JPH0788176B2 - Method for forming a body panel of honeycomb structure - Google Patents

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for forming an automobile body panel, and more particularly to a honeycomb sandwich structure in which a honeycomb core is sandwiched between a first face plate and a second face plate. The present invention relates to a method for forming a vehicle body panel configured by the above panel.

(Prior Art) Generally, a vehicle body panel such as a floor panel forming a floor surface of a vehicle interior of an automobile or a dash panel separating an engine rule and a vehicle interior has various properties depending on a place where the panel is provided. Is required.

For example, the floor panel must be prevented from being deformed by vibrations of the vehicle body during traveling, especially in the portion forming the floor surface of the vehicle compartment. Further, the floor panel is also required to play a major role of suppressing minute vibrations from each device such as an engine and blocking noise transmitted to the vehicle interior.

By the way, in general, the floor panel is often formed by a body panel portion that is press-molded integrally with a center tunnel member that constitutes a center tunnel extending in the front-rear direction of the vehicle body using a single flat plate. In such a case, if such a vehicle body panel portion is simply made flat, the floor panel has a relatively large area, so that the rigidity of the floor panel is reduced and the floor panel is easily deformed.

Therefore, usually, forming an uneven portion on the floor panel,
A reinforcing member such as a cross member is attached to increase rigidity.

In addition, such a floor panel cannot not only sufficiently dampen the minute vibrations transmitted from the engine, etc., but also cannot completely block noise such as running noise. A mel sheet and an insulator, which is a sound insulation material, are attached to prevent minute vibrations from being attenuated and noise to be transmitted to the passenger compartment.

However, the floor panel is required to be as flat as possible, but if the uneven portion is formed, it is not possible to obtain a flat surface. In addition, if the reinforcing material, the mel sheet, and the insulator are attached to the floor panel, the weight becomes extremely large.

Therefore, as disclosed in Japanese Utility Model Laid-Open No. 57-133479, the floor panel includes a first face plate and a second face plate.
That is, it has been proposed to form a honeycomb sandwich structure in which a honeycomb core is sandwiched between a lower surface plate and an upper surface plate.

The floor panel having such a sandwich structure is light in weight, has extremely high rigidity, and is excellent in sound insulation. Therefore, by using such a floor panel, it is possible to make the plane portion of the floor surface of the passenger compartment a large area.

(Problems to be solved by the invention) However, since such a honeycomb panel has extremely high rigidity, when the floor panel has a honeycomb sandwich structure, for example, it is pressed integrally with a body strength member such as a side sill or a center tunnel. It is impossible to mold. Therefore, in the one disclosed in the above publication, a floor panel having a honeycomb structure is formed as a single body and is joined to a vehicle body strength member such as a side sill or a center tunnel.

By the way, in connecting the floor panel having the honeycomb core structure to the vehicle body strength member, it is first considered to form a frame by assembling the vehicle body strength member such as the side sill and the center tunnel, and to connect the floor panel to the frame. To be However, when the body strength members are assembled into a skeleton, the design error of each member, the assembly error,
Alternatively, a slight distortion will inevitably occur in the skeleton due to the heat effect caused by welding or the like.

If such a distortion occurs in the frame, it becomes impossible for the honeycomb-structured floor panel having high rigidity to follow the distortion reliably. Therefore, the floor panel cannot be firmly connected to the frame.

As described above, it is extremely difficult to assemble the honeycomb sandwich structure floor panel to the vehicle body floor portion. Moreover, in order to adopt the method of assembling the floor panel thus formed as a single body to the strength member of the vehicle body, the floor panel is formed by the body panel portion integrally press-molded with the center tunnel member. It is necessary to drastically change the body assembly line.

Therefore, it is conceivable to assemble the bottom panel and the honeycomb core on the honeycomb structure floor panel individually in the vehicle body assembly line without assembling them in advance. By doing so, the upper and lower plates and the honeycomb core can be individually bent and twisted to some extent, so that the lower plate, the honeycomb core, and the upper plate can be made to follow the strain of the frame while they are being framed. The honeycomb structure floor panel can be firmly bonded to the frame.

However, in the vehicle body assembly line, if the upper and lower plates and the honeycomb core are individually assembled in such a manner, the number of work steps is increased, which is troublesome. As a result, other processes are affected and the vehicle body assembly line cannot be moved efficiently. Further, if the upper plate, the lower plate, and the honeycomb core are separately carried into the assembly line in this manner, the number of parts increases, and the parts management becomes complicated.

