JP6477761B2 - Method for manufacturing vehicle panel structure - Google Patents

Description

  The present invention relates to a method for manufacturing a vehicle panel structure, and more particularly to a method for manufacturing a vehicle panel structure in which a pair of base panels are coupled via a viscoelastic body.

  Conventionally, panel members constituting a wide surface of a vehicle body such as a roof panel and a floor panel spanned between vehicle body frames have been used. In such a panel member, vibration in a low frequency band (for example, 20 to 50 Hz) is propagated in a direction parallel to the panel surface due to vehicle body deformation caused by vibration transmitted from the road surface when the vehicle is traveling, The indoor comfort, the so-called riding comfort of the vehicle is impaired. If the rigidity of the panel member is increased in order to attenuate the vibration generated in the panel member, the riding comfort of the vehicle can be improved, but there is a possibility that the weight of the vehicle body and the production cost increase.

  In addition, viscoelastic bodies such as rubber are known to have vibration damping performance because they exhibit behavior such as creep deformation and stress relaxation. Creep deformation is viscoelastic deformation for a constant force, and stress relaxation phenomenon is a phenomenon that attempts to return to an equilibrium state when it deviates from a mechanical equilibrium state by a predetermined factor. When the viscoelastic body is stretched with vibration, the entropy of the viscoelastic body decreases, so that the viscoelastic body changes in the contraction direction to increase the reduced entropy. The amount of heat corresponding to the amount of entropy reduction due to this extension is released to the outside, and as a result, the viscoelastic body moves so as to return to the initial state.

  Based on the above, various proposals using the characteristics of this viscoelastic body have been made for the purpose of improving the vibration damping performance while avoiding an increase in the weight of the vehicle body. For example, the carbon fiber reinforced plastic molded body of Patent Document 1 has a viscosity separated in a plane parallel direction between a first CFRP (Carbon Fiber Reinforced Plastics) layer, a second CFRP layer, and first and second CFRP layers. A pair of damping elastic layers made of an elastic body and a high-rigidity resin region sandwiched between the pair of damping elastic layers between the first and second CFRP layers. Damping performance is secured by the damping elastic layer, and bending rigidity in the longitudinal direction of the first and second CFRP layers is secured by the high-rigidity resin region.

JP 2011-183562 A

  The carbon fiber reinforced plastic molded body of Patent Document 1 converts part of vibration energy into thermal energy by deforming a viscoelastic body (damping elastic layer) following the vibration of the base panel (CFRP layer). The vibration control performance is improved by reducing the vibration energy of the base panel. Here, in order to further improve the function, it is conceivable that a foam such as urethane is joined to the base panel and a viscoelastic body is joined to the foam. By adopting such a configuration, it is possible to expect an improvement in sound insulation in addition to weight reduction and vibration damping.

  However, as a result of investigation by the present inventor, in a panel member in which a foam is joined to a pair of base panels and a plurality of viscoelastic bodies are sandwiched between the pair of foams, vibration damping as expected It has been found that there is a possibility that the performance cannot be exhibited. Specifically, when forming this panel member, there is a possibility that the foams may come into contact with each other at a portion where the viscoelastic body is not disposed. In this case, the relative displacement in the direction parallel to the panel surfaces of the pair of foams is limited, and the viscoelastic body cannot be distorted and cannot exhibit vibration damping performance.

  The objective of this invention is providing the manufacturing method of the panel structure for vehicles which can improve vibration damping performance, aiming at weight reduction.

  According to a first aspect of the present invention, there is provided a method of manufacturing a vehicle panel structure in which a pair of base panels are formed to face each other, and a filling material portion is formed on each of the opposing inner surfaces of the pair of base panels. A material part forming step and a member arranging step of arranging the pair of base panels in the mold so that the filler parts face each other, and arranging a viscoelastic body and an adhesion preventing material between the filler parts And a joining step of joining the pair of base panels via the viscoelastic body by heating and joining the filler portions of the pair of base panels to the viscoelastic body. It is characterized by.

