JP6437750B2 - Method for manufacturing flush cover structure - Google Patents

Description

  The present invention relates to a method for manufacturing a flush cover structure suitable as a method for manufacturing a cover structure of a mounting portion of a headlamp cleaner in an automobile bumper.

  2. Description of the Related Art Conventionally, as an example of a flush cover structure for a vehicle exterior member, there is a cover structure for a headlamp cleaner mounting portion in a bumper that is an exterior member. In such a cover structure, a headlamp cleaner fixedly supported via a support member such as a bracket on the inner side (back side) of the bumper located below the headlamp is provided so as to protrude from an insertion hole formed in the bumper. The insertion hole is closed by a cover body provided flush with the bumper (see, for example, Patent Document 1). Specifically, it is as follows.

  The headlamp cleaner has an injection nozzle at the tip, and has a piston provided to move forward and backward with respect to the cylinder. A cover body that closes the insertion hole of the bumper is provided on the tip side of the piston so as to move integrally with the piston that moves forward and backward. The cover body is configured as a member that covers the entire insertion hole corresponding to the shape and dimensions of the insertion hole of the bumper. The cover body is flush with the surface (design surface) of the bumper with the insertion hole closed. During normal operation, that is, when the headlamp cleaner is not operated, the piston and the injection nozzle are housed inside the bumper, and the insertion hole of the bumper is closed by the cover body.

  When the headlamp cleaner is operated, that is, when the headlamp is cleaned, the piston protrudes from the insertion hole of the bumper by its forward movement, and the cleaning liquid is sprayed toward the headlamp from the spray nozzle moved to the outside of the bumper. Here, with the protrusion of the piston from the insertion hole of the bumper, the cover body moves to the outside of the bumper together with the injection nozzle, and opens the insertion hole in a state where the piston protrudes. When the operation of the headlamp cleaner is finished, the piston is retracted from the insertion hole of the bumper to the inside of the bumper by the retreating operation, and the injection nozzle is immersed inside the bumper. Accordingly, the cover body is accommodated in the insertion hole of the bumper, and the insertion hole is closed by the cover body that is flush with the bumper.

  In the flush cover structure as described above, between the insertion hole of the bumper and the cover body that covers the insertion hole flush with the bumper, that is, the inner peripheral side surface of the insertion hole and the outer peripheral side surface of the cover body that closes the insertion hole In between, there is a clearance called a parting gap. The parting gap appears as a black line on the appearance of the car and affects the appearance. Particularly, since the mounting portion of the headlamp cleaner is present at a position that is relatively easily noticeable in an automobile, the effect of the parting gap in the cover structure on the appearance is relatively large. The parting gap is preferably as narrow (small) as possible in terms of the appearance of the automobile, and is preferably as uniform as possible around the cover body.

  Therefore, in order to ensure the appearance quality in the flush cover structure, the positional accuracy between the bumper insertion hole and the headlamp cleaner that supports the cover body, that is, the bumper insertion hole and the headlamp cleaner should be Positional accuracy between a support member such as a bracket for supporting the bumper is important. Therefore, in Patent Document 1, in order to perform relative positioning of the bumper and the bracket, there is a technique in which a pair of protrusions is provided in the stepped recess on the bumper side, and an engagement portion that engages with the protrusion is provided on the bracket side. Have been described.

JP 2010-228594 A

  Certainly, according to the technique described in Patent Document 1, the positional accuracy of the relative positioning of the bumper and the bracket is determined by the engagement between the protrusion provided on the bumper and the engaging portion provided on the bracket. Can be improved. However, the technique described in Patent Document 1 is intended to improve the positional accuracy of the cover body with respect to the insertion hole of the bumper by positioning the bracket itself to the bumper. This depends on the processing accuracy of the protrusion and the engaging portion of the bracket. Therefore, if the processing accuracy of the bumper or the engaging portion of the bracket is low, the positional accuracy of the cover body is lowered.

  The present invention is made under the circumstances as described above, and relates to a cover structure in which an insertion hole formed in an exterior member of a vehicle is closed by a cover body provided flush with the exterior member. It is an object of the present invention to provide a method for manufacturing a flush cover structure that can narrow a parting gap around a cover body and can improve appearance.

  In the manufacturing method of the flush cover structure according to the present invention, the insertion hole formed in the exterior member of the vehicle is indirectly supported by the support member provided inside the exterior member and faces the exterior member. A method of manufacturing a surface-to-surface cover structure that is closed by a cover body provided on the surface, the step of fixing the support member at a predetermined position inside the exterior member, and the insertion hole being formed in the exterior member And a drilling step of performing a process of forming a support hole for indirectly supporting the cover body in the support member.

  Further, in the method for manufacturing the surface-cover structure according to one aspect of the present invention, the hole forming step is a process of forming a preliminary hole smaller than the insertion hole in a range where the insertion hole of the exterior member is formed. And a process of forming the support hole in the support member simultaneously using a common tool, a first hole forming step of forming the preliminary hole and the support hole, and a process of expanding the preliminary hole And performing a second hole forming step for forming the insertion hole.

  Further, in the method for manufacturing a flat surface cover structure according to one aspect of the present invention, the processing in the first drilling step and the processing in the second drilling step are cutting by a common end mill.

  Further, in the method for manufacturing a flat cover structure according to one aspect of the present invention, the exterior member is a bumper of an automobile, and the support member supports a headlamp cleaner provided so as to protrude from the insertion hole. The headlamp cleaner has a piston that is provided with an injection nozzle at the tip and moves forward and backward, and the cover body is supported and fixed on the tip side of the piston, and the piston moves forward and backward as the piston moves forward and backward. It is provided so as to move integrally with the piston.

  According to the present invention, the cover structure in which the insertion hole formed in the exterior member of the vehicle is closed by the cover body provided flush with the exterior member, the parting gap around the cover body can be narrowed, The appearance can be improved.

It is a perspective view from the back side which shows the structure of the surface-one cover structure which concerns on one Embodiment of this invention. It is a disassembled perspective view from the surface side which shows the structure of the surface-one cover structure which concerns on one Embodiment of this invention. It is a horizontal sectional view showing the composition of the surface covering structure concerning one embodiment of the present invention. It is a vertical sectional view showing the composition of the surface one cover structure concerning one embodiment of the present invention. It is explanatory drawing about the surface-one cover structure which concerns on one Embodiment of this invention. It is a schematic diagram which shows the structure of the surface cover structure which concerns on one Embodiment of this invention. It is explanatory drawing about the manufacturing method of the surface covering structure which concerns on one Embodiment of this invention. It is a figure which shows the manufacturing process of the surface covering structure which concerns on one Embodiment of this invention. It is explanatory drawing about the manufacturing method of the flush cover structure which concerns on other embodiment of this invention. It is explanatory drawing about the manufacturing method of the comparative example with respect to the surface covering structure which concerns on one Embodiment of this invention.

  The present invention provides a cover body on the inner side of an exterior member as a manufacturing method of a cover structure in which an insertion hole formed in an exterior member of a vehicle such as a bumper is closed by a cover body provided flush with the exterior member. After the bracket that indirectly supports the bracket is fixed to the exterior member in advance, a method of performing a drilling process on the exterior member and the bracket is adopted. Thus, the present invention aims to improve the appearance of the appearance by improving the punching accuracy and narrowing the parting gap around the cover body. Embodiments of the present invention will be described below.

[Structure of flush cover structure]
First, an example of a surface-to-cover structure that is a manufacturing object will be described with reference to FIGS. In this embodiment, a cover structure of a mounting portion of a headlamp cleaner in a bumper that is an exterior member of an automobile will be described as an example of a flush cover structure in an exterior member of a vehicle.

  As shown in FIGS. 1 to 5, a flush cover structure (hereinafter also simply referred to as “cover structure”) 1 according to the present embodiment is provided at a mounting portion of a headlamp cleaner 10 provided in an automobile. In the cover structure 1, an insertion hole (hereinafter referred to as a “bumper insertion hole”) 3 formed in the bumper 2 is indirectly supported by a bracket 4 as a support member provided inside the bumper 2 and is supported by the bumper 2. On the other hand, it is a structure that is closed by the cover body 5 provided flush.

