JP7372200B2 - Vehicle side door sash, vehicle side door, method for manufacturing a vehicle side door sash, and method for manufacturing a vehicle side door - Google Patents

Description

The present invention relates to a sash portion of a side door for a vehicle that constitutes a side portion of a vehicle body of a vehicle such as an automobile, a method for manufacturing a side door for a vehicle, a sash portion for a side door for a vehicle, and a method for manufacturing a side door for a vehicle.

2. Description of the Related Art Vehicles such as automobiles have a vehicle side door that forms a side part of the vehicle body. A vehicle side door includes a door main body portion and a sash portion, and a window glass is fitted into the sash portion. That is, the sash portion functions as a frame for supporting the window glass.

When a vehicle such as an automobile is running, the sash portion may be drawn outward in the width direction of the vehicle due to negative pressure acting on the window glass, causing the sash portion to be slightly bent and deformed. In this case, there is a problem in that a gap is formed between the vehicle side door and the vehicle body, and this gap generates wind noise.

To solve this problem, it is possible to increase the bending rigidity of the sash part by increasing the thickness of the sash inner or sash outer that constitutes the sash part, or by setting a reinforcing material inside the sash part. It is being said.

For example, Patent Document 1 describes the following vehicle door frame structure. That is, the vehicle door frame structure described in Patent Document 1 includes a door inner panel and a frame reinforcement joined to the door inner panel. The frame reinforcement includes a frame side sash section, a hinge reinforcement section whose upper end is joined to the front lower end of the frame side sash section, and a lock reinforcement whose upper end is joined to the rear lower end of the frame side sash section. including. The hinge reinforcement part and the lock reinforcement part have a thickness greater than the thickness of the frame side sash part.

Japanese Patent Application Publication No. 2016-144979

The vehicle door frame structure described in Patent Document 1 has a problem in that the frame reinforcement that constitutes the sash portion has a partially large thickness, which increases the weight of the vehicle side door and increases the weight of the vehicle. There is.

Further, by providing the reinforcing material inside the sash portion, the weight of the vehicle increases. On the other hand, since the reinforcing material is arranged at a position close to the neutral axis of the hollow cross-sectional structure with a necessary gap, there is a problem that it is not very effective in improving bending rigidity.

An object of the present invention is to manufacture a vehicle side door sash portion that can have high bending rigidity without significantly increasing vehicle weight, a vehicle side door equipped with the same, and a vehicle side door sash portion. An object of the present invention is to provide a method and a method for manufacturing a side door for a vehicle.

As a means for solving the above problems, the present inventors came up with the idea of forming both the door body part and the sash part, which constitute a vehicle side door, from aluminum. This makes it possible to reduce the weight of the vehicle side door. In addition, in this specification, "aluminum" includes an aluminum alloy, and is a metal material whose main component is aluminum.

However, if the sash portion is made of only aluminum, the bending rigidity required for the sash portion cannot be achieved because aluminum has a small Young's modulus.

Therefore, the present inventors came up with the idea of forming at least a part of the sash part from a cladding material having a laminated structure composed of aluminum and a metal material having a Young's modulus larger than that of aluminum.

Specifically, it is as follows.

The sash portion of the invented vehicle side door includes a sash inner, and the sash inner is disposed on the outer side in the vehicle width direction than the sash inner, and the sash inner is arranged to form a hollow cross section surrounding an interior space between the sash inner and the sash inner. a sash outer joined to the sash outer, at least one of the sash inner and the sash outer is formed of a clad material having a laminated structure in which a plurality of metal layers each made of a metal material are laminated, and the plurality of The metal layer includes a first metal layer made of aluminum, and a second metal layer made of a metal material having a larger Young's modulus than the aluminum, and the second metal layer has a lower part of the interior than the first metal layer. It is placed inside the laminated structure on the side closer to the space.

According to the sash portion of the vehicle side door, since at least one of the sash inner and the sash outer is formed of the clad material, the weight of the sash portion can be reduced.

Furthermore, according to the sash portion of the vehicle side door, since the cladding material includes the second metal layer made of a metal material having a larger Young's modulus than the aluminum, compared to the sash portion made only of aluminum, The bending rigidity of the sash portion can be improved.

Furthermore, according to the sash portion of the vehicle side door, since the second metal layer is disposed on the inside of the laminated structure on the side closer to the interior space than the first metal layer, the sash portion made of aluminum Compared to a case where a reinforcing material made of the same metal material as the metal material of the second metal layer is arranged at a position close to the neutral axis of the hollow cross section with a necessary gap, the moment of inertia of the sash part is reduced. As a result, the bending rigidity of the sash portion can be improved.

In a preferred embodiment of the sash portion of the vehicle side door, the sash inner has an outer surface that is a surface facing away from the interior space, and the material forming the outer surface of the sash inner is aluminum. There may be.

According to the sash portion according to this aspect, in a vehicle side door including a door body portion made of aluminum and the sash portion, the door inner panel made of aluminum of the door body portion and the outer surface of the sash inner However, when they are joined, since the door inner panel and the outer surface of the sash inner are made of the same metal material, aluminum, there is no difference between them. The occurrence of contact corrosion between different metals is suppressed. In addition, in this specification, "the same kind of metal material" shall mean "a metal material with the same main component."

In a preferred embodiment of the sash portion of the vehicle side door, the sash inner may be formed of the clad material, and the first metal layer may form the outer surface of the sash inner.

According to the sash portion according to this aspect, the bending rigidity of the sash inner to be joined to the door main body portion is improved, so that the bending rigidity of the entire vehicle side door is improved. Furthermore, since the first metal layer made of aluminum forms the outer surface of the sash inner, when the door inner panel made of aluminum and the outer surface of the sash inner are joined, there is no difference between them. The occurrence of contact corrosion between different metals is suppressed.

In a preferred embodiment of the sash portion of the vehicle side door, the sash inner has a sash inner joint surface that is an inner surface that is a surface closer to the interior space and is joined to the sash outer; The sash outer has a sash outer joint surface that is an inner surface that is a surface closer to the internal space and is joined to the sash inner joint surface, and the material forming the sash inner joint surface and the sash outer The materials forming the joint surfaces may be the same type of metal material.

According to the sash portion according to this aspect, since the material forming the sash inner joint surface and the material forming the sash outer joint surface are the same kind of metal material, the sash inner joint surface to be joined to each other and the material forming the sash outer joint surface are the same metal materials. The occurrence of contact corrosion of dissimilar metals with the sash outer joint surface is suppressed.

In a preferred embodiment of the sash portion of the vehicle side door, each of the sash inner and the sash outer may be formed of the clad material.

According to the sash portion according to this aspect, not only one but both of the sash inner and the sash outer are formed of the clad material, thereby realizing weight reduction of the sash portion more effectively. However, bending rigidity can be improved.

In a preferred embodiment of the sash portion of the vehicle side door, the sash inner has an outer surface that is a surface facing away from the interior space, and an outermost sash inner that is a metal layer disposed on the outermost side of the laminated structure. and a sash innermost metal layer which is a metal layer disposed at the innermost side of the laminated structure and has an inner surface that is a surface closer to the inner space, and the sash outer The sash outermost metal layer has an inner surface that is a surface closer to the space and is a metal layer disposed at the innermost side of the laminated structure, and the sash inner outermost metal layer is the first metal layer. The material forming the sash innermost metal layer and the material forming the sash outermost metal layer are the same metal materials, and the sash innermost metal layer and the sash outermost metal layer are the same. The sash inner and the sash outer may be joined while being in contact with each other so that they are butted against each other.

According to the sash portion according to this aspect, in the vehicle side door including the door main body portion made of aluminum and the sash portion, the outermost metal layer of the sash inner is the first metal layer made of aluminum, and the outermost metal layer is the first metal layer made of aluminum. Since it has a side surface, when the door inner panel made of aluminum and the outer surface of the sash inner are joined, the occurrence of contact corrosion of dissimilar metals between them is suppressed.

Furthermore, according to the sash portion, the material forming the sash innermost metal layer having the inner surface and the material forming the sash outer innermost metal layer having the inner surface are the same metal materials. Therefore, the occurrence of contact corrosion between different metals is suppressed between the respective inner surfaces of the sash inner and the sash outer that are joined to each other.