  With the above-described configuration, it is possible to form a vehicle panel structure having vibration damping performance by restricting the joining of a pair of opposing filler portions with an adhesion preventing material.

  According to a second aspect of the present invention, there is provided a method for manufacturing a vehicle panel structure in which a pair of base panels are formed so as to be opposed to each other, and the pair of base panels are spaced apart from each other in a mold. A member setting step in which a panel-like member in which a viscoelastic body and an adhesion preventing material are integrated between a pair of base panels is spaced from the pair of base panels, and the pair of base panels A filler material in a molten state is filled between the panel-shaped members to form filler portions joined to the pair of base panels, and the filler portions of the pair of base panels are It has a base panel coupling | bonding process which couple | bonds said one pair of base panels via the said viscoelastic body by joining to a viscoelastic body.

  With the above-described configuration, it is possible to form a vehicle panel structure having vibration damping performance by restricting the joining of a pair of opposing filler portions with an adhesion preventing material.

  According to a third aspect of the present invention, in the first aspect of the present invention, the filler portion is formed by a filler intermediate before completion of foaming or an unfoamed filler in the filler portion forming step, and the filler is formed in the bonding step. It is characterized by foaming the part.

  By the said structure, the process of foaming a filler part and the coupling | bonding process can be performed simultaneously, and a process can be simplified.

  According to a fourth aspect of the present invention, in any one of the first to third aspects of the present invention, after the joining step or the base panel joining step, the filler portions of the pair of base panels can be easily parallel to the panel surface. The anti-adhesive material processing step of processing the anti-adhesive material so that it can be displaced is provided.

  With the above configuration, the filler material of the pair of base panels can be easily displaced in the direction parallel to the panel surface, and the vibration damping performance can be exhibited by utilizing the strain deformation of the viscoelastic body.

  According to a fifth aspect of the present invention, in the fourth aspect of the invention, in the anti-adhesive material processing step, the anti-adhesive material is melted at a processing temperature higher than a bonding temperature in the bonding step or the base panel bonding step. It is a feature.

  With the above configuration, after the bonding of the pair of opposing filler portions is regulated by the adhesion preventing material, the adhesion preventing material can be removed by melting and easily displaceable in a direction parallel to the panel surface. The vibration damping performance can be exhibited by utilizing the strain deformation of the viscoelastic body.

  The invention of claim 6 is the invention of claim 5, further comprising a panel molding step after the coupling step or the base panel coupling step and before the adhesion preventing material treatment step, and the molding temperature of the panel molding step is The temperature is higher than the bonding temperature in the bonding step or the base panel bonding step and lower than the processing temperature in the adhesion preventing material processing step.

  With the above configuration, the vehicle panel structure can be easily molded.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the panel structure for vehicles which can improve vibration damping performance can be provided, aiming at weight reduction.

It is a principal part perspective view of the vehicle which applied the panel structure for vehicles formed with the manufacturing method of the panel structure for vehicles of this invention to the roof panel. It is a top view of a roof panel. It is the III-III sectional view taken on the line of FIG. It is sectional drawing of a base panel. FIG. 5 is a cross-sectional view of a base panel in which a filler part is formed in the base panel of FIG. 4 by a filler part forming step. It is sectional drawing which shows a member arrangement | positioning process and a coupling | bonding process. It is sectional drawing of the flat panel member with which a pair of base panel, the filler part, and the viscoelastic body couple | bonded. It is sectional drawing which shows a shaping | molding process. It is sectional drawing which shows an adhesion prevention material processing process. It is sectional drawing which shows the panel-shaped member with which the viscoelastic body and the adhesion preventing material were integrated. It is sectional drawing which shows a base panel joint process.

  Hereinafter, modes for carrying out the present invention will be described based on examples.

First, the overall configuration of the vehicle 1 will be described.
As shown in FIG. 1, the vehicle 1 is provided with a pair of left and right front pillars 2 positioned on both left and right sides of the front windshield, and a lower part of the pair of front pillars 2 is a hinge pillar ( (Not shown). The roof side rails 3 extending rearward are connected to the upper ends of the pair of front pillars 2, respectively. Although not shown, a front header is constructed between the front end portions of the pair of roof side rails 3, and a rear header is constructed between the rear end portions.

