KR20070017592A - Manufacturing method of tailgate panel assembly for vehicle - Google Patents

Abstract

The present invention relates to a method of manufacturing a tailgate panel assembly for a vehicle, the inner plate is produced by press-molding with a GMT material, the outer plate is produced by injection molding with a PC / ABS material, the method for bonding the inner plate and the outer plate produced so The present invention relates to a method for manufacturing a tailgate panel assembly for a vehicle, which is assembled into a single panel assembly.

According to the present invention, by molding the plastic instead of the existing steel, the moldability and corrosion resistance is improved, the design freedom is increased, and some trims can be integrally molded to reduce the number of parts, assembly labor, cost reduction . In addition, it is possible to reduce the weight of the product and to form a complicated shape even with a single mold, thereby improving productivity and reducing costs.

Vehicle, Tailgate, Panel, Inner Panel, Outer Panel, GMT, PC / ABS, Press Molding, Injection Molding, Plastic

Description

Manufacturing method of tailgate panel assembly for vehicle

Figure 1a is a perspective view showing the inner plate, outer plate, glass in a conventional vehicle tailgate,

Figure 1b is a front view showing the interior side of the conventional vehicle tailgate,

Figure 2 is a perspective view showing the inner plate and the outer plate with a glass of the tailgate panel assembly manufactured according to the present invention,

Figure 3 is a front view showing the interior side of the tailgate to which the inner plate prepared according to the present invention,

Figure 4 is an enlarged view showing a tailgate hinge configured to include a base portion integrally formed in the inner plate according to the present invention.

<Explanation of symbols for the main parts of the drawings>

110: tailgate panel 120: inner plate

120a: opening 121: rib pattern

122: vertical rib 123: horizontal rib

124a, 124b: inclined rib 125a: vertical rib

125b: horizontal rib 126: box structure

127: tailgate hinge 128: base portion

130: outer shell 130a: upper shell

130b: lower outer plate 131: lamp housing

132: garnish

The present invention relates to a method for manufacturing a tailgate panel assembly for a vehicle, and more particularly, press-molded the inner plate with a GMT material, the outer plate is produced by injection molding with a PC / ABS material, and the inner plate and the outer plate manufactured as described above The present invention relates to a method for manufacturing a tailgate panel assembly for a vehicle assembled by bonding to each other to produce a single integrated panel assembly.

In general, the tailgate is a part located between the side outer panel and the bumper, and means a rear door such as a van or an RV vehicle, and is a part that is used as an exterior part as well as a structural member.

The requirements for these tailgates include structural stiffness, maintaining a constant clearance and step with surrounding components, and color matching.

In general, the panel assembly of the tailgate is composed of an outer panel and an inner panel made of steel, and is fabricated by welding the outer plate and the inner plate by spot welding.

FIG. 1A is a perspective view illustrating an inner plate, an outer plate, and a glass in a conventional vehicle tailgate, and FIG. 1B is a front view illustrating an interior side surface of a conventional vehicle tailgate. 12) and lamp assembly including panel assembly 11, glass 14, inner trim 15, 16, 17, lens and reflector, lamp housing, etc. Not shown), a latch assembly 19 for door locking, and the like.

In FIG. 1B, reference numeral 15 denotes an upper trim at the inner trim, 16 a side trim, and 17 a lower trim, and these trims 15, 16 and 17 enclose the inner plate 12 to form a complex steel inside. Make it invisible

In addition, the panel assembly 11 is provided with various reinforcing structures for opening and closing the tailgate and installing the wiper.

For example, two hinge reinforcements are formed at the upper end of the panel assembly 11 at the center of rotation of the tailgate opening and closing operation, and two lift reinforcements are formed at both sides of the upper panel to easily open and close the tailgate.

In addition, a motor reinforcement part is configured at the lower center of the panel assembly 11 to install a wiper motor for the wiper system, and a latch reinforcement part is installed at the center of the lower part to mount the latch assembly 19 of the tailgate.