Further, according to the sash portion, the sash inner and the sash outer are joined while the sash inner and the sash outer are in contact with each other so as to be butted against each other. By forming a hollow cross section surrounding an internal space between the sash inner and the sash outer, the sash portion can be formed with high bending rigidity.

In a preferred embodiment of the sash portion of the vehicle side door, the metal material constituting the second metal layer may be steel.

According to the sash portion according to this aspect, since steel is a material having a significantly larger Young's modulus than aluminum, the bending rigidity of the sash portion can be improved more effectively.

In a preferred embodiment of the sash portion of the vehicle side door, the sash portion may be composed of only the first metal layer and the second metal layer.

According to the sash part according to this aspect, the sash part can be formed of the clad material having a two-layer structure, which is the simplest laminated structure, so it is possible to suppress costs even though the clad material is used. .

The conceived vehicle side door includes a door body and the sash, and the door body includes a door inner panel made of aluminum and is disposed on the outer side in the vehicle width direction than the door inner panel. a door outer panel made of aluminum, the sash inner of the sash portion has an outer surface that is a surface facing away from the interior space, and the material forming the outer surface of the sash inner is: The outer surface of the sash inner is joined to the door inner panel.

According to the vehicle side door, when the door inner panel and the outer surface of the sash inner are joined, the door inner panel and the outer surface of the sash inner are made of the same metal material, such as aluminum. , the occurrence of contact corrosion between dissimilar metals is suppressed.

In a preferred embodiment of the vehicle side door, the sash inner may be formed of the clad material, and the first metal layer may form the outer surface of the sash inner.

According to the vehicle side door according to this aspect, the flexural rigidity of the sash inner that is joined to the door main body portion is improved, so that the flexural rigidity of the entire vehicle side door is improved. Furthermore, since the first metal layer made of aluminum forms the outer surface of the sash inner, when the door inner panel made of aluminum and the outer surface of the sash inner are joined, there is no difference between them. The occurrence of contact corrosion between different metals is suppressed.

The invented method for manufacturing a sash portion of a vehicle side door is such that at least one side is formed of a cladding material having a laminated structure in which a plurality of metal layers each made of a metal material are laminated, and the plurality of metal layers are made of aluminum. and a second metal layer made of a metal material having a larger Young's modulus than the aluminum, the second metal layer being closer to the internal space than the first metal layer. a step of preparing a sash inner and a sash outer arranged inside, and joining the sash inner and the sash outer so as to form a hollow cross section surrounding an internal space between the sash inner and the sash outer. and a step of doing so.

According to the method for manufacturing a sash portion of a vehicle side door, at least one of the metal layers is formed of the cladding material, and the plurality of metal layers include a first metal layer made of aluminum and a metal material having a Young's modulus larger than that of the aluminum. Since the sash inner and the sash outer including the second metal layer made of can improve the bending rigidity of

Furthermore, according to the method for manufacturing a sash portion of a vehicle side door, the second metal layer is disposed inside the laminated structure on a side closer to the interior space than the first metal layer, and the sash inner and the Since the sash outer is prepared and manufactured, a reinforcing material made of the same metal material as the metal material of the second metal layer is placed at a position close to the neutral axis of the hollow section with a necessary gap in the sash part made of aluminum. The moment of inertia of the sash part can be improved compared to the case where the sash part is arranged, and thereby the bending rigidity of the sash part can be improved.

In a preferred embodiment of the method for manufacturing a sash portion of a vehicle side door, the step of preparing the sash inner and the sash outer includes the step of preparing the sash inner and the sash outer, each having an outer surface that is a surface facing away from the interior space, and forming the outer surface. The method may include the step of preparing the sash inner whose material is aluminum.

According to the method for manufacturing a sash portion of a vehicle side door according to this aspect, when manufacturing a vehicle side door including a door body portion made of aluminum and the sash portion, the door body portion is made of aluminum. The door inner panel and the outer surface of the sash inner are to be joined, and when they are joined, the door inner panel and the outer surface of the sash inner are made of the same metal material, such as aluminum. , the occurrence of contact corrosion between dissimilar metals is suppressed.

In a preferred embodiment of the method for manufacturing a sash portion of a vehicle side door, the step of preparing the sash inner includes aluminum constituting the first metal layer such that the material forming the sash inner is the cladding material. and a metal material constituting the second metal layer to form the laminated structure, and the first metal layer is arranged such that the first metal layer forms the outer surface of the sash inner. , the method may include a step of molding the sash inner.

According to the method for manufacturing a sash portion of a vehicle side door according to this aspect, a clad material having a laminated structure in which a first metal layer and a second metal layer are laminated can be used for the sash inner, and The rigidity of the sash inner, the sash portion including the sash inner, and the vehicle side door including the sash portion can be improved. Furthermore, since the first metal layer is arranged so as to form the outer surface of the sash inner, the aluminum door inner panel and the outer surface of the sash inner are bonded to each other. When this happens, the occurrence of contact corrosion between dissimilar metals is suppressed.

In a preferred embodiment of the method for manufacturing a sash portion of a vehicle side door, the step of preparing the sash inner and the sash outer includes forming an inner surface that is a surface closer to the interior space, which is joined to the sash outer. and the sash outer having a sash outer joint surface that is an inner surface that is a surface closer to the internal space and that is joined to the sash inner joint surface. The material forming the sash inner joint surface and the material forming the sash outer joint surface are the same metal materials, and the step of joining the sash inner and the sash outer includes the step of joining the sash inner and the sash outer together. The method may include a step of joining the sash inner joint surface and the sash outer joint surface by bringing them into contact so as to butt each other.

According to the method for manufacturing a sash portion of a vehicle side door according to this aspect, the material forming the sash inner joint surface and the material forming the sash outer joint surface are the same kind of metal material, and the material forming the sash inner joint surface is the same kind of metal material. Since the step of joining the sash inner joint surface and the sash outer joint surface includes a step of bringing the sash inner joint surface and the sash outer joint surface into butt contact and joining them, the sash inner joint surface and the sash outer joint surface are joined to each other. The sash portion may be manufactured in such a manner that contact corrosion of dissimilar metals is suppressed between the joint surfaces and a hollow cross section surrounding an internal space is formed between the sash inner and the sash outer. can.

The invented method for manufacturing a vehicle side door includes a step of manufacturing a sash portion in which the material forming the outer surface of the sash inner is aluminum, and a step of manufacturing a sash portion in which the material forming the outer surface of the sash inner is aluminum. a step of preparing a door body having a door inner panel and an aluminum door outer panel disposed outside the door inner panel in the vehicle width direction; and joining the outer surface of the sash inner to the door inner panel. and a step of doing so.

According to the method for manufacturing a vehicle side door, a sash portion in which the material forming the outer surface of the sash inner is aluminum is manufactured, the door body portion made of aluminum is prepared, and the vehicle side door is manufactured. Since it is manufactured by the manufacturer, it is possible to reduce the weight of the entire vehicle side door.

Further, according to the method for manufacturing a vehicle side door, a sash portion is manufactured in which the material forming the outer surface of the sash inner is aluminum, and a door main body portion having a door inner panel made of aluminum is prepared. After that, a step of joining the outer surface of the sash inner to the door inner panel is performed, but the door inner panel and the outer surface of the sash inner are made of aluminum, which is the same metal material. Therefore, the occurrence of contact corrosion between dissimilar metals is suppressed.

Furthermore, according to the method for manufacturing a vehicle side door, the sash portion, which is formed of the cladding material and has improved bending rigidity, and the door body portion are joined, so that the entire vehicle side door Bending rigidity can be improved.