  In the cover structure 1, a headlamp cleaner 10 fixedly supported via a bracket 4 on the inner side (back side) of a bumper 2 located below a headlamp 6 (see FIG. 5) provided in the automobile is provided from the bumper insertion hole 3. It is provided to appear and disappear. The bumper insertion hole 3 for allowing the headlamp cleaner 10 to appear and disappear is closed by a cover body 5 provided flush with the bumper 2. Therefore, since the cover structure 1 is provided below the headlamps 6 included in the automobile in the bumper 2, the cover structure 1 is generally provided at two places on the left and right sides of the automobile.

  The bumper 2 is an exterior part provided below the headlamp 6 at the front of the automobile, and is a resin molded member that is molded by injection molding of a synthetic resin material. The bumper 2 is a plate-like member having a bent shape with the convex side as the front side in an automobile, and has a front surface 2a serving as a design surface (outer surface) in the automobile and a back surface 2b serving as an inner surface.

  The bumper 2 is an upper part of the bumper 2 in the automobile as a part having the above-described bent shape, and is a flat upper slope part 2c that forms a forward slope and a lower part of the upper slope part 2c. And a lower surface portion 2d that is bent with respect to the inclined surface portion 2c. In the automobile, the bumper 2 positions the upper slope portion 2c immediately below the headlamp 6 (see FIG. 5). The bumper 2 is provided with a bumper insertion hole 3 through which the headlamp cleaner 10 is inserted.

  The bumper insertion hole 3 is formed at a predetermined position on the upper slope portion 2 c of the bumper 2. That is, the bumper insertion hole 3 is an opening formed so as to pass through the upper slope portion 2c, which is a plate-like portion, and an inner circumference that is a surface substantially perpendicular to the plate surface of the upper slope portion 2c. It is formed by the side surface 3a. In the present embodiment, the bumper insertion hole 3 has a horizontally long parallelogram shape. A headlamp cleaner 10 provided inside the bumper 2 projects a part thereof through the bumper insertion hole 3.

  The bracket 4 is a member that is provided on the back surface 2 b side of the bumper 2 and supports the headlamp cleaner 10 that is provided so as to protrude from the bumper insertion hole 3 with respect to the bumper 2. The bracket 4 is a resin member molded from a synthetic resin material. The bracket 4 has a substantially rectangular plate shape as a whole and has a bent shape that follows the bent shape of the bumper 2. The bracket 4 is provided in a state of being attached to the back surface 2b of the bumper 2 along the bent shape of the bumper 2 so that the longitudinal direction of the substantially rectangular plate-like outer shape is the left-right direction of the bumper 2.

  The bracket 4 has a horizontally long and substantially rectangular bracket main body 41 that is an upper portion in a state of being attached to the bumper 2 as a portion having the above-described bent shape, and one side (lower side) of the bracket main body 41. And a bent portion 42 provided along the edge portion.

  The bracket main body 41 is a portion having a substantially rectangular plate-like outer shape, and includes a front surface 41a that is a bonding surface with respect to the back surface 2b of the bumper 2, and a rear surface 41b that is a plate surface opposite to the front surface 41a. The bracket main body 41 has a recessed portion 43 that is a recessed portion with respect to the front surface 41a at an intermediate portion in the longitudinal direction. That is, the recessed portion 43 is a convex portion with respect to the rear surface 41 b of the bracket 4.

  The recessed portion 43 has a bottom surface portion 43a and a peripheral wall portion 43b as the concave portion. In this embodiment, the recessed part 43 is formed in the horizontally long substantially parallelogram shape which makes the longitudinal direction of the bracket main-body part 41 a longitudinal direction (refer FIG. 2).

  The bent portion 42 is provided on one side (lower side) of the bracket body 41 having a horizontally long substantially rectangular shape, and as a whole, the horizontally long rectangular shape having a shorter dimension in the shorter direction than the bracket body 41 is provided. It has a plate-like outer shape. The bent portion 42 includes a central projecting piece portion 44 formed in a bent shape in the central portion in the longitudinal direction with respect to the bracket body portion 41, and a plurality of bent piece portions 45 provided to be bent with respect to the bracket body portion 41. And have. In the present embodiment, two bent piece portions 45 are provided on each of the left and right sides of the central projecting piece portion 44 provided at the center portion in the longitudinal direction of the bracket body portion 41.

  Each of the central projecting piece portion 44 and the bent piece portion 45 constituting the bent portion 42 protrudes from the lower edge of the bracket body portion 41 with a slit-like gap 42 s therebetween, and the bracket body portion 41. It is provided in a state of being aligned along the lower edge. That is, a total of five pieces, that is, one central protruding piece 44 and four bent pieces 45, are formed so as to conform to a horizontally elongated, generally rectangular outer shape of the bent portion 42 as a whole, and the gap 42s. It is formed so that it may have a tooth-like form as a division piece part via. The boundary between the bracket body 41 and the bent portion 42, that is, the boundary between the bracket body 41, the central protruding piece 44, and each piece of the bent piece 45, is an upper slope 2 c that forms a bent shape in the bumper 2. And the shape of the boundary between the lower surface portion 2d.

  The central protruding piece 44 and the plurality of (four) bent pieces 45 are substantially rectangular plate-like portions protruding in the direction of bending with respect to the bracket body 41 at the lower edge of the bracket body 41, Only the upper side is connected to the bracket body 41. Further, the bent piece portion 45 is connected to the bracket main body portion 41 through a groove portion 45t along the boundary line between the bracket main body portion 41 and the bent portion. The groove 45t is formed along the upper side of each bent piece 45, and is a portion that partially reduces the plate thickness between the bracket main body 41 and the bent piece 45. The groove 45t is a portion that facilitates bending deformation of the bent piece 45 with respect to the bracket body 41, and the plurality of bent pieces 45 are bent and deformed with respect to the bracket body 41 independently of each other via the groove 45t. It is possible.

  In addition, a projecting piece 46 having a notch 46 a is provided on the upper side of the bracket 4, that is, on the edge of the bracket main body 41 opposite to the side on which the bent portion 42 in the short direction is provided. The projecting piece portion 46 is a portion that slightly protrudes in a horizontally long rectangular shape along the upper side portion of the bracket 4 at the middle portion of the upper side portion of the bracket 4, and the notch portion 46 a is formed at a substantially central position of the upper side portion of the bracket 4. Form. That is, the notch 46a is a groove formed between a pair of projecting pieces provided on the upper side of the bracket 4 with a predetermined gap therebetween. In addition, the projecting piece portion 46 forms a substantially “L” -shaped corner portion 46 b composed of the left and right side portions of the projecting piece portion 46 and the upper side portion of the bracket body portion 41 at the upper side portion of the bracket 4. Will be. That is, the corner portion 46 b becomes a stepped portion due to the protruding shape of the protruding piece portion 46 protruding from the upper side portion of the bracket body portion 41.

  Thus, the notches 46 a and the corners 46 b formed by the projecting pieces 46 are used for positioning the bracket 4 with respect to the bumper 2. Therefore, on the back surface 2b of the bumper 2, the locking protrusions 2e are provided at three positions corresponding to the notch portions 46a and the corner portions 46b of the bracket 4 (see FIG. 1). The three locking projections 2e are disposed at substantially equal intervals in the left-right direction on the back surface 2b of the upper slope 2c of the bumper 2.