  A region surrounded by the pair of roof side rails 3, the front header, and the rear header is covered with a roof panel 4 disposed so as to extend in the front-rear and left-right directions in the upper part of the vehicle body. As shown in FIGS. 2 and 3, the roof panel 4 is formed in a substantially rectangular shape in a plan view, and is formed in a gently curved shape in which a front part and a rear part are located below the intermediate part in a side view. ing. FIG. 3 shows an enlarged vertical scale.

Next, the roof panel 4 will be described.
As shown in FIGS. 1 to 3, the roof panel 4 includes a first base panel 10 and a second base panel 20 (a pair of base panels) opposed to each other in a spaced manner, and a first base panel 10 and a second base panel. A viscoelastic body between the first filler portion 12 and the second filler portion 22 (a pair of filler portions), and between the first filler portion 12 and the second filler portion 22 on the opposing inner surfaces of the panel 20. 31-34. The first and second filler parts 12 and 22 are joined via the viscoelastic bodies 31 to 34, and the first and second filler parts 12 and 22 are joined to the first and second base panels 10 and 20, respectively. Thus, the roof panel 4 is formed.

  The first and second base panels 10 and 20 are made of carbon fiber reinforced thermoplastic resin (thermoplastic CFRP) in which carbon fibers arranged to extend in the front-rear direction and carbon fibers arranged to extend in the left-right direction are used as reinforcing materials. ) It has excellent rigidity composed of materials. Moreover, the 1st, 2nd base panels 10 and 20 can also be comprised with the fiber reinforced thermoplastic resin material which mix | blended the thermoplastic resin base material with the short fiber as a reinforcing material. As the reinforcing material, glass fiber, aramid fiber, cellulose nanofiber, or the like can be used. Moreover, the 1st, 2nd base panels 10 and 20 can also be comprised with metal materials, such as an aluminum alloy.

  The first filler portion 12 is provided on the lower surface (inner surface) of the first base panel 10, and the second filler portion 22 is provided on the upper surface (inner surface) of the second base panel 20. The first and second filler portions 12 and 22 are made of a material having lower rigidity than the first and second base panels 10 and 20, for example, foams such as polypropylene, polyurethane, and polyester.

  As shown in FIG. 2, the viscoelastic bodies 31 to 34 are formed in the same substantially rectangular shape in plan view, and are a virtual front-rear direction line X and a vehicle width direction line Y that pass through the center P of the roof panel 4. Are arranged a predetermined distance apart in the front-rear direction and the left-right direction so as to be line-symmetric with respect to each other.

  As shown in FIG. 3, the viscoelastic bodies 31 and 34 are each formed in a panel shape so as to have substantially the same thickness as the thickness (for example, 1 to 2 mm) of the first and second filler parts 12 and 22. ing. Although not shown, the same applies to the viscoelastic bodies 32 and 33. The upper surfaces of these viscoelastic bodies 31 to 34 are bonded to the lower surface (inner surface) of the first filler portion 12, and the lower surfaces are bonded to the upper surface (inner surface) of the second filler portion 22. The viscoelastic bodies 31 to 34 are made of, for example, a rubber material such as styrene / butadiene rubber, chloroprene rubber, butyl rubber, nitrile rubber, or ethylene propylene rubber. Moreover, it may replace with the said rubber material and may use a polyester resin vinyl ester resin, a polyurethane resin, and another elastomer resin.

Next, the manufacturing method of the panel structure for vehicles of this invention is demonstrated along the manufacturing process of the roof panel 4. FIG. In addition, sectional drawing used for description has expanded and shown the thickness direction scale.
A flat plate-like first base panel 10 shown in FIG. 4 is prepared. As shown in FIG. 5, the first filler portion 12 is formed on the surface of the first base panel 10 which is the inner surface of the roof panel 4 in the filler portion forming step. Specifically, the panel-like first filler portion 12 formed of a foam is joined to the first base panel 10. Similarly, the second filler portion 22 is formed on the surface that becomes the inner surface of the roof panel 4 of the second base panel 20 of the same size.