Therefore, according to the sash portion of a vehicle side door, the vehicle side door equipped with the same, the method of manufacturing a sash portion of a vehicle side door, and the method of manufacturing a vehicle side door according to the present invention, the weight of the vehicle increases significantly. It is possible to have high bending rigidity without any

FIG. 1 is a front view of a vehicle side door according to an embodiment of the present invention, viewed from inside in the vehicle width direction. 2 is a sectional view taken along line II-II in FIG. 1. FIG. 2 is a sectional view taken along line III-III in FIG. 1. FIG. 2 is a sectional view taken along line IV-IV in FIG. 1. FIG. 2 is a sectional view taken along line VV in FIG. 1. FIG. 2 is a sectional view taken along line VI-VI in FIG. 1. FIG. 2 is a sectional view taken along line VII-VII in FIG. 1. FIG. FIG. 2 is a sectional view taken along line VIII-VIII in FIG. 1; FIG. 3 is a diagram showing a simulation model and a comparison model of a sash portion of a vehicle side door according to an embodiment of the present invention. 9 is a graph showing the results of simulation using the simulation model and the comparison model in FIG. 9, under the condition that the masses of the simulation model and the comparison model are constant, and the Young's modulus of the second metal layer or reinforcing material shown on the horizontal axis and It is a graph showing the relationship with the bending rigidity value of the sash portion shown on the vertical axis. 9 is a graph showing the results of simulation using the simulation model of FIG. 9, under the conditions that the thickness of the first metal layer of the simulation model is 1 mm and the bending rigidity value of the entire simulation model is constant, and is shown on the horizontal axis. It is a graph showing the relationship between the Young's modulus of the second metal layer and the thickness of the second metal layer shown on the vertical axis. It is a sectional view of the sash part of the vehicle side door concerning the modification of the present invention.

Preferred embodiments of the present invention will be described with reference to the drawings. Note that in this specification, direction is defined as follows. That is, in this specification, with respect to the direction indicated by the term inside or outside, with the internal space of the sash part as a reference, the side close to the internal space is defined as the inside, and the side away from the internal space is defined as the outside. Furthermore, when describing a direction with respect to the entire vehicle, the terms vehicle width direction, vehicle longitudinal direction, or vehicle vertical direction will be used. Furthermore, in each figure, although joint locations are not clearly shown, the locations that are in contact are joint locations or joinable locations.

The vehicle side door 10 constitutes a side portion of a vehicle body (not shown). As shown in FIG. 1, the vehicle side door 10 includes a door body 30 and a sash 20 joined to the door body 30 and located above the door body 30. The part corresponding to the boundary between the door main body part 30 and the sash part 20 is called a waistline WL. In addition, in FIG. 1, the III-III line overlaps the waistline WL.

The door main body part 30 is a part forming the main body of the vehicle side door 10, and can accommodate a window glass that moves up and down in the vehicle side door 10, and various modules are accommodated and attached thereto. The door main body 30 includes a door inner panel 32 made of aluminum and a door outer panel 34 made of aluminum. The door main body portion 30 is formed by hemming the respective outer peripheral portions of a door inner panel 32 and a door outer panel 34 with an adhesive interposed therebetween. The door main body 30 has a housing space SK for housing window glasses and various modules.

The door outer panel 34 is a plate-shaped member that forms an outer portion of the door body 30 in the vehicle width direction. As shown in FIGS. 4 and 5, the door outer panel 34 is disposed on the outer side of the door inner panel 32 in the vehicle width direction. In this embodiment, the door outer panel 34 has a flat plate shape that extends linearly in the longitudinal direction of the vehicle, as shown in FIG. 3 and the like. The door outer panel 34 has end portions 34e located on both sides in the longitudinal direction of the vehicle, and a center portion 34f located between both end portions 34e. Further, the door outer panel 34 has a door outer panel joining surface 34s, which is an inner surface in the vehicle width direction at the end portion 34e and is a surface to be joined to the door inner panel 32.

The door inner panel 32 is a plate-shaped member that forms an inner portion of the door body portion 30 in the vehicle width direction. The door inner panel 32 has end portions 32e located on both sides in the longitudinal direction of the vehicle, and a center portion 32f located between both end portions 32e. Further, the door inner panel 32 has a door inner panel joining surface 32s, which is a surface on the outside in the vehicle width direction at the end portion 32e and is a surface to be joined to the door outer panel 34.

The door inner panel 32 and the door outer panel 34 are hemmed together with, for example, an adhesive interposed, with the door inner panel joint surface 32s and the door outer panel joint surface 34s in contact with each other at the respective ends 32e and 34e. . Specifically, the end portion 34e of the door outer panel 34 is folded back inward in the vehicle width direction so as to sandwich the end portion 32e of the door inner panel 32, as shown in FIG. 3 and the like. Then, between the door inner panel joint surface 32s and the door outer panel joint surface 34s, and between the end 32e of the door inner panel 32 and the end 34e of the door outer panel 34 that sandwiches the end 32e, for example, an adhesive is applied. Both are joined.

In order to form the accommodation space SK in the door body 30, the door inner panel 32 is moved inward in the vehicle width direction from the end portion 32e to the center portion 32f, as shown in FIG. It has a shape that bulges in the direction away from. Thereby, a housing space SK is formed between the center portion 32f of the door inner panel 32 and the center portion 34f of the door outer panel 34.

Further, the door inner panel 32 is welded to front and rear ends (no reference numerals) of a sash inner 22 of the sash portion 20, which will be described later. Specifically, as shown in FIG. 3, FIG. 4, FIG. 5, FIG. 7, and FIG. They are welded together while making contact.

The sash portion 20 is a portion of the vehicle side door 10 that functions as a window glass frame. In the vehicle side door 10, the sash portion 20 is mainly located above the waist line WL, but the front and rear ends of the sash portion 20 extend below the waist line WL in the vertical direction of the vehicle. The front end and the rear end are welded to the door inner panel 32 of the door main body 30. Thereby, the door main body part 30 and the sash part 20 are joined, and the integral vehicle side door 10 is formed.

The sash portion 20 includes a sash inner 22 and a sash outer 24. The sash portion 20 has an internal space NK, as shown in FIG. 2 and the like.

The sash inner 22 is a plate-shaped member that forms an inner portion of the sash portion 20 in the vehicle width direction. The plate material forming the sash inner 22 is a clad material. The sash inner 22 has an end 22e1 on the side away from the window glass, an end 22e2 on the side close to the window glass, and a center part 22f between the ends 22e1 and 22e2. . The sash inner 22 is formed by press molding so that end portions 22e1 and 22e2 have a shape that can be butted against end portions 24e1 and 24e2, which will be described later, of the sash outer 24, respectively. At the same time, the inner sash 22 is formed in such a shape that an internal space NK can be formed between the inner sash 22 and the outer sash 24 at the central portion 22f. Specifically, as shown in FIGS. 2 and 6, the sash inner 22 has a shape that bulges inward in the vehicle width direction at a central portion 22f above the waistline WL. On the other hand, below the waistline WL, the sash inner 22 has a shape that follows the shape of the door inner panel 32, as shown in FIGS. 4, 5, 7, and 8. Further, on the waistline WL, the sash inner 22 has a shape that bulges inward in the vehicle width direction at the central portion 22f described above, as shown in FIG. It has a shape that follows. Further, at the front end portion of the sash inner 22, as can be seen from FIG. 5, the sash inner 22 extends below the position of the VV line in the vehicle vertical direction. As can be seen from FIG. 8, the sash inner 22 extends below the position of the VIII-VIII line in the vehicle vertical direction at the rear end.

As shown in FIG. 2 and the like, the sash inner 22 has an outer surface 22оs that is a surface away from the inner space NK, and an inner surface that is a surface closer to the inner space NK. The inner surface of the sash inner 22 is a sash inner joint surface 22is to be joined to the sash outer 24. As described above, since the sash inner 22 has a shape that follows the shape of the door inner panel 32, the outer surface 22оs of the sash inner 22 has a shape as shown in FIGS. 3, 4, 5, 7, and 8. On the waist line WL and below the waist line WL in the vertical direction of the vehicle, it is welded and joined while being in surface contact with the surface of the central portion 32f of the aluminum door inner panel 32 on the housing space SK side.