The panel assembly 11 is manufactured by separately forming the inner plate 12 and the outer plate 13 by a steel plate and then assembling the inner plate 12 and the outer plate 13 by spot welding.

However, in the conventional tailgate panel assembly 11, the outer plate 13 has a simple shape, but the inner plate 12 has a complicated shape for stiffness, and thus requires a plurality of moldings, and the inner plate 12 Since both the outer plate and the outer plate 13 were made of steel, there was a problem in corrosion resistance and the like, and thus an improvement thereof was required.

Therefore, the present invention is invented to solve the inconvenience as described above, the inner plate is produced by press-molding with a GMT material, the outer plate is produced by injection molding from PC / ABS material, the inner plate and the outer plate thus produced By assembling by gluing and manufacturing into one integrated panel assembly, by molding plastic instead of steel, moldability and corrosion resistance are improved, design freedom is increased, and some trims can be integrally molded. And to provide a method of manufacturing a tailgate panel assembly for a vehicle that can be reduced assembly costs, cost reduction, as well as light weight and mold cost can be reduced.

Hereinafter, the present invention will be described in detail with reference to the accompanying drawings.

The present invention comprises the steps of: forming an inner plate by pressing and simultaneously heating the GMT sheet between an upper mold and a lower mold having an inner plate-shaped molding space;

Molding the outer plate by injecting PC / ABS molten resin into an injection mold having a molding space having an outer plate shape;

Integrally adhering the inner plate and the outer plate formed as described above using a urethane-based adhesive to a portion in contact with each other;

Characterized in the method for manufacturing a vehicle tailgate panel assembly comprising a.

In particular, the inner plate is characterized in that the extrusion molding a plurality of box-shaped structure having a rib pattern and the inner space for stiffness complement on the inner surface.

In addition, the inner plate forms a plurality of vertical, horizontal and inclined ribs on the upper inner surface of the inner surface of the opening to cover the glass to complement the rigidity, and forms a plurality of inclined ribs on the inner surface of both sides, The lower inner surface is characterized in that the extrusion molding a plurality of box-like structure having a plurality of vertical and horizontal ribs and the inner space.

In addition, the inner plate is characterized in that the base portion coupled to the vehicle body side hinge bracket and the hinge pin of the tailgate hinge at each position on the left side and the right side of the upper end.

Hereinafter, the present invention will be described in more detail with reference to the accompanying drawings.

The present invention replaces the material of the tailgate panel assembly, which was made of steel, with a plastic material, and then fabricates and fabricates the inner plate of the GMT material and the outer plate of the thermosetting resin material, thereby improving vehicle weight, corrosion resistance, and design freedom. The present invention relates to a method of manufacturing a tailgate panel assembly for a vehicle.

2 is a perspective view showing the inner plate and the outer plate of the tailgate panel assembly manufactured according to the present invention together with the glass, and FIG. 3 is a front view showing an interior side surface of the tailgate to which the inner plate manufactured according to the present invention is applied. 4 is an enlarged view illustrating a tailgate hinge configured to include a base part integrally formed on an inner plate according to the present invention.

Referring to the manufacturing process according to the present invention, first, the inner plate 120 is manufactured by press molding a glass matted thermoplastics (GMT) material, using a mold apparatus having a molding space having an inner plate shape between the upper mold and the lower mold; The inner plate is formed by applying pressure simultaneously.

The GMT is a composite of a thermoplastic resin and a glass fiber mat, which is lightweight and recyclable, and particularly energy absorbency, design freedom, assembly, corrosion resistance, rigidity and resilience, sound insulation and agent It is a composite material with excellent intrinsic and elastic impact resistance.

The physical properties of the GMT used as the inner plate material in the present invention are shown in Table 1 together with the physical properties of PC / ABS, which is an outer plate material to be described below, and the properties of conventionally used steel.

In the molding of the GMT material, the sheet-shaped GMT material is placed between the upper mold and the lower mold, and heat and pressure are applied to obtain the shape of the product.

