JPS6245063B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing automobile plate materials used for vehicle body outer panels such as door panels and roof panels, and particularly relates to a method for manufacturing automobile plate materials used for car body outer panels such as door panels and roof panels. The present invention relates to a method for manufacturing automobile plate materials that are bonded together to improve strength and rigidity.

Conventionally, this type of automobile plate material includes, for example, a door outer panel 1a, which is the outer panel of a door D, as shown in FIG. 1A and B. As shown in FIG. is heat-cured. In addition, 25
2 is a door inner panel, 26 is a door window sash, 27 is a side window glass, and 28 is an outside door handle.

However, such a reinforcing material 22 cannot obtain a desired reinforcing effect unless its thickness is considerably increased, and a large amount of resin material is used, resulting in high production costs and increased weight. In addition to this problem, when adhering reinforcing material that has been molded and hardened in advance, it is difficult to mold the reinforcing material to perfectly match the shape of the board, and it is difficult to ensure perfect adhesion between the two. The problem was that it was difficult.

For this reason, as shown in FIG. 2 A and B, the door outer panel 1b is attached to the metal plate 21 and the inner surface of this plate 21, or to the coating 6 previously attached to this plate 21 for rust prevention. , and relates to an automobile outer panel comprising a tough thermosetting resin reinforcing material 2 to which a reinforcing material 4 such as glass fiber is added, and a bead-shaped bulge 3 formed on the reinforcing material 2. I have already proposed an invention. This invention completely eliminates all the problems of the prior art.

By the way, in order to form this bead-shaped bulging portion 3, as shown in FIG. 3, a foamable polyethylene sheet or a foamable epoxy sheet that is foamed by heating is added to a sheet-like reinforcing material 2a such as an uncured epoxy resin. It is necessary to pre-laminate unfoamed belt-shaped core materials 5 such as the following, and adhere them to a coating 6 such as a waterproof rubber plate.

However, since the core material 5 has a certain thickness so as to form a resin foam 5a whose volume is approximately 10 times as large as that shown in FIG. The core material 5 itself has rigidity, and due to this rigidity, even if the surface of the plate material 21 is a complicated curved surface, it will not deform to follow the surface, and the reinforcing material 2a covering the core material 5 will be lifted up and the plate material There is a problem in that it is difficult to stick it in close contact with 21.

In view of this situation, the present invention has been developed by laminating and adhering resin sheets with different dimensional changes due to heating and using them as a material for bead swelling of a reinforcing material, and forming a bead-shaped bulge using heating in a paint drying oven. The present invention also provides a method for manufacturing an automobile plate material in which the bulging portion can be continuously hardened.

Next, a method for manufacturing an automobile plate material according to the present invention will be explained in detail based on an embodiment shown in the drawings from FIG. 4 onwards. The same reference numerals and names will be used for parts and parts that are the same or equivalent to those in FIGS. 1 to 3, and redundant explanations will be omitted.