  Each locking projection 2e of the bumper 2 is a plate-like small projection portion in which the left-right direction of the bumper 2 is the plate thickness direction. Of the three locking projections 2e, the central locking projection 2e fits into the notch 46a, and the left and right locking projections 2e are positioned at the left and right corners 46b, whereby the bracket 4 is positioned on the bumper 2. The In other words, the projecting piece 46 is positioned between the left and right engaging projections 2e while the center engaging projection 2e is fitted in the notch 46a, whereby the bracket 4 is positioned on the bumper 2. Thus, the back surface 2b of the bumper 2 is formed by the cutout portions 46a and the corner portions 46b formed by the projecting piece portion 46 on the bracket 4 side and the three locking projections 2e provided on the back surface 2b on the bumper 2 side. The bracket 4 attached to the bumper 2 is locked and positioned with respect to the bumper 2.

  The bracket 4 is bonded to the back surface 2b of the bumper 2 by being bonded by a double-sided tape (fixing tape) 47 as an adhesive member. In the present embodiment, the double-sided tape 47 has respective ranges (substantially the entire surface of the front surface 41a around the recessed portion 43 of the bracket main body portion 41 and substantially the entire front surface side of the four bent piece portions 45 (the bracket 4 in FIG. 2). And is interposed between the back surface 2 b of the bumper 2 and the bracket 4.

  As described above, the bracket 4 is positioned by the three locking projections 2e by the notch portions 46a and the corner portions 46b, as well as being attached to the bumper 2 by the double-sided tape 47, and the upper slope portion 2c and the lower surface portion of the bumper 2. The bent shape by the bracket main body 41 and the bent portion 42 is made to correspond to the bent shape by 2d. That is, the bracket 4 has the bracket body 41 opposed to the upper slope 2c of the bumper 2 and the bent portion 42 opposed to the lower face 2d of the bumper 2, and between the bracket body 41 and the upper slope 2c, and A double-sided tape 47 is interposed between each bent piece 45 and the lower surface 2d. Further, in the manner of attaching the bracket 4 to the bumper 2, each bent piece 45 is adhered to the entire surface following the curved shape of the bumper 2 by bending deformation of the bracket main body 41 by the groove 45 t.

  In addition, a part, range, etc. which provide the double-sided tape 47 interposed between the bracket 4 and the bumper 2 are not limited to this embodiment. Further, in the present embodiment, regarding the fixing of the bracket 4 to the bumper 2, the adhesive fixing by the double-sided tape 47 is adopted, but this is only an example, and the configuration and method for fixing the bracket 4 to the bumper 2 are as follows. There is no particular limitation. For fixing the bracket 4 to the bumper 2, for example, an adhesive, a fixing member such as a bolt, or fitting by a predetermined fitting shape portion may be used.

  In the bracket 4 attached and fixed to the back surface 2 b of the bumper 2 as described above, an insertion hole (hereinafter referred to as “bracket insertion hole”) 8 through which the headlamp cleaner 10 is inserted is provided in the same manner as the bumper insertion hole 3. Is provided.

  The bracket insertion hole 8 is provided in the central portion of the bottom surface portion 43 a of the recessed portion 43 provided in the bracket main body portion 41 in the bracket 4. That is, the bracket insertion hole 8 is an opening formed so as to penetrate the bottom surface portion 43a which is a plate-shaped portion, and the inner peripheral side surface 8a which is a surface substantially perpendicular to the plate surface of the bottom surface portion 43a. It is formed by. In the present embodiment, the bracket insertion hole 8 has a substantially cross-shaped hole shape in which a rectangular recess is formed in the middle part of the long side of the horizontally long rectangular hole. A headlamp cleaner 10 provided inside the bumper 2 projects a part thereof through the bracket insertion hole 8.

  In this way, the bottom surface portion 43a of the recessed portion 43 provided with the bracket insertion hole 8 is formed so that the recessed portion 43 is opposed to the upper inclined surface portion 2c opposed to the bracket body portion 41 in a state where the bracket 4 is fixed to the bumper 2. It will be spaced apart from the inside (back side) of the bumper 2 by the depth. That is, the upper slope portion 2c of the bumper 2 in which the bumper insertion hole 3 is formed and the bottom surface portion 43a of the bracket 4 in which the bracket insertion hole 8 is formed have a dimension corresponding to the depth of the recess 43 between each other. The plate surface portions are substantially parallel to each other with a space of 2 to form a two-layer structure.

  The bumper insertion hole 3 and the bracket insertion hole 8 are holes for projecting a part of the headlamp cleaner 10 provided inside the bumper 2 as described above, and ensure a projecting path of the headlamp cleaner 10. For this reason, the bumper insertion hole 3 and the bracket insertion hole 8 are provided so as to overlap each other in the direction in which the upper inclined surface portion 2c of the bumper 2 and the bottom surface portion 43a of the bracket 4 face each other.

  In the present embodiment, the recessed portion 43 in which the bracket insertion hole 8 is formed in the bottom surface portion 43 a is provided so as to include the projection range of the opening range of the bumper insertion hole 3 with respect to the bracket 4. In other words, the bumper insertion hole 3 is formed within the projection range of the bottom surface portion 43a with respect to the upper slope portion 2c of the bumper 2. Further, the bumper insertion hole 3 is formed so as to include the entire projection range or substantially the entire projection range with respect to the upper slope 2c of the opening range of the bracket insertion hole 8. In other words, the bracket insertion hole 8 is formed so that the entire bracket insertion hole 8 or substantially the whole is within the projection range of the bumper insertion hole 3 with respect to the bottom surface portion 43a.

  Next, the headlamp cleaner 10 will be described. The headlamp cleaner 10 is an actuator provided with an injection nozzle 15 provided at the tip thereof and having a piston 14 that moves forward and backward, and is provided so that a portion of the piston 14 protrudes from and into the bumper 2 through the bumper insertion hole 3. The headlamp 6 is washed with the piston 14 and the injection nozzle 15 protruding from the bumper 2 to the outside. The headlamp cleaner 10 includes a cleaner device main body 11 including a piston 14 and an injection nozzle 15, and an attachment portion 12 provided at the tip of the cleaner device main body 11 for attaching the cleaner device main body 11 to the bracket 4. 4 is configured as a unit (assembly) that is integrally attached to the unit 4.

  The cleaner device body 11 includes a substantially cylindrical cylinder 13 and a piston 14 that is coaxially housed in the cylinder 13. The piston 14 is a substantially columnar member, and is provided so as to be able to protrude from one side of the cylinder 13 in the cylinder axis direction with respect to the cylinder 13. That is, the cleaner apparatus main body 11 is configured to expand and contract by the protruding and retracting operation (advancing / retracting operation) of the piston 14 from the cylinder 13.

  An injection nozzle 15 for injecting cleaning water (cleaning liquid) is provided at the tip of the piston 14 on the protruding side. The cleaner device main body 11 according to the present embodiment has a pair of left and right injection nozzles 15 (see FIG. 3). A cover body 5 that closes the bumper insertion hole 3 is provided on the tip end side of the injection nozzle 15 of the piston 14.

  A connecting portion 13a to which a hose 16 for supplying cleaning water is connected is provided at the rear end portion of the cylinder 13, that is, the end portion opposite to the side from which the piston 14 protrudes. The hose 16 is connected to a cleaning water tank (not shown), and the cleaning water in the cleaning water tank is supplied to the cleaner device main body 11 through the hose 16, passes through the water passage in the cleaner device main body 11, and is an injection nozzle. 15 is injected. That is, in the cleaner apparatus main body 11, a water passage that communicates from the connection portion 13 a of the cylinder 13 to the injection port of the injection nozzle 15 is provided. Such a water passage includes a water passage hole formed in the axial center portion of the piston 14.

  The piston 14 is provided so as to protrude from the front end side of the cylinder 13 due to the supply pressure of the cleaning water supplied from the hose 16 into the cylinder 13. A return spring (not shown) for biasing the piston 14 to a stored state with respect to the cylinder 13 is housed inside the cylinder 13 in a state of being fitted on the piston 14. In the cylinder 13, a check valve (not shown) for opening and closing the flush water passage is provided at the rear end of the piston 14.