  Next, in the member arranging step, as shown in FIG. 6, a positioning mold 36 is mounted on, for example, a work pallet 35, and the second base panel 20 with the second filler portion 22 facing upward is attached to the work pallet 35. Placed on. The first base panel 10 is positioned by the mold 36 and the adhesion preventing material 37 and the viscoelastic bodies 31 to 34 are arranged, and the outer edge of the first base panel 10 is aligned with the outer edge of the second base panel 20 thereon. Place. At this time, the first base panel 10 is disposed so that the first and second filler portions 12 and 22 face each other with the first filler portion 12 facing down.

  Next, in the joining step, the arranged member is heated to a joining temperature (for example, 100 ° C. to 120 ° C.) by a heating means such as a heater 38, and the first filler portion 12 is replaced with the upper surface portion of the viscoelastic bodies 31 to 34. And the second filler portion 22 is joined to the lower surface portions of the viscoelastic bodies 31 to 34. In this way, the flat panel member 40 shown in FIG. 7 in which the first base panel 10 and the second base panel 20 are joined is formed. In this bonding step, pressure may be applied so as to compress in the direction perpendicular to the panel surface.

  Next, in the molding step, as shown in FIG. 8, a flat panel member 40 is placed in a molding die formed by the molds 42 and 43, and a molding temperature higher than the joining temperature (for example, 130 ° C. to 150 ° C.). C.) to form a gentle curve by applying pressure while heating. At this time, the first and second filler parts 12 and 22, the viscoelastic bodies 31 to 34 and the adhesion preventing material 37 are disposed between the first and second base panels 10 and 20. The panel member 40 can be molded along the shape of the molds 42 and 43. Further, the adhesion preventing material 37 prevents the first filler portion 12 and the second filler portion 22 from being joined.

  Next, in the adhesion prevention material processing step, as shown in FIG. 9, the adhesion prevention material 37 is heated to a processing temperature (for example, 160 ° C. to 250 ° C.) of the adhesion prevention material 37 higher than the molding temperature to melt the heat and heat the outside. To discharge. Thereby, a space is formed between the first filler part 12 and the second filler part 22, and the relative displacement in the direction parallel to the panel surface of the first filler part 12 and the second filler part 22 is easily performed. Become. Therefore, distortion deformation of the viscoelastic bodies 31 to 34 is facilitated. The adhesion preventing material 37 may be removable by pulverizing by impact or the like or dissolving with a solvent or the like, and does not prevent displacement in the direction parallel to the surfaces of the first and second filler portions 12 and 22. In some cases, it may not be removed. Examples of the adhesion preventing material 37 include pulverizable paraffin, synthetic wax that melts with heat, and the like, and a processing method is appropriately selected according to the adhesion preventing material 37.

  Next, the molds 42 and 43 are cooled and removed to obtain the roof panel 4 having the vehicle panel structure shown in FIG. The thickness and temperature are only examples, and are not limited thereto.

A method for manufacturing the vehicle panel structure of the present invention, which is different from the first embodiment, will be described along the manufacturing process of the roof panel 4. Since the members constituting the roof panel 4 and the structure of the obtained roof panel 4 are the same as those in the first embodiment, the same reference numerals are given and description thereof is omitted.
The flat plate-like first and second base panels 10 and 20 shown in FIG. 4 are prepared. Moreover, as shown in FIG. 10, the panel-shaped member 39 which prepared the viscoelastic bodies 31-34 and integrated with the panel-shaped adhesion prevention material 37 is prepared. For example, the panel-like member 39 is formed by fitting the viscoelastic bodies 31 to 34 into openings corresponding to the viscoelastic bodies 31 to 34 that penetrate the panel-like adhesion preventing material 37 in the thickness direction. The thickness of the adhesion preventing material 37 is equal to the thickness of the viscoelastic bodies 31 to 34.