The present invention has been made in view of such a problem, and an object thereof is to slightly distort a vehicle body strength member to which a panel is coupled without significantly changing the conventional vehicle body assembly line. Even in the presence of such a problem, the vehicle body panel having the honeycomb sandwich structure can be formed by following the distortion.

Another object of the present invention is to reduce the number of man-hours for assembling work in a vehicle body assembly line, reduce the number of parts, and simplify part management. Is.

(Means for Solving the Problems) In order to achieve this object, in the present invention, the first face plate constituting the vehicle body panel of the honeycomb sandwich structure is formed of the vehicle body panel portion joined to the vehicle body strength member. Further, the sub-honeycomb structure is formed in advance by joining the second face plate and one end of the honeycomb core.

Then, an adhesive layer is provided on the first face plate, and then the sub-honeycomb structure is set on the first face plate.

(Operation) With this configuration, the first face plate that forms the vehicle body panel having the honeycomb sandwich structure is formed in the same process as a conventional assembly line in which the vehicle body panel portion that is joined to the vehicle body strength member is press-molded. Become so.

Further, the sub-honeycomb structure can be deformed extremely easily because the first face plate is not bonded.
That is, since the sub-honeycomb structure has flexibility, even if the vehicle body strength member and the first face plate are distorted due to twisting or the like, the sub-honeycomb structure is It becomes possible to follow the shape of the first face plate and follow it. Therefore, the honeycomb core and the first face plate can be bonded uniformly and surely.

In that case, since the adhesive layer for joining with the first face plate is not provided in the sub-honeycomb structure, its transportation and storage,
It can be easily set in a predetermined position.

Moreover, a vehicle body panel having a honeycomb structure is formed by simply joining the sub-honeycomb structure to the first face plate in the vehicle body assembly line. Therefore, the number of assembly work steps is reduced, and the time required for the work is shortened.

Further, since the sub-honeycomb structure in which the second face plate and the honeycomb core are integrally joined is carried into the vehicle body assembly line, the number of parts is reduced as compared with the case where these are separated. Therefore, the parts management becomes easy.

(Examples) Examples of the present invention will be described below with reference to the drawings.

FIG. 1 illustrates an embodiment of a method for forming a vehicle body panel having a honeycomb sandwich structure according to the present invention by using an example in which the vehicle body panel is applied to a floor panel. FIG. It is an exploded perspective view shown with. Further, FIG. 2 is a vertical cross-sectional view of the vehicle body floor portion in the vehicle body left-right direction before being set on the vehicle body panel portion where the sub-honeycomb structure is joined to the vehicle body strength member,
FIG. 3 is a vertical sectional view similar to FIG. 2 after the sub-honeycomb structure is set on the vehicle body panel portion.

As is apparent from FIGS. 1 and 2, a pair of side sills 1 and 1 extending in the front-rear direction are provided on both left and right sides of the vehicle body floor at a position corresponding to the vehicle compartment floor surface. The side sill 1 is composed of a side sill outer member 2 and a side sill inner member 3 and has a hollow closed cross section.

Further, a pair of center frames 4, 4 extending in the front-rear direction is provided substantially in the middle of the left and right side sills 1, 1.
The center frame 4 has a channel shape that opens upward.

Further, a channel-shaped center tunnel member 5 formed in the center and opened downward, and a vehicle body panel portion 6 extending from the member 5 to the left and right side sills 1, 1 are integrally pressed using a single flat plate. It is molded. The center tunnel member 5 is installed between the pair of center frames 4 and 4 and is joined to each other to form a center tunnel 7 having a hollow closed cross section reinforcing portion. A flange 8 is provided at the end of the vehicle body panel portion 6 opposite to the center tunnel 7, and the flange 8 is joined to the side wall 3a of the side sill inner member 3.

In this way, the vehicle body panel portion 6 is joined to the side sill 1 and the center tunnel 7 which are the vehicle body strength members.

A recess 9 having a predetermined shape is formed in the vehicle body panel portion 6, and the bottom 10 of the recess 9 is flat.

On the other hand, the top plate 11 is formed of a single flat plate that is thinner than the vehicle body panel portion 6. And the top plate 11
A sub-honeycomb structure 13 is formed by joining a honeycomb core 12 made of paper, aluminum, or the like to the lower surface of the substrate, leaving the outer peripheral end thereof. This structure 13 can be bent relatively easily because only the upper surface plate 11 is bonded to one side of the honeycomb core 12. That is, the structure 13 is flexible. Further, the upper surface plate 11 has a size that completely covers the recess 9 and can overlap the peripheral portion of the recess 9 of the vehicle body panel portion 6. Furthermore, the honeycomb core 12 is sized so that it can be completely accommodated in the recess 9.

