance area A, that is, the area below and toward the center of the vehicle is a part that cannot be seen from the side of the vehicle, or is difficult to be seen and difficult to see, so Quality is not important. Since the appearance quality is not considered important outside the main appearance area A, it can be determined that the appearance quality of the roof rail material is not impaired even if the welded portion is formed.

  As described above, in the roof rail material of the present invention, the welded portion is formed in the corner portion outside the main appearance region A and / or in the main appearance region A, and the welded portion is formed in the main appearance region A excluding the corner portion. There is no condition.

  In the roof rail member 10 shown in FIG. 2, the upper surface 12 faces upward, the outer side surface 13 faces the side of the vehicle, and the upper surface 12 and the outer side surface 13 are the main appearance region A. A corner 15 formed by the upper surface 12 and the outer side surface 13 is a corner in the main appearance area A. Therefore, in the roof rail member 10, it is the bottom surface 11, the inner side surface 14, and the corner portions 15 that are allowed to form a welded portion. In addition, formation of a welded portion is allowed also at the corner portion 16 formed by the top surface 12 and the inner side surface 14 and the corner portion 17 formed by the bottom surface 11 and the outer side surface 13. The corners 16 and 17 are on the boundary line between the main appearance area A and the non-main appearance area. However, even in the main appearance area A, the corners are allowed to form welds. 16 and 17 also allow formation of welds.

  As described above, since the position of the welded part corresponds to the position of the leg part 34 of the male mold 31, the position of the welded part can be determined by setting the position of the leg part 34. 3A and 3B, the two leg portions 34 are formed at positions corresponding to the corner portions 16 and 17, and the welded portions are formed at the corner portions 16 and 17, respectively. FIG. 4 shows the position of the two leg portions 34 of the port hole die 20 indicated by the diagonal line d1 superimposed on the cross section of the roof rail member 10.

  The number of legs in the porthole die is not limited. For example, a third leg portion can be added to the port hole die 20 in FIGS. 3A and 3B at a position corresponding to the corner portion 18 between the bottom surface 11 and the inner side surface 14. The position of the third leg is indicated by a broken line d2 in FIG. FIG. 5 shows an example in which four leg portions are formed. Two diagonal lines d1 and d3 superimposed on the cross section of the roof rail member 10 represent the positions of the leg portions, and four corner portions 15, 16, 17, 18 are shown. This is an example in which a welded portion is formed.

  In the present invention, the corners of the roof rail material are not limited to the angular shape formed by the intersection of the planes shown in FIG. Also included is a corner 50 with a rounded tip, as shown in FIG. Furthermore, a corner formed by the intersection of the curved surfaces and a corner formed by the intersection of the curved surface and the plane are included, and each has an angular corner and a rounded corner. FIG. 7 shows a rounded corner portion 53 formed by the intersection of the curved surfaces 51 and 52, and the curvature radius of the corner portion 53 is smaller than the curvature radius of the curved surfaces 51 and 52.

  The cross-sectional shape of the roof rail material of the present invention is not limited to a quadrangle. As shown in FIGS. 1A and 1B, the roof rail material can be attached to the vehicle via a support leg in addition to directly attaching the bottom surface to the roof panel, and is not limited to the flat bottom surface. FIG. 8 is an example of the roof rail material 56 attached to the roof panel 1 via the support legs 55. Even in a roof rail member having a cross section other than a quadrangle, a region facing upward and to the side of the vehicle in the mounted state is a main appearance region. 9 to 11 are other examples of the cross-sectional shape of the roof rail material, and the side of the vehicle is shown on the right side of the drawing in the attached state. The roof rail member 60 shown in FIG. 9 is a right-angled triangle having a slope 61 on the side facing the vehicle, and the slope 61 is the main appearance area A. The roof rail member 62 shown in FIG. 10 is an inverted right triangle having a slope 63 on the inward surface of the vehicle, and the upper surface 64 and the side surface 65 that form a right angle are the main appearance area A. The roof rail member 66 in FIG. 11 is circular, and the arc surface 67 outside the vertical line V passing through the center is the main appearance area A.