1 shown in Fig. 4 A and B is the door outer panel which is the outer panel of the door D.
As shown in FIG. 4C, which is an enlarged view of the main part of FIG. 6. Foamed epoxy sheets and foamed polyethylene sheets (for example, the Nippon Kogyo Shimbun dated April 4, 1972), which have the characteristic that the top and bottom width dimensions and thickness dimensions change approximately twice in the free state when heated, for example at 140°C. The first resin sheet 12 is made of polyester tape or cellophane tape (for example, Sekisui Chemical Co., Ltd.) which undergoes almost no dimensional change at the heating temperature (140° C.) and has its own adhesive strength. A core material 10 made of a soft and flexible thin material laminated with a flexible second resin sheet 14 such as Sumitomo 3M) and a reinforcing material 4 made of a glass fiber nonwoven fabric attached to the surface, and The core material is laminated with sheet-shaped thermosetting resin reinforcing material 16a such as uncured epoxy resin that is flexible and sticky at room temperature (for example, Penguin Sheet #1090 (E-6838) manufactured by Sunstar Chemical Co., Ltd.). The entire periphery of the reinforcing material 16a is brought into contact with the coating 6 so as to completely enclose the reinforcing material 10, and the reinforcing material 16a is sufficiently bonded with the adhesive force of the reinforcing material 16a.
Proceed to the baking and painting process. This reinforcing material 16a
The core material 10 is formed in a short strip shape that is long in the front and back and short in the top and bottom. In this baking painting process, the paint is dried at a temperature of 100°C in a paint drying oven.
The reinforcing material 16a is first softened as the temperature rises in this heating process, and then the first resin sheet 12 begins to foam. Since this first resin sheet 12 is a thin material, gas escapes in the thickness direction (horizontal direction in Figure 4 C), so there is almost no foaming, but in the width direction (vertical direction in Figure 4 C). foams greatly. However, since the second resin sheet 14 undergoes almost no dimensional change, it warps in a substantially C-shaped cross section due to the bimetal principle. At this time, reinforcement material 1
If the width of the reinforcing material 16a is 50 mm, and the width of the reinforcing material 16a is 50 mm, the reinforcing material 10a will not peel off from the covering 6 due to the core material 10. If the material of the first resin sheet 12 is selected so that the warpage is maximized at the temperature at which the reinforcing material 16a is in a softened state, the reinforcing material 16 will be formed by the core material 10 as shown in FIG.
a is pushed up to form a bead-shaped bulge 3, and when the temperature further reaches the hardening temperature of the reinforcing material 16a,
This reinforcing material 16a is cured while maintaining the shape of the bead-shaped bulging portion 3, and together with the reinforcing material 4, it becomes a tough reinforcing material 16 with excellent strength and rigidity, and the curing is completed. Note that the reinforcing material 16a and the core material 10 are the core material 1.
It is glued to the reinforcing material 16a at the center of the core material 1.
In most of the other parts of 0, the reinforcing material 16a becomes too soft and the adhesive strength is weakened, and when the core material 10 is warped, it peels off and does not become a hindrance to warping.

Therefore, according to this method of manufacturing a plate material for an automobile, the coating 6 of the rubber plate is attached directly or in advance to the portion of the plate material 21 to be reinforced, and the core material 10 and the uncured state are applied to the plate material 21 or the coating 6. Reinforcement material 16a
When the reinforcing material 16a hardens during the car body baking process, the first resin sheet 1
2, the core material 10 warps and the reinforcing material 16a is pushed up, and a bead-shaped bulge 3 is formed in the hardened reinforcing material 16. 3 exerts a reinforcing effect as a rib of the plate material 21 to which the reinforcing material 16 is attached, and the strength and rigidity of the manufactured automobile plate material 21 are significantly improved as shown in FIG.

That is, FIG. 6 is a chart showing the pattern of deformation amount with respect to load, and curve 17 is for door D without reinforcement.
Curve 18 is the surface stiffness curve of door D using the conventional reinforcing material without bead-like bulges, and curve 19 is the surface stiffness curve of door D using the reinforcing material of the present invention having bead-like bulges. The stiffness curves are shown respectively.

Furthermore, since the first resin sheet 12 of the core material 10 of the present invention needs to be changed into a C-shape by foaming not in the thickness dimension but in the vertical width dimension, the first resin sheet 12 is thin. Since the core material 10 of the present invention needs to be a solid material and does not have rigidity itself like the conventional core material 5 shown in FIG.
Even if the surface of the plate material 21 is a complicated curved surface,
The core material 10 and the reinforcing material can be reliably attached to the plate material 21 by being deformed to closely follow the surface.

Further, although the first resin sheet 12 of the core material 10 has been described as being made of a foamed material, it is not limited to this, and may be made of a material that shrinks when heated, such as vinyl chloride or polyethylene. Since the second resin sheet 14 has a characteristic that it does not shrink more than the first resin sheet, by heating it, it will be warped into a C-shaped cross section due to the bimetal principle.