The sash outer 24 is a plate-shaped member that forms an outer portion of the sash portion 20 in the vehicle width direction, and is disposed further outward than the sash inner 22 in the vehicle width direction. In this embodiment, the plate material forming the sash outer 24 is the same clad material as the clad material used for the sash inner 22. The sash outer 24 has an end 24e1 on the side away from the window glass, an end 24e2 on the side close to the window glass, and a center part 24f between the ends 24e1 and 24e2. . Above the waistline WL, the outer sash 24 is formed so that, like the inner sash 22, the ends 24e1 and 24e2 can be butted against the ends 22e1 and 22e2 of the inner sash 22, respectively. . At the same time, the outer sash 24 is formed by press molding so that the inner space NK can be formed between the outer sash 24 and the inner space NK at the center 24f of the inner sash 22. Specifically, as shown in FIGS. 2 and 6, the outer sash 24 has a shape that bulges outward in the vehicle width direction at a central portion 24f above the waistline WL. On the other hand, below the waistline WL, the sash outer 24 has a shape that follows the shape of the door inner panel 32 near the end 24e1, as shown in FIG. It has a shape that extends toward the door, and is spaced apart from both the door inner panel 32 and the door outer panel 34. The state in which the outer sash 24 is separated from both the door inner panel 32 and the door outer panel 34 is the same not only at the position along the IV-IV line shown in FIG. 4 but also at any position. Further, on the waistline WL, the sash outer 24 has a shape that bulges outward in the vehicle width direction at the center portion 24f described above, and the end portions 24e1 and 24e2 are shaped so as to bulge outward in the vehicle width direction, as shown in FIG. It has a shape that can be butted against the ends 22e1 and 22e2 of the inner 22. Further, the front end of the sash outer 24 extends to a position between the line IV--IV and the line V-V in the vehicle vertical direction, as can be seen from FIGS. 4 and 5. As can be seen from FIGS. 7 and 8, the sash outer 24 extends at the rear end to a position between the line VII-VII and the line VIII-VIII in the vehicle vertical direction.

As shown in FIG. 2, the outer sash 24 has an inner surface that is a surface closer to the inner space NK. The inner surface of the sash outer 24 is a sash outer joint surface 24is that is joined to the sash inner joint surface 22is.

In the sash portion 20, end portions 22e1 and 22e2 of the sash inner 22 and end portions 24e1 and 24e2 of the sash outer 24 are welded and joined such that they butt each other. Specifically, as shown in FIG. 2, FIG. 3, and FIG. It is formed by welding and joining the sash outer joint surface 24is in the vicinity while being in butt contact with each other. Similarly, the sash portion 20 is in contact with the end 22e2 of the sash inner 22 and the sash inner joint surface 22is in the vicinity thereof, and the end 24e2 of the sash outer 24 and the sash outer joint surface 24is in the vicinity thereof. It is formed by welding and joining. Thereby, the sash portion 20 forms a hollow cross section that surrounds the internal space NK located between the central portion 22f of the sash inner 22 and the central portion 24f of the sash outer 24.

The cladding material is a plate material having a laminated structure in which a plurality of metal layers each made of a metal material are laminated on each other. Clad material is formed by laminating multiple plates made of metal materials with different properties, rolling them, heat treating them, and bonding them surface-to-face to form a single plate. Since it is a bonded material, it is a single plate material that has the characteristics of multiple different metal materials.

The plurality of metal layers of the cladding material according to this embodiment is composed of two metal layers, and includes a first metal layer M1 made of aluminum and a second metal layer M2 made of steel. That is, the cladding material according to this embodiment is composed of only the first metal layer M1 and the second metal layer M2. Steel is a metallic material that has a greater Young's modulus than aluminum. In the cladding material according to the present embodiment, the second metal layer M2 is arranged on the inner side of the laminated structure, which is closer to the inner space NK than the first metal layer M1. Specifically, as shown in FIG. 2, in each of the sash inner 22 and the sash outer 24, the second metal layer M2 is arranged at a position on the inner side closer to the inner space NK and on the inner side of the laminated structure. The first metal layer M1 is arranged at a position on the outside of the laminated structure, which is on the side away from the internal space NK.

As shown in FIG. 2, the first metal layer M1 of the inner sash 22 forms an outer surface 22оs of the inner sash 22. That is, the material forming the outer surface 22оs of the sash inner 22 is aluminum.

Furthermore, as shown in FIG. 2, the second metal layer M2 of the sash inner 22 forms a sash inner joint surface 22is. Similarly, the second metal layer M2 of the outer sash 24 forms a sash outer joint surface 24is.

That is, the material forming the sash inner joint surface 22is and the material forming the sash outer joint surface 24is are respectively the steel forming the second metal layer M2, and are the same kind of metal materials.

In the sash inner 22 and the sash outer 24, the sash inner joint surface 22is and the sash outer joint surface 24is are butted against each other at the end portion 22e1, the end portion 24e1, the end portion 22e2, the end portion 24e2, and the vicinity thereof. They are welded together in contact with each other.

Furthermore, the laminated structure of the sash inner 22 is as follows. The sash inner 22 has a sash inner outermost metal layer (no code) which is a metal layer disposed at the outermost side of the layered structure away from the inner space NK in the layered structure, and an innermost layer of the layered structure close to the inner space NK in the layered structure. The sash innermost metal layer (no reference numeral) is a metal layer disposed in the sash innermost metal layer. In this embodiment, the sash inner outermost metal layer is the first metal layer M1, and the sash inner innermost metal layer is the second metal layer M2. In the sash inner 22 according to the present embodiment, the sash inner outermost metal layer has an outer surface 22оs of the sash inner 22, and the sash inner innermost metal layer has a surface closer to the inner space NK. It has an inner surface 22is, that is, a sash inner joint surface 22is. The outermost metal layer of the sash inner 22 having an outer surface 22оs is welded to a door inner panel 32 made of aluminum below the waistline WL.

Similarly, the laminated structure of the sash outer 24 is as follows. The sash outer 24 has a sash outermost metal layer (no code) which is a metal layer disposed on the outermost side of the laminated structure away from the inner space NK in the laminated structure, and an innermost side of the laminated structure close to the inner space NK in the laminated structure. A sash outer innermost metal layer (no reference numeral) is a metal layer disposed in the sash outer. In this embodiment, the sash outermost metal layer is the first metal layer M1, and the sash outermost metal layer is the second metal layer M2. In the sash outer 24 according to the present embodiment, the sash outer innermost metal layer has an inner surface, that is, a sash outer joint surface 24is, which is a surface closer to the internal space NK.

The material forming the innermost sash metal layer and the material forming the outermost sash metal layer are respectively steel forming the second metal layer M2, and are the same kind of metal materials.

In the sash inner 22 and the sash outer 24, the innermost metal layer of the sash inner and the innermost metal layer of the outer sash are formed at the end 22e1, the end 24e1, the end 22e2, the end 24e2, and the vicinity thereof. They are joined by welding while being in butt contact.

Next, a simulation model and simulation results will be described in order to explain the effects of the vehicle side door 10 and the sash portion 20 of the vehicle side door 10 according to the present embodiment.

FIG. 9 is a diagram showing a simulation model and a comparison model of a sash portion of a vehicle side door according to an embodiment of the present invention. Specifically, the simulation model in FIG. 9 assumes a virtual sash portion 20v, and in response to a load in the vehicle width direction, one of the sash inner 22v and the sash outer 24v from the neutral plane CA. This is a model for calculating the bending stiffness value by extracting only the parts that are apart from each other. In FIG. 9, the reinforcing material RI indicated by a two-dot chain line indicates a comparative model, and the comparative model is a sash inner made of only the first metal layer M1 (without the second metal layer M2). This is a model for calculating the bending rigidity value of the sash portion 20v when reinforcing materials RI are provided inside the sash portion 22v and the sash outer 24v at a 2 mm interval. FIG. 10 is a graph showing the results of simulation using the simulation model and comparison model in FIG. The relationship between the Young's modulus of the second metal layer M2 or the reinforcing material RI shown on the horizontal axis and the bending rigidity value of the sash part 20v shown on the vertical axis under the condition that the mass value of the sash part whose thickness is 3 mm) This is a graph representing In FIG. 10, the five line types are based on a simulation model in which the thickness of the first metal layer M1 is 2.0 mm, 1 mm, 0.5 mm, or 3 mm (without the second metal layer M2), or Comparative models are shown in which the thickness is 1 mm and the reinforcing material RI is provided at an interval of 2 mm inward from the first metal layer M1. FIG. 11 is a graph showing the results of simulation using the simulation model of FIG. and the bending rigidity value of the first metal layer M1 without the reinforcing material RI and having a thickness of 3 mm), the Young's modulus of the second metal layer M2 shown on the horizontal axis and the second metal layer shown on the vertical axis. It is a graph showing the relationship with the thickness of M2.