  In the roof rail material of the present invention, at least a part of the main appearance region A is polished. The appearance of the roof rail material in which the aluminum base appears in the appearance is enhanced by polishing the surface to obtain a high glossiness, while the presence of the welded portion is emphasized by polishing, so the position of the welded portion is defined. The effect obtained by this is more remarkable than the unpolished extruded material, and the application significance is great. Therefore, by defining the position of the welded portion, the effect of improving the appearance quality by polishing can be fully enjoyed. Although the glossiness obtained by polishing is not limited, it is highly applicable to roof rail materials having a glossiness defined by 60-degree specular glossiness (JIS Z 8741) of 250 or more, and good appearance quality exhibiting metallic luster Is obtained. A roof rail material having a glossiness of 300 or more is further significant in application. The polishing method is not limited, and a known method such as buffing, chemical polishing, or electrolytic polishing may be used, and polishing may be performed by combining two or more methods.

  The polished roof rail material can form a film on the surface as long as the aluminum substrate appears in the appearance. The anodized film is a film that improves the corrosion resistance of the aluminum material, and is a film suitable for the roof rail material that is attached to the outer surface of the vehicle. When aluminum is anodized, the glossiness is lowered. However, it is preferable that the glossiness is 200 or more even after the formation of the anodized film in order to make use of the glossiness of aluminum. The conditions for anodizing treatment are not limited, and examples of the conditions for obtaining a glossiness of 200 or more include those obtained by subjecting buffing and chemical polishing to a glossiness of 430 or more and sulfuric acid anodizing treatment.

  Moreover, the coating film by transparent resin can be illustrated as a membrane | film | coat which can show an aluminum base body in an external appearance.

  Using A6063, a hollow roof rail material 10 having a trapezoidal cross section shown in FIG. 2 was extruded by a porthole die. The cross-sectional shape of the roof rail member 10 is common to each example, and the port hole die used differs only in the number and position of male legs.

(Examples 1 and 2)
The port hole die 20 shown in FIGS. 3A and 3B was used. That is, the male mold 31 has legs 34 at positions corresponding to the two corners 16 and 17 of the roof rail member 10, and the molded roof rail member 10 is welded to the corners 16 and 17 as shown in FIG. Part is formed, and no welded part exists in the main appearance area A.

( Reference Examples 3, 4, 5)
In Examples 1 and 2, port hole dies (not shown) having different positions and numbers of male legs were used. The used male mold has four legs on the two diagonal lines d1 and d3 of the roof rail member 10, as shown in FIG. The molded roof rail material 10 has welded portions formed at four corners 15, 16, 17, and 18, and the welded portion exists only at the corners 15 in the main appearance area A.

(Comparative Examples 1, 2, 3)
In Examples 1 and 2, port hole dies (not shown) having different positions and numbers of male legs were used. As shown in FIG. 12, the male mold used has four leg portions on one diagonal line d1 of the roof rail member 10 and on a straight line d4 extending from the corner portion 18 to the outer side surface 13 which is the opposite surface. Have. The molded roof rail material 10 has welds at the three corners 16, 17, 18 and the outer side surface 13.

  Table 1 shows the positions and the number of male legs (welded portions) of the roof rail material of each example.

  The roof rail material molded in each example was cut to a length of 2,000 mm after aging at 200 ° C. for 3 hours, and was subjected to a bending process with a bending amount of W 60 mm as shown in FIG.

  Next, the entire outer peripheral surface of the roof rail material was buffed and further chemically polished. In these polishings, the polishing conditions were changed intentionally so that a difference in glossiness occurred. After polishing, glossiness was measured at three locations in the main appearance area A with a gloss checker IG-410 manufactured by HORIBA, Ltd., and the average value at the three locations (rounded to the first digit) was taken as the glossiness of the roof rail material. Further, the glossiness of 300 or more was judged as ◎, 200 or more and less than 300 as ○, and less than 200 as ×. These results are shown in Table 1.

  The gloss unevenness of the polished roof rail material was determined according to the following criteria. The determination results are shown in Table 1.