  The cleaner device main body 11 having such a configuration is attached to the bracket 4 by an attachment portion 12 provided on the distal end side of the cleaner device main body 11. The attachment portion 12 includes a locking member 17 having a substantially box shape with one side open, and a clamp member 18 for fixing the locking member 17 to the cleaner device main body 11.

  The locking member 17 is attached to the distal end side of the cylinder 13 with the cleaner device main body 11 penetrating so that the distal end side of the cleaner device main body 11 faces the open side. The clamp member 18 is a plate spring-like member, and is provided on the opposite side to the opening side of the locking member 17, and comes into contact with a predetermined shape portion on the cleaner device main body 11 side, so that the locking member is caused by elastic force. 17 is fixedly supported on the cleaner apparatus main body 11.

  The locking member 17 has a pair of locking claws 17a provided on surfaces facing each other on the open side. The locking claw 17 a is a shape portion for locking the mounting portion 12 to the bracket 4. The locking claw 17 a is locked to the edge of the bracket insertion hole 8. That is, the headlamp cleaner 10 is supported and fixed to a portion of the bracket 4 where the bracket insertion hole 8 is formed by the locking action of the locking claw 17a of the mounting portion 12 provided on the distal end side of the cleaner device body 11. The

  The cover body 5 is supported and fixed to the distal end side of the piston 14 that moves forward and backward in the cleaner device main body 11, and is provided so as to move integrally with the piston 14 as the piston 14 moves forward and backward. The cover body 5 is a member that is provided so as to cover the injection nozzle 15 from the tip end side of the piston 14 and functions as a nozzle cover, and covers the bumper insertion hole 3 entirely corresponding to the shape and dimensions of the bumper insertion hole 3. It is configured as a closing member. The cover body 5 is substantially flush with the surface 2a which is the design surface of the bumper 2 in a state where the bumper insertion hole 3 is closed.

  The cover body 5 includes a cover main body portion 51 that is a lid portion that covers the entire bumper insertion hole 3 and a support portion 52 that is supported and fixed to the piston 14 of the cleaner device main body 11.

  The cover main body 51 is a plate-like portion having substantially the same shape and size as the bumper insertion hole 3 and having substantially the same thickness as that of the upper slope portion 2 c of the bumper 2. It is a portion that fits into the hole 3 and is substantially flush with the upper slope 2 c of the bumper 2. Therefore, the cover main body 51 includes a surface 51a as a design surface which is one plate surface and substantially flush with the surface 2a of the bumper 2, a back surface 51b which is a plate surface opposite to the surface 51a, and a surface 51a. And an outer peripheral side surface 51c between the rear surface 51b. A support portion 52 is provided on the back surface 51 b side of the cover main body portion 51.

  The support part 52 has a plurality of plate-like projecting piece parts 52a, and an insertion space in which the tip part 14a of the piston 14 is inserted into the center part of the back surface 51b of the cover main body part 51 by these projecting piece parts 52a. 53 is formed. The distal end portion 14 a is a portion that protrudes toward the distal end side from the pair of injection nozzles 15 provided at the distal end portion of the piston 14. By inserting the front end portion 14 a of the piston 14 into the insertion space 53 of the support portion 52, the injection nozzle 15 is covered by the cover main body portion 51 from the front end side of the piston 14.

  In a state where the tip portion 14 a of the piston 14 is inserted into the insertion space 53, the piston 14 and the support portion 52 are engaged with each other by the predetermined engaging portions provided in the support portion 52 and the piston 14. Thus, the piston 14 is fixedly supported by the support portion 52. In this way, the cover body 5 is supported and fixed to the tip portion of the headlamp cleaner 10.

  Thus, the cover body 5 is indirectly supported with respect to the bracket 4 via the head lamp cleaner 10. In other words, the cylinder 13 portion of the headlamp cleaner 10 is supported and fixed to the bottom surface portion 43 a of the bracket 4 by the mounting portion 12 provided at the distal end portion of the cleaner apparatus body 11, and the distal end of the piston 14 that moves forward and backward with respect to the cylinder 13. The cover body 5 is supported and fixed to the part. In other words, the mounting portion 12 constituting the headlamp cleaner 10 and the cylinder 13 side portion of the cleaner apparatus main body 11 are fixed to the bumper 2 side (vehicle side) via the bracket 4, and the fixed portion with respect to the bumper 2 side is fixed. A piston 14 provided with a cover body 5 at the tip thereof is provided so as to advance and retreat with respect to the included cylinder 13.

  Further, the mounting portion 12 constituting the headlamp cleaner 10 is locked and supported with respect to the bracket insertion hole 8 of the bracket 4 by the locking member 17. Therefore, the cover body 5 provided at the tip of the piston 14 in the headlamp cleaner 10 is indirectly supported with respect to the bracket insertion hole 8 via the mounting portion 12, the cylinder 13 of the cleaner device body 11, the piston 14, and the like. The Thus, the bracket insertion hole 8 of the bracket 4 serves as a support hole for indirectly supporting the cover body 5 to the bracket 4.

  In the above-described configuration, the piston 14 and the injection nozzle 15 are housed inside the bumper 2 during normal operation, that is, when the headlamp cleaner 10 is not in operation, and the bumper insertion hole 3 is closed by the cover body 5. It is.

  When the headlamp cleaner 10 is operated, that is, when the headlamp 6 is cleaned, the piston 14 moves forward against the urging force of the return spring built in the cylinder 13 by the water pressure of the cleaning water supplied to the cylinder 13. Operates, advances from the cylinder 13 and protrudes from the bumper insertion hole 3, and the injection nozzle 15 at the tip of the piston 14 moves to a predetermined injection position on the outer front side of the bumper 2 (see FIG. 5). Here, as the piston 14 protrudes from the bumper insertion hole 3, the cover body 5 provided at the tip of the piston 14 moves to the outside of the bumper 2 together with the injection nozzle 15 from the state where the bumper insertion hole 3 is closed. The bumper insertion hole 3 with the piston 14 protruding is opened.

  In the course of the forward movement of the piston 14, when the piston 14 reaches a predetermined position, the check valve on the proximal end side of the piston 14 is opened, and the cleaning water supplied into the cylinder 13 passes through the water passage through the passage of the piston 14. It is pumped toward the front end side and is ejected from the ejection port of the ejection nozzle 15 at a predetermined ejection position toward the surface 21a of the headlamp lens 21 as the front cover constituting the headlamp 6 (FIG. 5, reference numeral X1). reference). In the headlamp 6, a lamp chamber is formed by the headlamp lens 21 and a concave housing member 22 provided with the open side facing the headlamp lens 21, and a reflector, a bulb, and a lens are formed in the lamp chamber. Etc. are arranged.

  When the supply of the cleaning water to the cylinder 13 is stopped, the check valve in the cylinder 13 is closed and the injection of the cleaning water from the injection nozzle 15 is stopped. Along with this, the piston 14 moves backward by the urging force of the return spring in the cylinder 13 and is pulled into the cylinder 13. As described above, when the operation of the headlamp cleaner 10 is completed, the piston 14 is retracted from the bumper insertion hole 3 to the inside of the bumper 2 by the retreating operation, and the piston 14 and the injection nozzle 15 are immersed inside the bumper 2. Accordingly, the cover body 5 is accommodated in the bumper insertion hole 3, and the bumper insertion hole 3 is closed by the cover body portion 51 of the cover body 5 that is substantially flush with the bumper 2.

  In a state where the bumper insertion hole 3 is closed by the cover body 5, the surface 51 a of the cover body 5 is substantially flush with the surface 2 a of the upper slope portion 2 c of the bumper 2. In the present embodiment, the cover main body 51 slightly protrudes outward with respect to the bumper 2. That is, the surface 51a of the cover main body 51 is positioned slightly outside (for example, about a few millimeters) with respect to the surface 2a of the upper slope 2c of the bumper 2. Such a relationship between the cover body 5 and the bumper 2 is based on the viewpoint of avoiding that the outer edge portion formed at the edge portion of the bumper insertion hole 3 is positioned on the outermost side in the cover structure 1. As described above, as the flush cover structure according to the present invention, the surface 51a of the cover body 5 slightly protrudes from the surface 2a of the bumper 2 as in the cover structure 1 of the present embodiment, and these surfaces are substantially the same. A flush structure is also included.