The bending stiffness value shown on the vertical axis of FIG. 10 was calculated using the following calculation formula. The Young's modulus of the first metal layer M1 is E ₁ , the moment of inertia of the first metal layer M1 is I ₁ , the Young's modulus of the second metal layer M2 or the reinforcing material RI is E ₂ , the second metal layer M2 or the reinforcing material If the moment of inertia of _the RI is _I2 , then the bending _stiffness value can be calculated as follows: _E1I1 + _E2I2 .

From the graph of FIG. 10, the following results can be understood.

The Young's modulus of the second metal layer M2 exceeds 7 x 10 ⁴ MPa in all line type graphs, except for the line type graphs indicated by two-dot chain lines and circle marks and the dotted line graphs. The bending stiffness value of the simulation model composed of the first metal layer M1 and the second metal layer M2 is higher than the bending stiffness value of the graph consisting of only the first metal layer M1 (the graph of the single layer of M1 indicated by the dotted line). The bending stiffness value is large. That is, since 7×10 ⁴ MPa is equal to the Young's modulus of aluminum, when the Young's modulus of the second metal layer M2 becomes larger than the Young's modulus of the first metal layer made of aluminum, the bending rigidity value of the simulation model becomes the first It is larger than a layer made only of metal, that is, made only of aluminum.

Furthermore, in the region in FIG. 10 where the Young's modulus of the second metal layer M2 exceeds 7×10 ⁴ MPa, the first metal layer The thinner the thickness of M1 is in the graph of the line type, the better the bending rigidity value of the simulation model is. That is, the thicker the second metal layer, which has a larger Young's modulus than the first metal layer M1, improves the bending rigidity value of the simulation model.

Further, in FIG. 10, the graph of the line type shown by the two-dot chain line and marked with a circle, that is, the reinforcing material RI is placed inside the sash inner 22v and the sash outer 24v, which are made of only the first metal layer M1, at intervals. The bending stiffness value shown in the graph showing the results of the comparative model in which This is smaller than the bending stiffness value shown in the simulation model graph. In particular, the graph of the comparative model in which the reinforcing material RI is provided is the graph of the line types marked with square marks, that is, the simulation in which the second metal layer M2 is present and the first metal layer M1 has a thickness of 1 mm. The curve is drawn on the side with the smaller bending stiffness value while maintaining approximately the same spacing as the model graph.

That is, from the above results, the bending rigidity of the simulation model made of the cladding material made up of the first metal layer M1 and the second metal layer M2 is greater than that of the comparison model in which the reinforcing material RI is provided. I understand. The reason for this is as follows. A comparison model in which the reinforcing material RI is provided inside from the first metal layer M1 at a certain distance, that is, at a position close to the neutral plane CA, and a second metal layer M2 is provided inside along the first metal layer M1. In comparison with the simulation model, since the second metal layer M2 is provided at a position farther from the neutral plane CA than the reinforcement RI, the moment of inertia of the second metal layer M2 is equal to that of the reinforcement RI. Greater than the second moment of area. Therefore, the simulation model has greater bending rigidity than the comparison model.

Next, from the graph of FIG. 11, the following results can be understood.

Under the conditions that the thickness of the first metal layer M1 of the simulation model is 1 mm and the bending rigidity value of the entire simulation model is constant, the larger the Young's modulus of the second metal layer M2, the greater the thickness of the second metal layer M2. is getting smaller. In particular, by making the Young's modulus of the second metal layer M2 larger than the Young's modulus of aluminum, 7×10 ⁴ MPa, the thickness of the second metal layer M2 becomes smaller than 2 mm, which makes it possible to reduce the thickness of the sash inner 22v or the sash outer. It can be seen that the thickness of 24v is smaller than 3mm. This means that by making the Young's modulus of the metal material constituting the second metal layer M2 larger than that of aluminum, the thickness of the second metal layer M2 can be reduced while achieving the bending rigidity required for the sash part. As a result, the overall thickness is reduced, which, in combination with the first metal layer M1 made of aluminum, makes it possible to reduce the weight of the sash portion, which in turn makes it possible to reduce the weight of the vehicle side door. ing.

Based on the above simulation results, the effects of the vehicle side door 10 and the sash portion 20 of the vehicle side door 10 according to the present embodiment will be described.

According to the vehicle side door 10 and the sash portion 20 of the vehicle side door 10, each of the sash inner 22 and the sash outer 24 includes a first metal layer M1 made of aluminum and a metal material having a Young's modulus larger than that of the aluminum. Since the sash portion is formed of a cladding material including a second metal layer, the weight of the sash portion can be reduced. This point is as shown in the results shown in FIG. 11 described above.

Furthermore, according to the vehicle side door 10 and the sash portion 20 of the vehicle side door 10, the bending rigidity of the sash portion can be improved. Specifically, there are the following two points.

First, according to the vehicle side door 10 and the sash portion 20 of the vehicle side door 10, the cladding material includes the second metal layer M2 made of steel having a Young's modulus larger than that of aluminum. The bending rigidity of the sash portion can be improved compared to a sash portion made of only the sash portion. This point is as shown in the results shown in FIG. 10 described above.

Second, according to the vehicle side door 10 and the sash portion 20 of the vehicle side door 10, the second metal layer M2 is arranged on the inside of the laminated structure, which is closer to the interior space NK than the first metal layer M1. Therefore, a reinforcing material made of the same steel as the metal material of the second metal layer M2 is arranged at a position close to the neutral axis of the hollow cross section surrounding the internal space NK with a necessary gap in the sash part made of aluminum. The moment of inertia of the sash portion can be improved compared to the case where the sash portion is provided with the sash portion, and thereby the bending rigidity of the sash portion can be improved. This point is as shown in the comparison result between the graph of the comparison model and the simulation model shown in FIG. 10 described above.

Further, according to the vehicle side door 10 and the sash portion 20 of the vehicle side door 10, it is possible to suppress the occurrence of contact corrosion of different metals between the sash inner 22 and the door inner panel 32 that are joined. Specifically, in a vehicle side door 10 that includes a door body 30 and a sash 20 made of aluminum, the door inner panel 32 and the outer surface 22оs of the sash inner 22, which are welded to each other, are made of the same metal material. Since it is made of certain aluminum, it is possible to suppress the occurrence of contact corrosion between different metals.

That is, since the outermost metal layer of the sash inner is the first metal layer M1 made of aluminum and has the outer surface 22оs, when the door inner panel 32 made of aluminum and the outer surface 22оs of the sash inner 22 are joined, The occurrence of contact corrosion between dissimilar metals is suppressed.

Further, according to the vehicle side door 10 and the sash portion 20 of the vehicle side door 10, since the sash inner 22 is formed of a clad material as described above, the sash to be joined to the door body portion 30 The bending rigidity of the inner 22 is improved, and the bending rigidity of the entire vehicle side door 10 is improved.

Furthermore, according to the vehicle side door 10 and the sash portion 20 of the vehicle side door 10, the material forming the sash inner joint surface 22is and the material forming the sash outer joint surface 24is are made of steel, which is the same metal material. Therefore, the occurrence of contact corrosion of different metals is suppressed between the sash inner joint surface 22is and the sash outer joint surface 24is that are joined to each other.

That is, the material forming the sash inner innermost metal layer having the sash inner joint surface 22is and the material forming the sash outer innermost metal layer having the sash outer joint surface 24is are steel, which are the same metal materials. The occurrence of contact corrosion between different metals is suppressed between the sash inner joint surface 22is and the sash outer joint surface 24is that are joined to each other.

Further, according to the vehicle side door 10 and the sash portion 20 of the vehicle side door 10, the sash inner 22 and the sash outer 24 forming the sash portion 20 are joined to each other by butt welding of steel. High strength.

Furthermore, according to the vehicle side door 10 and the sash portion 20 of the vehicle side door 10, the sash inner joint surface 22is and the sash outer joint surface 24is, that is, the sash innermost metal layer and the sash outermost metal layer, Since the sash inner 22 and the sash outer 24 are welded together while being in contact with each other, a hollow cross section surrounding the internal space NK is formed between the sash inner 22 and the sash outer 24, thereby forming a sash portion with high bending rigidity. I can do it.