When joining such a sub-honeycomb structure 13 to the vehicle body panel portion 6, the side sill 1, the vehicle body panel portion 6, the center tunnel 7 and the like are attached to the white body in the vehicle body assembly line as shown in FIG. As described above, first, a general adhesive is applied to the upper surface of the bottom 10 of the recess 9 to form the adhesive layer 14. Then, as shown in FIG. 3, a sub-honeycomb structure
13 is set in the vehicle body pulse portion 6 so as to be housed in the concave portion 9 of the honeycomb core 12. In this state, the outer peripheral end portion of the upper surface plate 11 is joined to the vehicle body panel portion 6 via a sealing material such as a sealer. In that case, honeycomb core 12
The bottom end of the sub-honeycomb structure 13 surely enters the adhesive layer 14 due to the pressing force of the sub-honeycomb structure 13 toward the vehicle body panel portion 6 and the weight of the structure 13 itself.

And white body is the next process of the body assembly line,
For example, the adhesive 14 is solidified during the movement to the coating process, so that the honeycomb core 12 and the bottom 10 of the recess 9 are joined. In that case, when the honeycomb core 12 is made of paper, the adhesive penetrates into the core 12, and thus the bonding force between the core 12 and the bottom 10 becomes large. Since the core 12 and the vehicle body panel portion 6 are firmly joined to each other by the adhesive in this way, the outer peripheral end portion of the upper surface plate 11 and the vehicle body panel portion 6 can be joined relatively easily. Become.

In this way, between the side sill 1 and the center tunnel 7,
A floor panel 15 having a honeycomb sandwich structure integrated with the center tunnel 7 is formed. In that case, the vehicle body panel portion 6 formed integrally with the center tunnel member 5 constitutes the lower surface plate 16.

The lower surface plate 16 and the upper surface plate 11 constitute the first face plate and the second face plate of the present invention, respectively. And the bottom 10 of the recess 9
Is the honeycomb core joining surface of the first face plate.

In the floor panel 15 configured in this manner, the center tunnel member 5 of the lower plate 16 is integrally press-molded by a single flat plate, but such integral molding is performed in a conventional vehicle body assembly line. It can be molded in the same process. Further, since the sub-honeycomb structure 13 is formed by previously bonding the upper surface plate 11 and the honeycomb core 12, when bonding the sub-honeycomb structure 13 to the lower surface plate 16, an adhesive agent is used in the vehicle body assembly line. It is only necessary to apply it to the bottom plate 16. Moreover, by setting only the sub-honeycomb structure 13 from above the vehicle body panel portion 6, that is, from one side, the upper plate 11
The floor panel 15 having a honeycomb structure can be easily formed only by bonding the outer peripheral end portion of the above to the lower surface plate 16 and solidifying the adhesive while moving to the next step of the vehicle body assembly line in that state. Therefore, the number of man-hours for assembling the sub-honeycomb structure 13 and the lower surface plate 16 is reduced, and the working time is shortened. As a result, it is not necessary to consider the adjustment with other steps of the vehicle body assembly line. Moreover, since the conventional vehicle body assembly line can be used with almost no change, the floor panel 15 can be manufactured at a relatively low cost.

Further, since the sub-honeycomb structure 13 is flexible, even if the vehicle body panel portion 6 is distorted due to twisting, the structure 13 conforms to the shape of the vehicle body panel portion 6 and follows. You will be able to. Therefore, the honeycomb core 12 and the bottom 10 of the recess 9 are substantially evenly and reliably bonded over the entire surface.

Moreover, since the sub-honeycomb structure 13 is formed by previously joining the upper surface plate 11 and the honeycomb core 12, the number of components carried into the vehicle body assembly line is reduced. Therefore, management of parts becomes simple.

On the other hand, since the concave portion 9 is formed in the vehicle body panel portion 6,
Due to the shape effect, the rigidity is high. Therefore, the vehicle body panel portion 6 does not bend, and the installation work of the integrally press-molded product of the vehicle body panel portion 6 and the center tunnel member 5 on the jig or the like before the sub-honeycomb structure 13 is attached can be performed accurately. It can be done easily.

Moreover, the structure 13 can be set in the vehicle body panel portion 6 by simply accommodating the honeycomb core 12 of the structure 13 in the recess 9. Therefore, no special measures need to be taken to position the structure 13 with respect to the vehicle body panel portion 6.