  In the above-described flush cover structure, as shown in FIG. 6, the bumper insertion hole 3 and the cover body 5 that covers the bumper insertion hole 3 flush with the bumper 2, that is, the inside of the bumper insertion hole 3. As a clearance (see reference numeral S1) between the peripheral side surface 3a and the outer peripheral side surface 51c of the cover body 5, there is a parting gap 60. The parting gap 60 appears as a black line on the appearance of the automobile and affects the appearance. In particular, since the mounting portion of the headlamp cleaner 10 exists at a position that is relatively easily noticeable in an automobile, the effect of the parting gap 60 in the cover structure 1 on the appearance is relatively large.

  Therefore, in the manufacturing method of the cover structure 1 according to the present embodiment, the bracket 4 that indirectly supports the cover body 5 inside the bumper 2 is fixed to the bumper 2 in advance so as to narrow the parting gap 60. A method of drilling the bumper 2 and the bracket 4 is adopted. Hereinafter, the manufacturing method of the cover structure of this embodiment is demonstrated.

[Method for manufacturing flush cover structure]
(First embodiment)
1st Embodiment of the manufacturing method of the cover structure of this embodiment is described using FIG. 7 and FIG.

  As shown in FIG. 7A, in the method for manufacturing the cover structure of the present embodiment, first, there is a coating process for coating the bumper 2 as a molded product molded by injection molding of a synthetic resin material. Done. In this coating process, the paint is sprayed onto the surface 2a of the bumper 2 by a predetermined coating device 71, and the bumper 2 is painted.

  Next, a step of fixing the bracket 4 at a predetermined position inside the bumper 2 (hereinafter referred to as “bracket fixing step”) is performed. That is, as shown in FIG. 7B, a step of attaching the bracket 4 to a predetermined position of the bumper 2 by the double-sided tape 47 is performed.

  In the bracket fixing step, the double-sided tape 47 is a predetermined part of the bracket 4, and in this embodiment, a part of the bracket main body part 41 and each bent piece part 45 on the front side of the bracket 4 (see the hatched part of the bracket 4 in FIG. 2). Affixed in advance. Then, the bracket 4 to which the double-sided tape 47 is attached positions the three locking projections 2e provided on the back surface 2b at the central notch 46a and the left and right corners 46b with respect to the bumper 2, The protrusions 46 are positioned by engaging the locking protrusions 2 e at the three locations, and are fixed to the back surface 2 b of the bumper 2 by being attached.

  In a state where the bracket 4 is attached and fixed to the bumper 2, the bracket 4 is bent by the bracket main body 41 and the bent portion 42 and by bending deformation of the bracket main body 41 by the groove 45 t of each bent piece 45. Following the bent shape and curved surface shape of the upper slope portion 2c and the lower surface portion 2d of the bumper 2, the entire surface is bonded. In a state where the bracket 4 is fixed to the bumper 2, the bracket body 41 faces the upper slope 2 c of the bumper 2 via the double-sided tape 47, and the bent portion 42 faces the lower surface 2 d of the bumper 2 via the double-sided tape 47. It will be in the opposite state. Then, at the opposing portion of the bracket main body 41 and the upper slope 2c of the bumper 2, the bumper 2 has a positioning accuracy of the bracket 4 with respect to the bumper 2 by the locking projection 2e and the notch 46a and the corner 46b. The portion of the bracket 4 where the bracket insertion hole 8 is formed is positioned with respect to the portion where the insertion hole 3 is formed.

  In the bracket fixing step, there are no particular limitations on the part, range, etc., where the double-sided tape 47 interposed between the bracket 4 and the bumper 2 is provided. Further, the double-sided tape 47 may be attached in advance to a predetermined portion on the back surface 2b of the bumper 2 instead of the bracket 4 side. The method of fixing the bracket 4 to the bumper 2 is not limited to the method using a double-sided tape. For example, as described above, an adhesive, a fixing member such as a bolt, and fitting with predetermined fitting shape portions, etc. The method using may be used. However, from the viewpoint of simplifying the manufacturing process and obtaining the necessary and sufficient fixing strength for fixing the bracket 4 to the bumper 2, a method using the double-sided tape 47 as in the present embodiment is preferable.

  Subsequently, a drilling process is performed in which the bumper insertion hole 3 is formed in the bumper 2 and the bracket 4 is formed in the bracket 4. In the present embodiment, the opening of the bumper insertion hole 3 and the bracket insertion hole 8 is performed by cutting with a general-purpose end mill processing machine including the end mill 72.

  In the drilling process of the present embodiment, a first hole drilling process is performed in which a preliminary hole that finally becomes the bumper insertion hole 3 is formed in the bumper 2 and a process of forming the bracket insertion hole 8 in the bracket 4 is performed. A two-stage drilling process is performed by a second drilling process in which a preliminary hole formed in the bumper 2 is processed simultaneously with the bracket insertion hole 8 so as to form the bumper insertion hole 3.

  That is, in the present embodiment, the first hole forming step includes a process of forming a preliminary hole 3X smaller than the bumper insertion hole 3 within a range in which the bumper insertion hole 3 of the bumper 2 is formed, and a bracket insertion hole in the bracket 4 This is a step of forming the preliminary hole 3X and the bracket insertion hole 8 by simultaneously performing the process of forming 8 with a common tool. The second hole forming step is a step of forming the bumper insertion hole 3 by performing a process of expanding the preliminary hole 3X formed in the bumper 2. Specifically, the drilling process of the present embodiment including the first drilling process and the second drilling process is performed as follows.

  First, in the drilling process in the drilling process, the bumper 2 to which the bracket 4 is fixed is set on a predetermined jig as a workpiece to be processed in a general-purpose end mill processing machine.

  Then, as shown in FIG. 7 (c), in the first drilling step, bumpers which are two layers of plate surface portions substantially parallel to each other with a distance corresponding to the depth of the recess 43 between each other. An end mill 72 having a direction substantially perpendicular to the plate surface of these plate surface portions as a rotation axis direction acts on the upper slope portion 2c of 2 and the bottom surface portion 43a of the bracket 4, and the preliminary hole 3X and the bracket insertion hole 8 ( The inner peripheral side surface 8a) is simultaneously formed by simultaneous cutting (first cutting). The preliminary hole 3X is an opening formed so as to penetrate the upper slope portion 2c, which is a plate-like portion, and is an inner peripheral side surface that is a surface substantially perpendicular to the plate surface of the upper slope portion 2c. It is formed by 3Xa.

  In the first drilling step, the common hole moves at a predetermined feed speed while rotating at a predetermined rotation speed along a predetermined movement path (see broken line arrow A1) for forming the preliminary hole 3X and the bracket insertion hole 8. The cutting by the end mill 72 is performed simultaneously on the bumper 2 and the bracket 4 which are resin parts, so that the preliminary hole 3X and the bracket insertion hole 8 are simultaneously formed. Therefore, the end mill 72 acts simultaneously on at least the upper inclined surface portion 2c of the bumper 2 and the bottom surface portion 43a of the bracket 4 spaced from each other by a distance corresponding to the depth of the recessed portion 43 so as to make a hole. It has a length that can be cut.

  In the first drilling process in which the end mill 72 performs simultaneous machining on the bumper 2 and the bracket 4 as described above, the cutting shapes of the bumper 2 and the bracket 4 are common to each other. That is, the shape and size of the cutting range for the bumper 2 and the bracket 4 in the first drilling step are common to each other, and the preliminary hole 3X and the bracket insertion hole 8 are formed as holes having the same or substantially the same shape and size. The In the present embodiment, the preliminary hole 3X and the bracket insertion hole 8 are formed as substantially horizontally long rectangular holes (see FIG. 8A).