Furthermore, according to the vehicle side door 10 and the sash portion 20 of the vehicle side door 10, the metal material constituting the second metal layer M2 is steel, and steel is a material having a large Young's modulus of about 200 GPa. , it is possible to more effectively improve the bending rigidity of the sash portion.

Furthermore, according to the vehicle side door 10 and the sash portion 20 of the vehicle side door 10,
Since the sash portion 20 can be formed of a cladding material having a two-layer structure, which is the simplest laminated structure, costs can be suppressed even though the cladding material is used.

Next, a method for manufacturing the sash portion 20 of the vehicle side door 10 according to the above embodiment will be described.

The method for manufacturing the sash portion 20 of the vehicle side door 10 includes a cladding material forming step, a cladding material press molding step, and a sash inner-sash outer joining step.

The clad material forming step is a step in which a plate made of aluminum and a plate made of steel are stacked, rolled in a stacked state using a rolling mill, and heat treated. That is, the cladding material forming step is a step of forming one plate material having a laminated structure in which the first metal layer M1 made of aluminum and the second metal layer M2 made of steel are laminated. Through the cladding material forming step, two cladding materials to become the sash inner 22 and the sash outer 24 are formed.

The cladding material press molding step is a step of molding the two cladding materials formed in the cladding material forming step into the shape of the sash inner 22 and the shape of the sash outer 24 using a press molding machine, respectively.

The cladding material forming step and the cladding material press molding step are steps for preparing the sash inner 22 and the sash outer 24.

That is, in the step of preparing the sash inner 22 and the sash outer 24, the sash inner 22 and the sash outer 24 are formed together using a clad material having a laminated structure in which a plurality of metal layers each made of a metal material are laminated on each other, and the plurality of metal layers are made of aluminum. The layered structure includes a first metal layer M1 and a second metal layer M2 made of steel having a Young's modulus larger than that of aluminum, and the second metal layer M2 is located on the inner side of the layered structure that is closer to the internal space NK than the first metal layer M1. This is a step of preparing the sash inner 22 and the sash outer 24 which are arranged.

Further, in the step of preparing the sash inner 22 and the sash outer 24, the sash inner 22 is prepared, which has an outer surface 22оs that is a surface on the side away from the inner space NK, and the material forming the outer surface 22оs is aluminum. Including process.

Furthermore, the step of preparing the sash inner 22 and the sash outer 24 includes preparing the sash inner 22 which has a sash inner joint surface 22is, which is an inner surface that is a surface closer to the inner space NK and is to be joined to the sash outer 24. , the step of preparing an outer sash 24 having a sash outer joint surface 24is that is an inner surface that is a surface closer to the internal space NK and is joined to the sash inner joint surface 22is. As described above, the material forming the sash inner joint surface 22is and the material forming the sash outer joint surface 24is are steel, and are the same metal materials.

Furthermore, the step of preparing the sash inner 22 includes laminating aluminum constituting the first metal layer M1 and steel constituting the second metal layer M2 so that the material forming the sash inner is the cladding material. The method includes a step of forming the inner sash 22 so as to have a laminated structure and arranging the first metal layer M1 so that the first metal layer M1 forms the outer surface 22оs of the inner sash.

The step of forming the sash inner 22 includes a sash inner clad material press forming step, which is a step of press forming a clad material in which the first metal layer M1 and the second metal layer M2 are laminated.

The process of preparing the sash outer 24 is a repetition of the same explanation as the process of preparing the sash inner 22, but aluminum constituting the first metal layer M1 and steel constituting the second metal layer M2 are laminated. The sash outer 24 is formed by forming the sash outer 24 into a laminated structure and arranging the first metal layer M1 so that the first metal layer M1 forms the outer surface of the sash outer.

The process of forming the sash outer 24 includes a cladding material press-forming process of the sash outer, which is a process of press-forming a cladding material in which the first metal layer M1 and the second metal layer M2 are laminated.

Subsequently, in the sash inner-sash outer joining step, the end of the sash inner 22 and the end of the sash outer 24 are joined together to form a hollow cross section surrounding the internal space NK between the sash inner 22 and the sash outer 24. This is a joining process.

Specifically, it is as follows. In the sash inner-sash outer joining step, the sash inner joint surface 22is at the end 22e1 of the sash inner 22 and the sash outer joint surface 22is at the end 24e1 of the sash outer 24 and the vicinity thereof are brought into contact with each other. A first joining step is included in which the sash inner 22 and the sash outer 24 are welded and joined while being in contact with each other. Furthermore, in the sash inner-sash outer joining step, the sash inner joint surface 22is at the end 22e2 of the sash inner 22 and the vicinity thereof and the sash outer joint surface 24is at the end 24e2 of the sash outer 24 and the vicinity thereof are brought into contact with each other. A second joining step is included in which the sash inner 22 and the sash outer 24 are welded and joined while being in contact with each other. By the sash inner-sash outer joining process, an internal space NK is formed between the central part 22f of the sash inner 22 and the central part 24f of the sash outer 24, and a hollow cross section surrounding the internal space NK is formed in the sash part 20. . In the sash inner-sash outer bonding step, since the material forming the sash inner bonding surface 22is and the material forming the sash outer bonding surface 24is are steel, which are the same metal materials, the sash inner 22 and the sash outer 24 are bonded together. can be easily welded and joined.

Further, in the sash inner-sash outer joining step, the sash inner joining surface 22is and the sash outer joining surface 24is are butted against each other at the ends 22e1, 22e2, 24e1, 24e2 of the sash inner 22 and the sash outer 24 and in the vicinity thereof. The method includes a step of welding the sash inner 22 and the sash outer 24 so that they are in contact with each other.

Next, a method for manufacturing the vehicle side door 10 according to the above embodiment will be described.

The method for manufacturing the vehicle side door 10 includes a step of manufacturing a sash portion, a step of preparing a door body portion, and a step of joining the sash portion and the door body portion.

The process of manufacturing the sash part is a process of manufacturing the sash part 20 in which the material forming the outer surface 22оs of the sash inner 22 is aluminum by the method for manufacturing the sash part 20 of the vehicle side door 10 described above.

The step of preparing the door body is a step of preparing a door body 30 having an aluminum door inner panel 32 and an aluminum door outer panel 34 disposed on the outer side of the door inner panel 32 in the vehicle width direction. .

The step of joining the sash part and the door body part is to join the outer surface 22оs of the sash inner 22 in the sash part 20 to the door inner panel 32, and to join the door outer panel 34 to the door inner panel 32 to which the sash inner 22 has been joined. This is the process of

Next, the effects of the method for manufacturing the sash portion 20 of the vehicle side door 10 and the method for manufacturing the vehicle side door 10 according to the present embodiment will be described.

According to the method for manufacturing the sash portion 20 of the vehicle side door 10, the first metal layer M1 is formed of the cladding material and the plurality of metal layers are made of aluminum and made of steel having a Young's modulus larger than that of the aluminum. Since the sash inner 22 and the sash outer 24 are prepared and manufactured, the sash inner 22 and the sash outer 24 including the second metal layer are prepared and manufactured. Bending rigidity can be improved.

Furthermore, according to the manufacturing method of the sash portion 20 of the vehicle side door 10, the sash inner 22 is arranged in such a manner that the second metal layer M2 is disposed inside the laminated structure on the side closer to the interior space NK than the first metal layer M1. Since the sash outer 24 and sash outer 24 are prepared and manufactured, the sash is made of aluminum, compared to a case where a reinforcing material made of steel is placed at a position close to the neutral axis of the hollow cross section with a necessary gap in the sash part made of aluminum. It is possible to improve the moment of inertia of the sash, thereby improving the bending rigidity of the sash.

Furthermore, according to the method for manufacturing the sash portion 20 of the vehicle side door 10, there is no need for a step of assembling the reinforcing material RI into the internal space NK of the sash portion 20. Compared to manufacturing methods, the number of steps can be reduced.

Further, according to the method for manufacturing the sash portion 20 of the vehicle side door 10, when manufacturing the vehicle side door 10 including the door body portion 30 and the sash portion 20 made of aluminum, the door body portion 30 is made of aluminum. The door inner panel 32 and the outer surface 22оs of the sash inner 22 are joined together, but when they are joined, the door inner panel 32 and the outer surface 22оs of the sash inner 22 are made of the same metal material. Since it is made of aluminum, which is aluminum, the occurrence of contact corrosion between different metals is suppressed.