In other words, the GMT sheet is placed on the molding space of the lower mold and heat is applied to the upper mold, and the upper mold is pressed. The advantage is that it requires high pressure.

The pattern of placing the pre-fabricated GMT sheet on the lower mold is called pattern, and after several test work in advance, finds the best pattern with good flow and effective, and performs molding for full-scale product manufacturing.

In particular, in the present invention, since the inner plate 120 is a part requiring structural rigidity, the plurality of rib patterns 121 and the box-like structure 126 are integrally formed on the inner plate to compensate for the insufficient rigidity in comparison with the steel material.

As an example, the basic thickness of the inner plate 120 is 3cm, the thickness of the ribs 122, 123, 124a, 124b, 125a, 125b can be designed to 3.0 ~ 3.5cm, the opening 120a is covered by the glass 140 Rib is formed around the perimeter.

In the embodiment of Figure 2, the inner surface of the upper end of the inner plate 120, that is, the inner surface of the upper portion of the upper portion of the opening (120a) vertical ribs 122 formed vertically long in all areas and horizontal ribs formed horizontally long ( 123 and the obliquely elongated inclined ribs 124a are formed in plural, respectively, and a plurality of inclined ribs 124b are uniformly arranged on the inner surfaces of both side portions of the opening 120a.

In addition, a plurality of vertical ribs 125a which are formed vertically and elongated at a predetermined interval are formed on a lower portion of the inner surface of the inner plate 120, that is, a lower portion of the lower portion of the opening 120a, and a latch portion of the lower portion of the inner plate 120. On the inner side, a horizontal rib 125b having a thickness of 3 cm is formed horizontally with respect to the vertical rib 125a.

In addition, a plurality of box-like structures 126 having an inner space in the lower portion of the opening 120a in the inner plate 120 are formed to protrude inward.

In addition, as illustrated in FIG. 3, the base portion 128 of the tailgate hinge is integrally formed on the outer surface (vehicle interior surface) of the upper end of the inner plate 120.

FIG. 4 is a view illustrating a tailgate hinge 127 including a base portion 128 integrally formed on the inner plate 120 in the present invention, wherein the hinge bracket 129a and the inner plate 120 are fixed to the vehicle body. The base portion 128 is coupled to the hinge pin 129b, so that the tail gate 100 can rotate about the hinge 127 when the tailgate 100 is opened and closed.

The rib pattern 121 and the box-shaped structure 126 are formed to compensate for the stiffness that is insufficient compared to that of the steel material, and the structure using the computer aided engineering (CAE) for the inner plate 120 shown in FIG. 2. Through the analysis, we simulated whether the designed structure has sufficient stiffness, and the results of the analysis are shown in Table 2 below.

Next, separately from the inner plate 120, the outer plate 130 is manufactured by an injection molding method using an injection mold having an outer plate-shaped molding space using a PC / ABS material that is a thermosetting resin having excellent paintability and surface quality. In this case, the outer plate 130 may be manufactured in two pieces (2 pieces) of the upper outer plate (130a) and the lower outer plate (130b).

As an example, the basic thickness of the outer plate 130 may be designed to 2.5cm.

In the present invention, the PC / ABS used as the material of the outer plate 130 alloys polycarbonate and ABS (Acrylonitryl Butadiene Styrene) resin to complement each other's disadvantages and maximize the advantages. As an engineering plastic utilizing, it is known that it is excellent in mechanical strength, thermal property, workability, and weather resistance.

The upper outer panel 130a and the lower outer panel 130b formed by injecting the PC / ABS molten resin into the injection mold as described above are coated to match the color of the outer panel of the vehicle body. The outer plates 130 and 130a and 130b are assembled to one piece of tailgate panel 110 by adhering with a urethane-based adhesive to a portion bonded to each other.

The tailgate panel 110 made of a plastic material, in which the inner plate 120 and the outer plate 130 are assembled, is assembled with the glass 140 and completed as a single tailgate 100. The inner plate 120 and the outer plate ( 130, other reinforcement and brackets, the lamp housing 131, the garnish 132, a part of the trim may be integrally formed in each corresponding portion as necessary.