  Next, in the member setting step, as shown in FIG. 11, the first and second base panels 10 and 20 are spaced apart from each other in the injection mold 44, and the panel-like member 39 is placed between them. The first base panel 10 and the second base panel 20 are spaced apart from each other by a predetermined distance. The mold 44 is provided with passages 45 and 46 for introducing the filling material 13.

  Next, in the base panel coupling step, the molten filling material 13 is filled from the passages 45 and 46 between the first and second base panels 10 and 20 and the panel-like member 39. The filling material 13 contains a foaming agent and is filled while foaming, and the filled foam is cooled and cured to form the first and second filler parts 12 and 22 shown in FIG. The foaming agent foams at the time of filling, and the first and second filler parts 12 and 22 are formed of a foam that has been completely foamed.

  When the foam comes into contact with the first and second base panels 10 and 20 or the viscoelastic bodies 31 to 34 and is cooled and hardened, the first and second base panels 10 and 20 or the viscoelastic bodies 31 to 31 are in contact with each other. 34. The mold 44 is maintained at a bonding temperature (for example, 100 ° C. to 120 ° C.) at which the foam can be cured. After completion of filling, the plate 44 is cooled and the mold 44 is removed to obtain the flat panel member 40 of FIG. Thereafter, the roof panel 4 shown in FIG. 3 is formed through the same molding process and adhesion preventing material treatment process as in the first embodiment.

Next, functions and effects of the present invention will be described.
In the vehicle panel structure manufacturing method according to the first embodiment, the first and second filler portions 12 and 22 are formed on the first and second base panels 10 and 20 in the filler portion forming step, respectively. The first and second base panels 10 and 20 are arranged so that the first and second filler portions 12 and 22 face each other through the viscoelastic bodies 31 to 34 and the adhesion preventing material 37, and the bonding temperature is set in the bonding step. The first and second filler parts 12 and 22 are joined to the viscoelastic bodies 31 to 34 by heating. In the portion where the viscoelastic bodies 31 to 34 are not disposed, the bonding between the first filler portion 12 and the second filler portion 22 is also regulated by the adhesion preventing material 37. Therefore, a vehicle panel structure having vibration damping performance can be formed.

  In the method for manufacturing a vehicle panel structure according to the second embodiment, in the member setting step, the first is separated from the panel-like member 39 in which the viscoelastic bodies 31 to 34 and the adhesion preventing material 37 are integrated in the mold 44. The second base panels 10 and 20 are arranged to face each other, and in the base panel coupling step, the first and second filler parts 12 and 22 are formed by filling the filler 13 in a molten state. The first filler part 12 is joined to the first base panel 10 and the viscoelastic bodies 31 to 34, and the second filler part 22 is joined to the second base panel 20 and the viscoelastic bodies 31 to 34. In the portion where the viscoelastic bodies 31 to 34 are not disposed, the bonding between the first filler portion 12 and the second filler portion 22 is regulated by the adhesion preventing material 37. Therefore, a vehicle panel structure having vibration damping performance can be formed.

  In the adhesion preventing material processing step after the joining step or the base panel joining step, the adhesion preventing material 37 is arranged so that the first and second filler portions 12 and 22 can be easily displaced in a direction parallel to the panel surface. Since it processes, vibration damping performance can be exhibited using the distortion deformation of the viscoelastic bodies 31-34.

  In the adhesion preventing material processing step, the adhesion preventing material 37 is melted at a temperature higher than the bonding temperature in the bonding step or the base panel bonding step, so that the bonding of the first and second filler parts 12 and 22 is performed by the adhesion preventing material 37. After the regulation, the adhesion preventing material 37 is melted and discharged, so that it can be easily displaced in the direction parallel to the panel surface, and the vibration damping performance utilizing the strain deformation of the viscoelastic bodies 31 to 34. Can be demonstrated.