Further, either one of the first resin sheet 12 and the second resin sheet 14 of the core material 10 is made of foam having a characteristic that when heated, for example, at 140° C., the top and bottom width dimensions and thickness dimensions change approximately twice in a free state. If a foamed material such as an epoxy sheet or a foamed polyethylene sheet is used on the other hand, and a material that shrinks when heated such as vinyl chloride or polyethylene is used, the warpage upon heating will be large and the shape will become cylindrical.When pushing up the reinforcing material 16a, the position Since the bead-like bulging portion 3 does not swing up and down, the raised position of the bead-shaped bulge portion 3 has better reproducibility.

As described above, according to the method for manufacturing a plate material for an automobile according to the present invention, the core material is formed extremely thin, so it has excellent flexibility, and the reinforcing material covers the core material and abuts the plate material, so that it is in close contact with the plate material. For example, since the core material can be deformed along the curved surface of the plate material, there is no need to push up the reinforcing material. For this reason, the adhesion strength is increased regardless of the shape of the plate material itself at the portion that requires reinforcement, and this has the practical effect of significantly increasing its effectiveness as a reinforcing member.

In addition, although the above embodiment is explained using a door outer panel as an example, it is not necessary to be limited to this.
The present invention can be applied to reinforcing all metal outer panels of a vehicle body, such as a roof panel, front fender, rear fender, etc., as well as other panel parts.

[Brief explanation of the drawing]

Figure 1A is an explanatory front view of a door formed from a conventional automobile plate material, Figure 1B is an explanatory cross-sectional view of Figure 1A, and Figure 1C is an enlarged view of part C in Figure 1B. 2A is a perspective view of the main part of the door outer panel that has already been proposed as a solution to the conventional example, FIG. FIG. 2B is a corresponding sectional explanatory view showing the relationship between the reinforcing material 2a and the core material 5 before reaching FIG.
Figure B is an explanatory diagram of the state of the unfoamed core material according to the cross section of the Ro-Ro line in Figure 4A, Figure 4C is an explanatory enlarged cross-sectional view of the C part in Figure 4B, and Figure 5 is FIG. 4 is a corresponding cross-sectional view showing a bead-shaped portion formed by foaming in a drying oven from the above state, and FIG. 6 is an explanatory view of a correlation curve between load and deformation amount. D... Door, 1, 1a, 1b... Door outer panel, 2, 16, 22... Reinforcement material, 2a, 16a
... Reinforcement material, 3 ... Bead-shaped bulge, 4, 24
... Reinforcement material, 5,10 ... Core material, 6 ... Coating,
12...First resin sheet, 14...Second resin sheet, 21...Plate material.

Claims (1)

[Claims] 1. When forming an automobile plate material in which a thermosetting resin reinforcing material in which a bead-shaped bulge is formed is attached to a metal plate material forming an outer panel of a vehicle body, etc., the thermosetting resin reinforcing material is flexible so as to fit well along the plate material at room temperature. A thin first resin sheet that has a dimensional change that either expands or contracts when heated, and a thin material that changes in dimension less than the first resin sheet or changes in a direction opposite to the direction of change of the first resin sheet. A second resin sheet is pre-laminated and adhesively laminated onto a reinforcing material in the form of an uncured sheet that is flexible and adhesive at room temperature, or
After adhesion of the resin sheet, a second resin sheet is adhesively laminated on the first resin sheet, and at least both upper and lower sides of the reinforcing material are adhered to the metal plate material or a coating previously attached to this plate material for rust prevention. By heating in this state, both of the resin sheets are warped into a C-shaped cross section, pushing up the reinforcing material in a softened state to form a reinforcing material having a bead-like bulge. A method of manufacturing plate materials for automobiles.