Furthermore, according to the method for manufacturing the sash portion 20 of the vehicle side door 10, the sash inner 22 can be made of a clad material having a laminated structure in which the first metal layer M1 and the second metal layer M2 are laminated. , the rigidity of the sash inner 22, the sash portion 20 including the sash inner 22, and the vehicle side door 10 including the sash portion 20 can be improved. Furthermore, since the first metal layer M1 is arranged so as to form the outer surface 22оs of the inner sash 22, the inner door panel 32 made of aluminum and the outer surface 22оs of the inner sash 22 are bonded to each other. When this happens, the occurrence of contact corrosion between dissimilar metals is suppressed.

Furthermore, according to the method for manufacturing the sash portion 20 of the vehicle side door 10, the material forming the sash inner joint surface 22is and the material forming the sash outer joint surface 24is are steel, which are the same metal materials, The step of joining the sash inner joint surface 22 and the sash outer joint surface 24 includes the step of bringing the sash inner joint surface 22is and the sash outer joint surface 24is into contact so as to butt each other. The sash part 20 is suppressed from causing contact corrosion of different metals with the sash outer joint surface 24is, and forms a hollow cross section surrounding the internal space NK between the sash inner 22 and the sash outer 24. can be manufactured.

Subsequently, according to the method for manufacturing the vehicle side door 10, the sash portion 20 whose material forming the outer surface 22оs of the sash inner 22 is aluminum is manufactured, the aluminum door body portion 30 is prepared, and the vehicle side door 10 is manufactured. Since the vehicle side door 10 is manufactured, weight reduction of the entire vehicle side door can be achieved.

Furthermore, according to the manufacturing method of the vehicle side door 10, the sash part 20 is manufactured in which the material forming the outer surface 22оs of the sash inner 22 is aluminum, and the door body part 30 having the door inner panel 32 made of aluminum is manufactured. After the preparation, a step of joining the outer surface 22оs of the sash inner 22 to the door inner panel 32 will be performed. , the occurrence of contact corrosion between dissimilar metals is suppressed. In addition, when they are joined by welding, joining becomes easy.

Furthermore, according to the method for manufacturing the vehicle side door 10, the sash portion 20, which is formed of the cladding material and has improved bending rigidity, and the door body portion 30 are joined, so that the entire vehicle side door Bending rigidity can be improved.

The present invention is not limited to the embodiments described above. For example, the following modifications are possible.

The present invention is not limited to those in which the sash inner and the sash outer included in the sash portion are each formed of a clad material, but only one of the sash inner and the sash outer is formed of a clad material. You can.

Further, in the present invention, the number of metal layers constituting the cladding material is not limited. For example, the cladding material may be composed of three or more metal layers.

FIG. 12 shows a sash portion 20A that is an example of the modification. The sash portion 20A includes a sash inner 22A having a three-layer laminated structure and a single-layer sash outer 24A.

The sash inner 22A is formed of a clad material having a laminated structure in which three metal layers are laminated on each other. Regarding the cladding material of the sash inner 22A, assuming that the three metal layers are the first layer L1, the second layer L2, and the third layer L3 from the outside away from the internal space NK, the first layer L1 is the first layer made of aluminum. The second metal layer M1 is the metal layer M1, the second layer L2 is made of steel, and the third layer L3 is the first metal layer M1 made of aluminum like the first layer. Also in the sash inner 22A, the second metal layer M2 is arranged on the inside of the laminated structure, which is closer to the internal space NK than the first metal layer M1 of the first layer L1.

In the sash inner 22A, the first layer, which is the outermost metal layer of the sash inner, has an outer surface 22Aоs, which is a surface on the side away from the inner space NK. Therefore, also in this modification, the material forming the outer surface 22Aоs is aluminum.

In the sash inner 22A, the third layer, which is the innermost metal layer of the sash inner, has a sash inner joint surface 22Ais, which is an inner surface that is a surface closer to the internal space NK and is to be joined to the sash outer 24A. ing. Therefore, in this modification, the material forming the sash inner joint surface 22Ais is aluminum.

On the other hand, the sash outer 24A is formed not from a clad material but from a single-layer plate material consisting only of the first metal layer M1. That is, the sash outer 24A is a plate-shaped member made of aluminum.

The outer sash 24A has a sash outer joint surface 24Ais, which is an inner surface that is a surface closer to the internal space NK and is joined to the sash inner joint surface 22Ais. Therefore, in this modification, the material forming the sash outer joint surface 24Ais is aluminum.

Therefore, the material forming the sash inner joint surface 22Ais and the material forming the sash outer joint surface 24Ais are each aluminum, and are the same metal materials.

The sash inner 22A and the sash outer 24A are welded together at each end and in the vicinity thereof, with the sash inner joint surface 22Ais and the sash outer joint surface 24Ais being butted and in contact with each other.

Also in this sash portion 20A, since the cladding material constituting the sash inner 22A includes the first metal layer M1 made of aluminum and the second metal layer M2 made of steel having a higher Young's modulus than the first metal layer M1, aluminum Compared to the sash part composed only of the first metal layer M1, or the conventional sash part that is thicker or has a reinforcing material inside, the sash part is lighter and has improved bending rigidity. It can be realized.

That is, in the sash portion 20A, the first layer L1 and the third layer L3 of the cladding material constituting the sash inner 22A are constituted by the first metal layer M1 made of aluminum, and further, the sash outer 24A is made of aluminum. Since it is composed of only the first metal layer M1, the weight of the sash part can be reduced compared to when the thickness of the sash inner or sash outer is increased or when a reinforcing material is provided inside the sash part. .

Furthermore, also in this sash portion 20A, since the second metal layer M2 of the second layer L2 is arranged inside the laminated structure on the side closer to the internal space NK than the first metal layer M1 of the first layer surface L1, the sash portion can improve the bending rigidity of That is, according to the sash part 20A, the bending rigidity of the sash part can be improved compared to a sash part made only of aluminum, and a necessary gap is provided in the sash part made of aluminum so that the neutral axis of the hollow cross section The bending rigidity of the sash portion can be improved compared to the case where a reinforcing material made of steel is placed at a close position.

Furthermore, according to the sash portion 20A of the vehicle side door, the first layer L1 which is the outermost metal layer of the sash inner is the first metal layer M1 made of aluminum and has the outer surface 22Aоs, so that the door body portion 30 When the door inner panel 32 made of aluminum and the outer surface 22Aоs of the sash inner 22A are joined, the occurrence of contact corrosion between different metals is suppressed.

Furthermore, according to the sash portion 20A, the material forming the first metal layer M1, which is the third layer L3 (sash innermost metal layer) having the sash inner bonding surface 22Ais, and the material forming the sash outer bonding surface 24Ais are Since they are made of aluminum, which is the same type of metal material, the occurrence of contact corrosion between different metals is suppressed between the sash inner joint surface 22Ais and the sash outer joint surface 24Ais, which are joined to each other.

Next, regarding a method for manufacturing a sash portion 20A of a vehicle side door according to a modified example of the present invention, differences from the method for manufacturing a sash portion 20 of a vehicle side door according to the embodiment described above will be explained.

The method for manufacturing the sash portion 20A of a vehicle side door includes a step of forming a three-layer cladding material.

In the step of forming the three-layer clad material, a plate made of aluminum, a plate made of steel, and a plate made of aluminum are stacked together, and the stacked pieces are rolled and heat treated to form a single sheet having a three-layer laminate structure. This is the process of forming a board.

Next, a modification included in the present invention and different from the modification described above will be described.

The present invention is not limited to the case where the sash inner is made of a clad material, but the sash outer may be made of a clad material. That is, in the description of the sash portion 20A according to one of the above-mentioned modifications, the sash inner was made of a clad material, and the sash outer was made of a single-layer plate made only of aluminum. In the present invention, at least one of the sash inner and the sash outer may be formed of a clad material. Therefore, the sash inner is formed of a single-layer plate material made only of aluminum, and the sash outer is formed of a clad material. It may be something that has been done.