  Next, a second drilling step is performed. As shown in FIG. 7D, in the second drilling step, the end mill 72 performs a cutting process (second cutting process) only on the bumper 2 to form the bumper insertion hole 3. That is, in the second drilling step, the shaft moves at a predetermined feed speed while rotating at a predetermined rotation speed along a predetermined movement path (see the broken line arrow A2) for forming the bumper insertion hole 3 from the preliminary hole 3X. By performing the cutting process by the end mill 72 only on the bumper 2, the outer edge portion of the preliminary hole 3 </ b> X is cut off, and the preliminary hole 3 </ b> X is expanded to form the bumper insertion hole 3.

  By performing the second hole forming step, the bumper insertion hole 3 larger than the bracket insertion hole 8 of the bracket 4 by one or more times is formed in the bumper 2. In the present embodiment, the bumper insertion hole 3 is formed as a horizontally long, substantially parallelogram-shaped hole (see FIG. 8B). By forming the bumper insertion hole 3 by the second drilling process, the processing of the drilling process is completed.

  As described above, in the drilling process of the present embodiment, the machining in the first drilling process and the machining in the second drilling process are performed as cutting by the common end mill 72. That is, in the drilling process in which the first drilling process and the second drilling process are performed, in the drilling process, the bumper 2 to which the bracket 4 is attached is set as a workpiece in a predetermined jig, Cutting for forming the preliminary hole 3X and the bracket insertion hole 8 (first cutting process) by the end mill 72 provided in the end mill processing machine, and cutting for forming the bumper insertion hole 3 by expanding the preliminary hole 3X ( The second cutting process) is sequentially performed as a two-stage cutting process.

  The cover structure 1 according to the present embodiment is provided at the left and right two locations in the bumper 2 corresponding to the left and right headlamps 6 included in the automobile as described above. The perforating process) is performed simultaneously or one by one in a predetermined order. When performed at the same time, the general-purpose end mill processing machine is provided with two right and left end mills 72 corresponding to each cover structure 1, and the drilling process (drilling process) for the left and right cover structures 1 is performed at the same timing. It will be.

  Regarding the cutting conditions such as the rotational speed and feed rate of the end mill 72 in the drilling process, cutting conditions appropriately set for the first drilling process and the second drilling process in the general-purpose end mill machine are used. . For example, the bumper insertion hole 3 formed in the second hole forming step is a hole that forms the parting gap 60 together with the cover body 5 and appears in the appearance. For this reason, in order to improve the finish of the cutting surface (inner peripheral side surface 3a) of the bumper insertion hole 3, the rotational speed of the end mill 72 in the second drilling process is higher than the rotational speed of the end mill 72 in the first drilling process. The feed speed of the end mill 72 in the second drilling process is set to be lower than the feed speed of the end mill 72 in the first drilling process.

  According to the cover structure manufacturing method of the present embodiment as described above, the cover structure 1 in which the bumper insertion hole 3 formed in the bumper 2 is closed by the cover body 5 provided flush with the bumper 2, The parting gap 60 around the cover body 5 can be narrowed, the appearance of the appearance can be improved, and high versatility can be obtained. Such an effect is demonstrated concretely.

  First, according to the manufacturing method of the cover structure of the present embodiment, the positioning accuracy of the bracket 4 with respect to the bumper 2 is determined so that the positioning accuracy in the bumper insertion hole 3 of the cover body 5 is the size of the parting gap 60. There is no direct impact. This means that the positioning accuracy of the bracket insertion hole 8 that indirectly supports the cover body 5 via the headlamp cleaner 10 with respect to the bumper insertion hole 3 does not depend on the positioning accuracy of the bracket 4 with respect to the bumper 2. Based.

  That is, according to the manufacturing method of the cover structure of the present embodiment, after the bracket 4 is fixed to the bumper 2 in advance, the bumper insertion hole 3 and the bracket insertion hole are inserted into the integrated structure of the bumper 2 and the bracket 4. Since the drilling process for forming the hole 8 is performed, the accuracy of the positional relationship between the bumper insertion hole 3 and the bracket insertion hole 8 that affects the size of the parting gap 60 is substantially the bumper insertion hole by the end mill 72. 3 and the machining accuracy of the bracket insertion hole 8 only.

  Therefore, since the variation in the position of the bracket insertion hole 8 with respect to the bumper insertion hole 3 can be reduced, the positioning of the cover body 5 supported by the bracket insertion hole 8 via the headlamp cleaner 10 with respect to the bumper insertion hole 3 can be performed. The accuracy can be improved and the parting gap 60 can be reduced. As a result, the appearance of the cover structure 1 can be improved.

  In addition, according to the manufacturing method of the cover structure of this embodiment, the positioning accuracy of the bracket 4 with respect to the bumper 2 does not directly affect the size of the parting gap 60 as described above. Regarding positioning with respect to the bumper 2, it is possible to cope with the accuracy of the relative positional relationship of the bracket insertion hole 8 with respect to the bumper insertion hole 3 by positioning with a relatively coarse accuracy. For this reason, the burden for ensuring the positioning accuracy of the bracket 4 with respect to the bumper 2 is reduced, and the efficiency and time of the process for fixing the bracket 4 to the bumper 2 can be reduced.

  Moreover, according to the manufacturing method of the cover structure of this embodiment, in the bumper 2 and the bracket 4, the positioning accuracy of the bracket 4 with respect to the bumper 2, that is, the bracket insertion hole 8 with respect to the bumper insertion hole 3, in order to reduce the parting gap 60. There is no need to provide a shape portion for improving positioning accuracy. For this reason, the shape of the bracket 4 can be simplified. Here, an example of a cover structure using a predetermined positioning shape portion provided on the bracket and a bumper insertion hole for positioning the bracket with respect to the bumper and an example of a method for manufacturing the cover structure are as follows. A comparative example will be described with reference to FIG.

  In the cover structure of this comparative example, as shown in FIG. 10 (d), a rib portion 148 is provided on the bracket 104 as a shape portion for positioning with respect to the bumper 102. The rib portion 148 is a cylindrical or protruding piece portion provided so as to protrude from the front surface 141a of the bracket main body portion 141 to the side opposite to the recessed portion 143 where the bracket insertion hole 108 is formed, that is, the bumper 102 side. It is.

  The rib portion 148 is inserted into the bumper insertion hole 103 when the bracket 104 is fixed to the bumper 102, and is used for positioning the bracket 104 with respect to the bumper 102. That is, the outer surface 148 a of the rib portion 148 comes into contact with or faces the inner peripheral side surface 103 a of the bumper insertion hole 103, and the bracket 104 is positioned with respect to the bumper 102.

  A method for manufacturing the cover structure of the comparative example will be described with reference to FIG. As shown in FIG. 10A, in the method for manufacturing the cover structure of the comparative example, as described above, first, the surface 102a of the bumper 102 as a molded product molded by injection molding of a synthetic resin material or the like is used. The painting process of painting is performed.

  Next, a punching process is performed in which the bumper insertion hole 103 is formed in the bumper 102. Here, as shown in FIG. 10 (b), for example, by a cutting process using an end mill processing machine including an end mill 172 or a punching process using a punch 173 and a die (not shown), A bumper insertion hole 103 is formed.

  Subsequently, as shown in FIG. 10C, a step of fixing the bracket 104 at a predetermined position inside the bumper 102 is performed. Here, a bracket insertion hole 108 is formed in advance in the bracket 104 fixed to the bumper 102 by cutting with an end mill machine or punching with a punch or a die. In the step of fixing the bracket 104 to the bumper 102, the rib portion 148 of the bracket 104 is used, the bracket 104 is positioned with respect to the bumper 102 by the bumper insertion hole 103, and the bracket 104 is bumped by the double-sided tape 147. Affixed to 102 and fixed. Thereby, as shown in FIG.10 (d), the cover structure of a comparative example is manufactured.