  A: The gloss unevenness of the welded portion cannot be confirmed even if it is visually confirmed by holding it in the hand and changing the viewing angle or the way the light hits.

  ○: When visually confirmed by holding in the hand and changing the viewing angle and the way the light hits, the unevenness of the welded portion may be confirmed thinly, but it is usually not visible.

  Δ: When visually held and confirmed by hand, unevenness of the welded portion can be easily confirmed, but cannot be confirmed after 1 m away.

  X: The thing which can confirm the nonuniformity of a welding part visually from the place 1m away.

The roof rail materials of Examples 1 and 2, Reference Examples 3 and 4, and Comparative Examples 1 to 3 were subjected to sulfuric acid anodization after polishing to form an anodized film having a thickness of 10 μm. About the roof rail material after anodizing treatment, the glossiness was measured by the same method as that after polishing, and the glossiness and gloss unevenness were determined by the same standard. The determination results are shown in Table 1.

  Furthermore, based on the results of the glossiness determination and gloss unevenness determination, each test roof rail material was comprehensively determined. The judgment criteria are as follows.

◎: Both glossiness judgment and gloss unevenness judgment ◎
○: Of the glossiness judgment and gloss unevenness judgment, the one with the lower evaluation
Δ: Low evaluation of glossiness judgment and gloss unevenness judgment
×: Low evaluation of glossiness judgment and gloss unevenness judgment ×

  From Table 1, it was confirmed that each example had high appearance quality in the main appearance region.

The present invention can be applied to a roof rail material in which the metallic luster of aluminum is shown in the appearance.

DESCRIPTION OF SYMBOLS 1 ... Roof panel 2 ... Roof rail 10, 56, 60, 62, 66 ... Roof rail material (hollow extrusion material)
12 ... Upper surface (main appearance area)
13. Outer side surface (main appearance area)
15, 16, 17, 18, 50, 53 ... corner 20 ... port hole die 21 ... female die 31 ... male die 32 ... mandrel 34 ... leg A ... main appearance area

Claims (7)

It is a roof rail material made of a hollow extruded material made of aluminum and attached to the left and right edges of the outer surface of the roof panel of the vehicle in a manner extending in the front-rear direction of the vehicle,
When the region facing the side of the upper and the vehicle as a main appearance regions in the mounted state of the roof rail member, the welding portion of the hollow extruded member is formed outside the main exterior region, the welded portion on the major exterior areas Is not formed,
A roof rail material in which at least a part of the surface of the main appearance region is polished.   The roof rail material according to claim 1, wherein the glossiness after polishing in the main appearance region is 250 or more.   The roof rail material according to claim 1, wherein an anodized film is formed on the ground main appearance region, and the glossiness in the main appearance region is 200 or more. The roof rail material that is attached to the left and right edges of the outer surface of the roof panel of the vehicle in a manner that extends in the longitudinal direction of the vehicle is made of an aluminum hollow extruded material, and the region facing the upper side and the side of the vehicle in the state of attachment of the roof rail material. When the main appearance area
And a female die having a bearing hole for forming the outer surface of the hollow extruded member having a mandrel for molding the inner surface of the hollow extruded member, corresponding to the part fraction legs for supporting the mandrel corresponds to the non-core appearance region is formed in a portion, with Horodaisu a combination of a male not leg portion is formed on a portion corresponding to major exterior region, the extrusion step of forming an aluminum extruded hollow extruded material,
A method for producing a roof rail material, comprising performing a polishing step of polishing at least a main appearance surface of the hollow extruded material formed by the extrusion step.   The method for manufacturing a roof rail material according to claim 4, wherein in the polishing step, polishing is performed so that the glossiness of the main appearance region becomes 250 or more.   The method for producing a roof rail material according to claim 4 or 5, wherein the hollow extruded material after the polishing step is subjected to an anodizing treatment to form an anodized film having a glossiness of 200 or more in a main appearance region.   The method for producing a roof rail material according to any one of claims 4 to 6, wherein the number of male legs of the horodice is two.

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