Further, the present invention is not limited to a cladding material having a two-layer or three-layer laminated structure, but may have four or more layers. Further, in the present invention, the sash inner and the sash outer may be formed of different cladding materials. That is, in the description of the sash part 20 according to the above embodiment, the sash inner 22 and the sash outer 24 are each made of the same clad material having a two-layer laminated structure, and the sash part 20 according to the modified example In the description of the section 20A, the sash inner 22A has been described as being formed of a cladding material having a three-layer laminated structure, but the present invention provides a case where at least one of the sash inner and the sash outer has a laminated structure of four or more layers. The sash inner 22 and the sash outer 24 may each be formed of a clad material having a laminated structure with a different number of layers or a clad material composed of different metal materials. It may be something.

Further, in the present invention, when the cladding material has a laminated structure of three or more layers, the structure of the cladding material may be made of different metal materials, or the same metal material may have a large Young's modulus. It may be configured to sandwich different metal materials. That is, in the description of the sash portion 20A according to the above modification, the first layer L1 and the third layer L3 are made of the same first metal layer M1, that is, aluminum, but the third layer L3 may be a metal layer formed of a metal material different from aluminum. In this case, it is preferable that the metal material forming the third layer L3 and the metal material forming the joint surface of the opposing sash inner or sash outer be the same type of metal material. Moreover, it is preferable that the material forming the outer surface of the sash inner is aluminum.

Further, the present invention is not limited to the second metal layer made of steel. That is, in the present invention, the second metal layer may be made of a metal material having a larger Young's modulus than the aluminum forming the first metal layer. For example, the first metal layer may be made of 6000 series aluminum. In this case, the second metal layer may be made of 7000 series aluminum.

In the case where the second metal layer is made of steel, the present invention is not limited to the case where the steel is mild steel, and may be, for example, a steel other than mild steel such as medium carbon steel, high tensile steel, stainless steel, etc.

Although the above description has been made assuming that the joining is a welding joint, the joining in the present invention is not limited to a welding joint, and may be a mechanical joining.

Further, in the case where the joint in the present invention is a weld joint, the weld joint may be any weld joint such as arc welding, gas welding, spot welding, and laser welding.

10 Vehicle side door 20, 20v, 20A Sash part 22, 22v, 22A Sash inner 22e1, 22e2 End of sash inner 22f Center part of sash inner 22is, 22Ais Sash inner joint surface 22оs, 22Aоs Outer surface of sash inner 24, 24v, 24A Sash outer 24e1, 24e2 End of sash outer 24f Center of sash outer 24is, 24Ais Sash outer joint surface 30 Door body 32 Door inner panel 32e End of door inner panel 32f Center of door inner panel 32s Door Inner panel joint surface 34 Door outer panel 34e Edge of door outer panel 34f Center part of door outer panel 34s Door outer panel joint surface L1 1st layer L2 2nd layer L3 3rd layer M1 1st metal layer M2 2nd metal layer NK Internal space SK Accommodation space RI Reinforcement material CA Neutral surface WL Waistline

Claims (15)

Sash inner and
a sash outer disposed outside the sash inner in the vehicle width direction and joined to the sash inner so as to form a hollow cross section surrounding an internal space with the sash inner;
Equipped with
At least one of the sash inner and the sash outer is formed of a clad material having a laminated structure in which a plurality of metal layers each made of a metal material are laminated on each other,
The plurality of metal layers include a first metal layer made of aluminum and a second metal layer made of a metal material having a larger Young's modulus than the aluminum,
The second metal layer is disposed inside the laminated structure on a side closer to the internal space than the first metal layer,
Vehicle side door sash. The sash inner has an outer surface that is a surface facing away from the inner space,
the material forming the outer surface of the sash inner is aluminum;
The sash portion of a vehicle side door according to claim 1. The sash inner is formed of the clad material,
the first metal layer forming the outer surface of the sash inner;
The sash portion of a vehicle side door according to claim 2. The sash inner has an inner surface that is a surface closer to the internal space, and has a sash inner joint surface for joining with the sash outer,
The sash outer has a sash outer joint surface that is an inner surface that is a surface closer to the internal space and is joined to the sash inner joint surface,
The material forming the sash inner joint surface and the material forming the sash outer joint surface are the same kind of metal material,
The sash portion of a vehicle side door according to any one of claims 1 to 3. Each of the sash inner and the sash outer is formed of the clad material,
The sash portion of a vehicle side door according to claim 1. The sash inner has an outer surface that is a surface away from the inner space, and a sash inner outermost metal layer that is a metal layer disposed on the outermost side of the laminated structure, and a surface that is closer to the inner space. a sash innermost metal layer, which is a metal layer having a certain inner surface and arranged at the innermost side of the laminated structure;
The sash outer has an inner surface that is a surface closer to the internal space, and a sash outer innermost metal layer that is a metal layer disposed at the innermost side of the laminated structure,
The sash inner outermost metal layer is the first metal layer,
The material forming the innermost sash metal layer and the material forming the outermost sash metal layer are the same metal materials,
The sash inner and the sash outer are joined to each other while the sash inner and the sash outer are in contact with each other so as to be butted against each other.
The sash portion of a vehicle side door according to claim 5. The metal material constituting the second metal layer is steel,
The sash portion of a vehicle side door according to any one of claims 1 to 6. The cladding material is composed of only the first metal layer and the second metal layer,
The sash portion of a vehicle side door according to any one of claims 1 to 7. A side door for a vehicle,
a door body,
The sash portion according to any one of claims 1 to 8,
The door main body includes an aluminum door inner panel and an aluminum door outer panel disposed outside the door inner panel in the vehicle width direction,
The sash inner of the sash portion has an outer surface that is a surface facing away from the internal space,
The material forming the outer surface of the sash inner is aluminum,
the outer surface of the sash inner is joined to the door inner panel;
Vehicle side door. The sash inner is formed of the clad material,
the first metal layer forming the outer surface of the sash inner;
The vehicle side door according to claim 9. At least one of the metal layers is formed of a clad material having a laminated structure in which a plurality of metal layers each made of a metal material are laminated, and the plurality of metal layers have a Young's modulus larger than that of the first metal layer made of aluminum and the aluminum. A sash inner and a sash outer are prepared, the sash inner and the sash outer including a second metal layer made of a metal material having a sash structure, the second metal layer being disposed inside the laminated structure on a side closer to the internal space than the first metal layer. process and
joining the sash inner and the sash outer so as to form a hollow cross section surrounding an internal space between the sash inner and the sash outer;
including,
A method for manufacturing a sash part of a vehicle side door. A method for manufacturing a sash portion of a vehicle side door according to claim 11, comprising:
The step of preparing the sash inner and the sash outer includes the step of preparing the sash inner, which has an outer surface that is a surface facing away from the inner space, and the material forming the outer surface is aluminum.
A method for manufacturing a sash part of a vehicle side door. A method for manufacturing a sash portion of a vehicle side door according to claim 12, comprising:
The step of preparing the sash inner includes laminating aluminum constituting the first metal layer and a metal material constituting the second metal layer so that the material forming the sash inner becomes the cladding material. forming the sash inner with the laminated structure and arranging the first metal layer so that the first metal layer forms the outer surface of the sash inner;
A method for manufacturing a sash part of a vehicle side door. A method for manufacturing a sash portion of a vehicle side door according to any one of claims 11 to 13, comprising:
The step of preparing the sash inner and the sash outer includes the step of preparing the sash inner, which has an inner surface that is a surface closer to the inner space, and has a sash inner joint surface to be joined to the sash outer, and the inner space. the sash outer having a sash outer joint surface that is an inner surface that is a surface closer to the sash inner joint surface and is joined to the sash inner joint surface;
The material forming the sash inner joint surface and the material forming the sash outer joint surface are the same kind of metal material,
The step of joining the sash inner and the sash outer includes the step of bringing the sash inner joining surface and the sash outer joining surface into contact with each other so as to butt each other, and joining them.
A method for manufacturing a sash part of a vehicle side door. A step of manufacturing a sash portion in which the material forming the outer surface of the sash inner is aluminum by the method for manufacturing a sash portion of a vehicle side door according to claim 12 or 13;
preparing a door body having an aluminum door inner panel and an aluminum door outer panel disposed outside the door inner panel in the vehicle width direction;
joining the outer surface of the sash inner to the door inner panel;
Equipped with
A method of manufacturing a vehicle side door.

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