  As described above, in the cover structure of the comparative example and the manufacturing method thereof, the rib portion 148 of the bracket 104 is applied to the inner peripheral side surface 103a of the bumper insertion hole 103 formed in the bumper 102 in advance by the end mill 172 or the punch 173. The bracket 104 is positioned with respect to the bumper 102. Since the bumper insertion hole 103 and the bracket insertion hole 108 are formed in advance in the bumper 102 and the bracket 104, which are fixed to each other, the positioning accuracy of the bracket 104 with respect to the bumper 102 is determined by the bumper insertion hole 103 and the bracket 104. This directly affects the accuracy of the positional relationship of the insertion hole 108.

  According to the cover structure of the comparative example and the manufacturing method thereof, the space for the positioning rib portion 148 in the parting gap 160 in the parting gap 160 (see S <b> 2) around the cover body 105 in the bumper insertion hole 103. The parting gap 160 is widened as much as it is necessary to ensure. Further, with respect to the positioning accuracy of the bracket 104 with respect to the bumper 102, since the molding error of both the bumper insertion hole 103 and the rib portion 148 is effective, the backlash between the bumper 102 and the bracket 104 increases. This causes the parting gap 160 to be widened.

  In contrast to the cover structure and its manufacturing method of the comparative example as described above, according to the cover structure and its manufacturing method according to the present embodiment, as described above, after the bracket 4 is fixed to the bumper 2 in advance, the bumper 2 Since the bumper insertion hole 3 and the bracket insertion hole 8 are simultaneously processed for the bracket 4 and the bracket 4, the variation in the position of the bracket insertion hole 8 with respect to the bumper insertion hole 3 can be reduced. The gap 60 (see FIG. 6) can be reduced. Further, according to the cover structure and the manufacturing method thereof according to the present embodiment, there is no positioning shape portion such as the rib portion 148 in the comparative example between the cover body 5 and the bumper insertion hole 3. It is not necessary to secure that much space, and from this, the parting gap 60 can be reduced.

  In relation to the above-described comparative example, according to the cover structure and the manufacturing method thereof according to the present embodiment, the size of the parting gap can be reduced to about half. Specifically, while the parting gap in the case of the comparative example is about 1.3 mm, according to the cover structure and the manufacturing method thereof according to the present embodiment, the parting gap can be about 0.7 mm. .

  In addition, as in the method for manufacturing the cover structure of the comparative example described above, as a process for forming the bumper insertion hole 103, a punching die is generally used. In this case, the bumper insertion hole 103 is formed by a punch die in the post-processing of the molding process for the bumper 102 formed by injection molding of a synthetic resin material or the like. However, punching with a punch or die is relatively advantageous in terms of machining accuracy and mass productivity, but it requires a dedicated facility for each vehicle type and type of parts, so it is not very versatile. Capital investment is required and the equipment becomes large, making it difficult to secure the installation space for the equipment.

  In this regard, in the method for manufacturing the cover structure according to the present embodiment, when the bumper insertion hole 3 and the bracket insertion hole 8 are formed, the two-layer structure is simultaneously processed by the upper slope portion 2c of the bumper 2 and the bottom surface portion 43a of the bracket 4. Is what you do. For this reason, punching with a punch die as in the comparative example described above is substantially difficult, and as a process for forming the bumper insertion hole 3 and the bracket insertion hole 8, cutting with an end mill machine is required. Preferably employed.

  As processing for forming the bumper insertion hole 3 and the bracket insertion hole 8, it is possible to use a general-purpose processing machine of existing equipment by adopting cutting with an end mill processing machine, so new capital investment, new equipment It is not necessary to secure space, and the production method can be easily introduced. Moreover, since a general-purpose processing machine can be used as the end mill processing machine, it can be applied to a plurality of vehicle types and parts types, and high versatility can be obtained.

  As described above, according to the method for manufacturing the cover structure according to the present embodiment, it is possible to improve the drilling accuracy of the bumper insertion hole 3 and the bracket insertion hole 8 while obtaining high versatility. The appearance appearance can be improved by narrowing the parting gap 60.

  In particular, in the manufacturing method of the cover structure according to the present embodiment, the drilling process includes a first drilling process in which the bumper 2 and the bracket 4 are simultaneously processed to form the preliminary hole 3X and the bracket insertion hole 8, A second hole forming step of processing the bumper 2 in order to form the bumper insertion hole 3. Therefore, the bumper insertion hole 3 is formed by a two-stage process including a process for forming the preliminary hole 3X in the first drilling process and a process for forming the final bumper insertion hole 3 in the second drilling process. Yes.

  According to such a processing method, the preliminary hole 3X which is later widened to become the bumper insertion hole 3 and the bracket insertion hole 8 which functions to support the headlamp cleaner 10 without appearing in the appearance are cut. The surface, that is, the finish of the inner peripheral side surfaces 3Xa and 8a of each hole is allowed to be relatively rough. For this reason, about the cutting conditions of the preliminary hole 3X and the bracket insertion hole 8 that are simultaneously formed in the first drilling step, the rotational speed of the end mill 72 is relatively slowed or the feed speed of the end mill 72 is fastened. Can do.

  In particular, with regard to the cutting process in the first drilling step, the load acting on the end mill 72 during machining is the simultaneous machining of the two-step plate-like parts of the upper slope part 2c of the bumper 2 and the bottom face part 43a of the bracket 4. However, it is larger than the processing (second cutting processing) for the one-stage plate-like portion. For this reason, if it is going to obtain the high finish like the hole which appears in the external appearance about the cutting surface of the preliminary hole 3X and the bracket insertion hole 8 which are formed by simultaneous processing, it will take time for drilling by cutting. Become. Therefore, the ability to increase the feed speed of the end mill 72 in the first drilling step works advantageously in the sense of shortening the machining time.

  On the other hand, the finished surface of the bumper insertion hole 3 that appears in the appearance, that is, the inner peripheral side surface 3a, requires a certain degree of accuracy in appearance. For this reason, as for the cutting conditions of the bumper insertion hole 3 formed in the second drilling step, it is necessary to relatively increase the rotational speed of the end mill 72 or to decrease the feed speed of the end mill 72. Further, the cutting process in the second drilling step is a process for the one-stage plate-like part of the upper slope part 2c of the bumper 2, and is a process for the part where the preliminary hole 3X is formed in advance. Sometimes, the load acting on the end mill 72 is small compared to the processing for the plate-like portion in which the two-step and preliminary holes are not formed as in the first cutting processing. For this reason, about the inner peripheral side surface 3a of the bumper insertion hole 3, it can be set as a beautiful finish comparatively easily.

  As described above, according to the method for manufacturing the cover structure according to the present embodiment, it is possible to realize cutting with high efficiency and finish as required. That is, it is possible to achieve both the work efficiency of the drilling process and the appearance.

  Further, in the method for manufacturing the cover structure according to the present embodiment, the first cutting process in the first drilling step for forming the preliminary hole 3X and the bracket insertion hole 8, and the preliminary hole 3X are widened so that the bumper insertion hole 3 is formed. The second cutting process in the second drilling step for forming is performed as a cutting process by a common end mill 72. For this reason, since the process for forming the bumper insertion hole 3 and the bracket insertion hole 8 can be performed as a coaxial cutting process, the machining axes of both holes are not displaced at all, and high drilling accuracy is obtained. Therefore, the parting gap 60 can be effectively reduced.

(Second Embodiment)
A second embodiment of the method for manufacturing the cover structure of the present embodiment will be described with reference to FIG. In addition, about the part which is common in 1st Embodiment, a common code | symbol is used.

  In the manufacturing method of the present embodiment, when forming the bumper insertion hole 3, the preliminary hole 3X is not formed, but only the bumper 2 is first processed to form the bumper insertion hole 3, and then only the bracket 4 is formed. The bracket insertion hole 8 is formed by processing the above. That is, in the drilling process of this embodiment, the bumper drilling process for forming the bumper insertion hole 3 in the bumper 2 and the bracket drilling process for processing to form the bracket insertion hole 8 in the bracket 4 are performed. Staged drilling is performed.