In the above-mentioned embodiment, a general adhesive is used as the adhesive layer 14, but the present invention is not limited to this, and other adhesives such as urethane foam or rubber, Asphalt-modified materials such as thermoplastic resins and thermosetting resin-modified materials can also be used. In that case, if a foam material is used, the clearance between the honeycomb core 12 and the lower surface plate 16 caused by a molding error, distortion, or the like can be more effectively absorbed. Furthermore, for example, if a vibration damping material such as a mel sheet is used as an adhesive, it has a vibration damping function for damping minute vibrations, so that the floor panel 15 is provided from each device such as an engine. It becomes possible to effectively absorb minute vibrations.

Further, if the adhesive layer 14 is provided on the vehicle body panel portion 6 after washing with water in the painting process and then the sub-honeycomb structure 13 is set on the vehicle body panel portion 6, the honeycomb core 12 is not wet by the washing water. So the top plate
The seal between 11 and the bottom plate 16 does not need to be so tight. Therefore, the waterproofing process can be simplified.

Furthermore, in the above-mentioned embodiments, the vehicle body panel having the honeycomb sandwich structure is described as being applied to the floor panel 15, but it is possible to prevent vibration, noise, and heat from the engine room from being transmitted to the vehicle interior. In addition to the required dash panel, the method for forming a honeycomb sandwich structure vehicle body panel according to the present invention can be applied to other vehicle body panels that are required to have functions such as damping, sound insulation, and heat insulation.

(Effects of the Invention) As is apparent from the above description, according to the present invention, a honeycomb body in which a honeycomb core is sandwiched between a first face plate and a second face plate in a vehicle body panel portion coupled to a vehicle body strength member is provided. Since it is configured as the first face plate in the sandwich structure, the first face plate can be formed in the same process as the conventional vehicle body assembly line for press-molding the vehicle body panel portion joined to the vehicle body strength member. Therefore, it is not necessary to significantly change the conventional vehicle body assembly line, and it is possible to easily form a honeycomb sandwich structure vehicle body panel at an extremely low cost.

Further, since the second face plate and the honeycomb core are pre-bonded to each other to form the sub-honeycomb structure, the first face plate is provided with the adhesive layer. Therefore, in the vehicle body assembly line, the sub-honeycomb structure is used as the first face plate. A vehicle body panel having a honeycomb sandwich structure is formed by simply setting it from one side. Therefore, the number of man-hours for the assembling work is reduced, and the time required for the work is shortened. As a result, it does not affect other processes of the vehicle body assembly line. Moreover, the sub-honeycomb structure in which the second face plate and the honeycomb core are integrated may be carried into the vehicle body assembly line, and the number of parts is reduced, so that parts management is simplified.

Further, the sub-honeycomb structure has flexibility because the first face plate is not joined. Therefore, even if the vehicle body strength member and the first face plate are slightly distorted, the sub-honeycomb structure can follow their shapes. As a result, the upper surface plate and the honeycomb core can be bonded to the first surface plate uniformly and reliably.

In addition, the sub-honeycomb structure does not need to be provided with an adhesive layer for bonding with the first face plate, and thus is relatively light. Therefore, the structure can be easily set on the first face plate.

[Brief description of drawings]

FIG. 1 illustrates an embodiment of a method for forming a vehicle body panel having a honeycomb sandwich structure according to the present invention by using an example in which the vehicle body panel is applied to a floor panel. The floor panel is shown together with a vehicle body floor portion. FIG. 2 is an exploded perspective view, FIG. 2 is a vertical cross-sectional view of the vehicle body floor portion in the left-right direction of the vehicle body before the sub-honeycomb structure is set on the vehicle body panel portion joined to the vehicle body strength member, and FIG. FIG. 7 is a vertical cross-sectional view of the vehicle body floor portion in the vehicle body left-right direction after the structure is set on the vehicle body panel portion. 1 …… Side sill (body strength member) 6 …… Vehicle panel portion 7 …… Center tunnel (body strength member) 11 …… Top plate (second face plate) 12 …… Honeycomb core 13 …… Sub-honeycomb structure 14 …… Adhesive layer 16: bottom plate (first face plate)

Claims (1)

[Claims] 1. A method for forming a vehicle body panel having a honeycomb sandwich structure in which a honeycomb core is sandwiched between a first face plate and a second face plate and joined together; a vehicle body panel in which the first face plate is joined to a vehicle body strength member. A sub-honeycomb structure is formed by joining the second face plate and the honeycomb core together, and an adhesive layer is provided on the honeycomb core joining face of the first face plate. A method for forming a vehicle body panel having a honeycomb sandwich structure, in which a body is set on the adhesive layer of the first face plate.