Next, an example in which the above embodiment is partially changed will be described.
[1] In the filler part forming step of the first embodiment, the first and second filler parts 12 and 22 are formed on the first and second base panels 10 and 20 by an unfoamed filler or a filler intermediate before foaming is completed. And the foaming of the first and second filler parts 12 and 22 may be completed in the joining step. The foaming of the filler portion and the heating for joining can be performed simultaneously, the process can be simplified and the formation of the vehicle panel structure can be facilitated. Further, the thickness of the adhesion preventing material 37 is made smaller than that of the viscoelastic bodies 31 to 34, and part of the side surfaces of the viscoelastic bodies 31 to 34 are joined to the first and second filler parts 12 and 22, respectively. You may make it regulate the slip between 31-34 and the 1st, 2nd filler parts 12 and 22. FIG.

[2] In the first embodiment, when the position of the member is difficult to be generated because the vehicle panel structure has a small curvature after molding, the member arranging step, the joining step, and the panel in the molding dies 42 and 43 are performed. The molding process and the adhesion preventing material treatment process may be continuously performed. The process can be simplified to facilitate the formation of the vehicle panel structure.
[3] In the member setting step of the second embodiment, a protruding or columnar spacer member protruding from the adhesion preventing material 37 of the panel-like member 39 and contacting the first base panel 10 or the second base panel 20 may be provided. . The space | interval with the 1st, 2nd base panel 10 and 20 can be maintained, and the dispersion | variation in the thickness of the 1st, 2nd filler material parts 12 and 22 can be suppressed.

[4] The formed vehicle panel structure can be applied to a floor panel, a side panel, etc. in addition to the roof panel, and a vehicle having rigidity and vibration absorption performance can be configured.
[5] In addition, those skilled in the art can implement the present invention by adding various modifications without departing from the spirit of the present invention, and the present invention includes such modifications. It is.

4 Roof panel 10 1st base panel 12 1st filler part 13 Filling material 20 2nd base panel 22 2nd filler part 31-34 Viscoelastic body 36 Mold 37 Adhesion prevention material 38 Heater 39 Panel-like member 40 Panel member 42-44 mold

Claims (6)

In a method for manufacturing a vehicle panel structure in which a pair of base panels are coupled in an opposing manner,
A filler part forming step of forming filler parts on the mutually opposing inner surfaces of the pair of base panels;
A member disposing step of disposing the pair of base panels in the mold so that the filler portions face each other, and disposing a viscoelastic body and an adhesion preventing material between the filler portions,
And a joining step of joining the pair of base panels via the viscoelastic body by heating and joining the filler portions of the pair of base panels to the viscoelastic body. A method for manufacturing a vehicle panel structure. In a method for manufacturing a vehicle panel structure in which a pair of base panels are coupled in an opposing manner,
The pair of base panels are spaced apart from each other in a mold, and a panel-like member in which a viscoelastic body and an adhesion preventing material are integrated between the pair of base panels is a pair of base panels. A member setting step for disposing each at an interval,
A filler material in a molten state is filled between the pair of base panels and the panel-like member to form filler portions joined to the pair of base panels, respectively, and each of the pair of base panels A method for manufacturing a panel structure for a vehicle, comprising: a base panel joining step for joining the pair of base panels via the viscoelastic body by joining the filler portion to the viscoelastic body.   The said filler part is formed in the said filler part formation process by the filler intermediate body before foaming completion or an unfoamed filler, and the said filler part is foamed in the said coupling | bonding process. Manufacturing method for a vehicle panel structure.   An anti-adhesive treatment for treating the anti-adhesive material so that the filler portions of the pair of base panels can be easily displaced in a direction parallel to the panel surface after the joining step or the base panel joining step. The manufacturing method of the panel structure for vehicles of any one of Claims 1-3 provided with the process.   5. The vehicle panel structure according to claim 4, wherein, in the adhesion preventing material treatment step, the adhesion prevention material is melted at a treatment temperature higher than a joining temperature in the joining step or the base panel joining step. Production method.   A panel molding step is provided after the bonding step or the base panel bonding step and before the adhesion preventing material treatment step, and the molding temperature of the panel molding step is higher than the bonding temperature of the bonding step or the base panel bonding step. 6. The method for manufacturing a vehicle panel structure according to claim 5, wherein the temperature is lower than the processing temperature in the adhesion preventing material processing step.