Referring to FIG. 3, the conventional upper trim and side trim except for the lower trim 133 are deleted. This is because the outer surface (car interior side) of the GMT inner plate 120 serves as the upper trim and side trim. This is because the GMT inner plate 120 may be formed into a trim shape in order to reduce trims.

Therefore, in the case of manufacturing the plastic tailgate by applying the present invention, it is possible to reduce the number of parts and assembly labor, and to reduce the weight, and to reduce costs by integrating and integrally molding some trims.

The following Table 3 shows a comparison of the weight of the plastic panel according to the present invention compared to the conventional steel panel, the overall weight reduction effect of about 27.6% was obtained.

As shown in Table 3, in the case of the inner plate 120, some trims such as the reinforcement portion including the rib pattern 121 and the box-shaped structure 126 and various brackets, and the base portion 128 of the tailgate hinge 127 are shown. ) Is integrally molded so that the weight is heavier than that of the existing steel plate, but in the case of the outer plate 130, the lamp housing 131 and the garnish 132 are integrally molded and lighter than the existing steel plate.

And, the weight of the adhesive is added, the lamp housing 131 and the garnish 132 is included in the weight of the outer plate 130, the base portion 128 is included in the weight of the inner plate 120, the remaining trims not integrally formed ( 133), the overall weight of the plastic panel assembly is significantly lighter than that of conventional steel.

And, in order to determine the applicability of the present invention, the tailgate made of the plastic panel according to the present invention was mounted on the vehicle body and subjected to the opening and closing endurance test in the actual vehicle state, and cracks and deformations were performed until the opening and closing operation was performed 20,000 times. There was no occurrence, and it was confirmed that no other abnormal operation occurred.

As described above, according to the method of manufacturing a tailgate panel assembly for a vehicle according to the present invention, the inner plate is produced by press-molding with a GMT material, the outer plate is produced by injection molding with a PC / ABS material, and the inner plate and By assembling the outer plate by bonding to each other to produce a single panel assembly, the following effects are achieved.

1) Since plastic is used instead of steel, moldability and corrosion resistance can be improved and design freedom can be increased.

2) It is possible to reduce the number of parts, assembly labor and cost by integrating some trims, and to produce panels with light weight and improved fuel efficiency because the thickness is thicker but relatively low compared to steel materials.

3) When the steel material is used, the shape for rigidity is complicated, but the molding has to be performed several times. However, in the present invention, plastic can be used to mold a complex shape even with a single mold, thereby improving productivity and reducing costs. You can get it.

4) It is easy to supplement the stiffness by reinforcing the thickness and rib on the desired part.

Claims (4)

Placing the GMT sheet between the upper mold and the lower mold having an inner plate-shaped molding space and applying heat to press molding the inner plate to form an inner plate; Molding the outer plate by injecting PC / ABS molten resin into an injection mold having a molding space having an outer plate shape; Integrally adhering the inner plate and the outer plate formed as described above using a urethane-based adhesive to a portion in contact with each other; Method for manufacturing a vehicle tailgate panel assembly comprising a. The method according to claim 1, The inner plate is a method of manufacturing a tailgate panel assembly for a vehicle, characterized in that for extrusion molding a plurality of box-shaped structure having a rib pattern and the inner space for stiffness on the inner surface. The method according to claim 1 or 2, The inner plate forms a plurality of vertical, horizontal and inclined ribs on the upper inner surface of the inner surface of the opening to cover the rigidity, and forms a plurality of inclined ribs on the inner surface of both sides of the inner surface of the glass. A method of manufacturing a tailgate panel assembly for a vehicle, comprising: protruding a plurality of box-shaped structures having a plurality of vertical and horizontal ribs and an inner space on a surface thereof. The method according to claim 1 or 2, The inner plate is a method of manufacturing a tailgate panel assembly for a vehicle, characterized in that the base portion coupled to the body side hinge bracket and the hinge pin of the tailgate hinge at each position on the left side and the right side of the upper end.

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