  As shown in FIG. 9A, in the method for manufacturing the cover structure of the present embodiment, as in the case of the first embodiment, first, a bumper as a molded product formed by injection molding of a synthetic resin material or the like. 2 is performed by a predetermined coating apparatus 71.

  Next, a step of fixing the bracket 4 at a predetermined position inside the bumper 2 (bracket fixing step) is performed. That is, as shown in FIG. 9B, as in the case of the first embodiment, a step of attaching the bracket 4 to a predetermined position of the bumper 2 is performed by the double-sided tape 47.

  Subsequently, a process of forming a bumper insertion hole 3 in the bumper 2 and a process of forming a bracket insertion hole 8 in the bracket 4 are sequentially performed. In the present embodiment, the bumper insertion hole 3 and the bracket insertion hole 8 are formed by cutting with a general-purpose end mill processing machine including an end mill 72. The end mill 72 is supported by, for example, a robot arm or the like in a general-purpose end mill processing machine.

  In the drilling process of the present embodiment, two-stage drilling is performed by the bumper drilling process for forming the bumper insertion hole 3 and the bracket drilling process for forming the bracket insertion hole 8 as described above. Specifically, the drilling process of the present embodiment including the bumper drilling process and the bracket drilling process is performed as follows.

  First, in the drilling process in the drilling process, the bumper 2 to which the bracket 4 is fixed is set on a predetermined jig as a workpiece to be processed in a general-purpose end mill processing machine.

  Then, as shown in FIG. 9C, in the bumper drilling step, the end mill 72 cuts only the bumper 2 to form the bumper insertion hole 3 (inner peripheral side surface 3a). In the bumper drilling step, cutting is performed by an end mill 72 that moves at a predetermined feed speed while rotating at a predetermined rotation speed along a predetermined movement path (see broken line arrow B1) for forming the bumper insertion hole 3. The bumper insertion hole 3 is formed by applying to a predetermined portion of the upper slope 2c of the bumper 2.

  Next, a bracket hole forming step is performed. As shown in FIG. 9 (d), in the bracket hole drilling step, the end mill 72 cuts only the bracket 4 to form the bracket insertion hole 8 (inner peripheral side surface 8a). In the bracket hole forming step, a predetermined feed is performed while rotating the shaft at a predetermined rotation speed along a predetermined movement path (see the broken line arrow B2) for forming the bracket insertion hole 8 in a state of passing through the bumper insertion hole 3. The bracket insertion hole 8 is formed by cutting the end mill 72 that moves at a speed on a predetermined portion of the bottom surface portion 43a of the bracket 4.

  By forming the bracket insertion hole 8 by the bracket hole forming process, the processing of the hole forming process is completed. Also in the drilling process of this embodiment, the machining in the bumper drilling process and the machining in the bracket drilling process are performed as cutting by a common end mill 72. Thereby, as above-mentioned, the bumper penetration hole 3 and the bracket penetration hole 8 can be formed by coaxial cutting, and a drilling precision can be improved.

  Regarding the cutting conditions such as the rotational speed and feed rate of the end mill 72 in the drilling process, cutting conditions appropriately set for the bumper drilling process and the bracket drilling process in the general-purpose end mill machine are used. For example, since the bumper insertion hole 3 appears in the appearance, the rotational speed of the end mill 72 in the bumper drilling process is set in the bracket drilling process to improve the finish of the cutting surface (inner peripheral side surface 3a) of the bumper insertion hole 3. The rotational speed of the end mill 72 is set higher than the rotational speed of the end mill 72, and the feed speed of the end mill 72 in the bumper drilling process is set slower than the feed speed of the end mill 72 in the bracket drilling process.

  Like the manufacturing method of the cover structure of the second embodiment described above, only the bumper 2 is first processed to form the bumper insertion hole 3, and then only the bracket 4 is processed to form the bracket insertion hole. 8 can also be formed.

  The cover structure manufacturing method according to the embodiment of the present invention described above is an application example to the cover structure of the mounting portion of the headlamp cleaner in the bumper that is an exterior member of an automobile. In the manufacturing method, the insertion hole formed in the exterior member of the vehicle is indirectly supported by the support member provided inside the exterior member and is covered with the cover body provided flush with the exterior member. Any structure can be applied. As another application example, a cover structure of an arrangement portion of a sensor for detecting an obstacle in a bumper of an automobile can be cited. That is, the manufacturing method of the cover structure according to the present invention is attached to the inside of an exterior part such as a bumper via a support member such as a bracket, such as a headlamp cleaner or a sensor, and the insertion hole and surface of the exterior part. There is a possibility of application in a mounting portion of a device or the like that supports the cover body that becomes one.

  Moreover, the manufacturing method of the cover structure which concerns on this invention is not limited to the manufacturing method which concerns on embodiment mentioned above, A various aspect is employable in the range along the meaning of this invention. For example, the drilling target is not limited to the resin component such as the bumper 2 but may be a metal component or the like. Further, the processing method for forming the bumper insertion hole 3, the bracket insertion hole 8, and the preliminary hole 3X is not limited to the cutting process by the end mill processing machine, but may be a drilling process using a laser. However, the object to be processed in the drilling process according to the present invention is a two-layer structure of the exterior part and the support member, and the drilled parts exist at different height positions, so from the viewpoint of work efficiency and versatility. It can be said that cutting with an end mill machine is preferable. Moreover, it can be said that the cutting by an end mill processing machine is preferable from the viewpoint of maintaining the coating even in the case where a part to be coated in advance in the drilling process is a processing target like the bumper 2 of the above-described embodiment.

1 Cover structure (flat cover structure)
2 Bumper (exterior parts)
3 Bumper insertion hole 3X Spare hole 4 Bracket (support member)
5 Cover body 6 Headlamp 8 Bracket insertion hole (support hole)
DESCRIPTION OF SYMBOLS 10 Head lamp cleaner 11 Cleaner apparatus main body 12 Mounting part 13 Cylinder 14 Piston 15 Injection nozzle 47 Double-sided tape 72 End mill

Claims (4)

A surface-to-surface cover in which an insertion hole formed in an exterior member of a vehicle is indirectly supported by a support member provided inside the exterior member and is closed by a cover body provided flush with the exterior member A structure manufacturing method comprising:
Fixing the support member at a predetermined position inside the exterior member;
After the fixing step, a process of forming the insertion hole in the exterior member and a hole forming process of performing a process of forming a support hole for indirectly supporting the cover body in the support member are provided. ,
The drilling step includes
A process of forming a preliminary hole smaller than the insertion hole within a range where the insertion hole of the exterior member is formed and a process of forming the support hole in the support member are simultaneously performed by a common tool. And a first hole forming step for forming the preliminary hole and the support hole,
A method of manufacturing a flush cover structure, comprising: a second hole forming step of forming the insertion hole by performing a process of expanding the preliminary hole . The method for manufacturing a surface-to-surface cover structure according to claim 1 , wherein the processing in the first drilling step and the processing in the second drilling step are cutting by a common end mill. A surface-to-surface cover in which an insertion hole formed in an exterior member of a vehicle is indirectly supported by a support member provided inside the exterior member and is closed by a cover body provided flush with the exterior member A structure manufacturing method comprising:
Fixing the support member at a predetermined position inside the exterior member;
After said fixed to step, the processing and forming the through hole in the outer member, before Symbol drilling performed separately and processed to form a support hole for indirectly supporting the cover body on the support member step And a method for producing a flush-cover structure. The exterior member is an automobile bumper,
The support member is a bracket that supports a headlamp cleaner provided so as to protrude from the insertion hole.
The headlamp cleaner has a piston that is provided with an injection nozzle at the tip and moves back and forth,
The said cover body is supported and fixed to the front end side of the said piston, and it is provided so that it may move integrally with the said piston with the advance-and-retreat operation | movement of the said piston. 2. A method for producing a flush cover structure according to item 1.

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