WO2012098787A1 - 凹凸部を有する板材並びにこれを用いた車両パネル及び積層構造体 - Google Patents
凹凸部を有する板材並びにこれを用いた車両パネル及び積層構造体 Download PDFInfo
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- WO2012098787A1 WO2012098787A1 PCT/JP2011/078741 JP2011078741W WO2012098787A1 WO 2012098787 A1 WO2012098787 A1 WO 2012098787A1 JP 2011078741 W JP2011078741 W JP 2011078741W WO 2012098787 A1 WO2012098787 A1 WO 2012098787A1
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
- B32B3/28—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D47/00—Making rigid structural elements or units, e.g. honeycomb structures
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60J—WINDOWS, WINDSCREENS, NON-FIXED ROOFS, DOORS, OR SIMILAR DEVICES FOR VEHICLES; REMOVABLE EXTERNAL PROTECTIVE COVERINGS SPECIALLY ADAPTED FOR VEHICLES
- B60J5/00—Doors
- B60J5/04—Doors arranged at the vehicle sides
- B60J5/042—Reinforcement elements
- B60J5/045—Panel type elements
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
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- B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
- B62D25/08—Front or rear portions
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Definitions
- the present invention relates to a plate material having increased rigidity by forming an uneven portion, and a vehicle panel and a laminated structure configured using the plate material.
- Patent Document 1 proposes a material in which a large number of protrusions are formed by embossing in order to ensure sufficient rigidity without increasing the plate thickness. Further, not only heat insulators but also plate materials having improved rigidity by forming uneven portions such as embossing for various uses have been proposed (Patent Documents 2 to 7).
- Japanese Patent No. 4388558 Japanese Patent No. 3332353 JP 2000-257441 A JP-A-9-254955 Japanese Patent Laid-Open No. 2000-288643 JP 2002-307117 A JP 2002-321018 A
- a plate material having a corrugated shape or a large number of uneven portions formed on the plate material has higher rigidity than a flat plate having no uneven portions.
- the rigidity of the plate material provided with the corrugated shape is directional, and although the rigidity is improved in one direction, the desired rigidity improvement effect may not be obtained in the other direction.
- the rigidity improvement effect is about twice that of the flat plate not forming the concave and convex portions.
- the weight reduction effect is about 20%, which does not necessarily satisfy the requirement.
- the present invention has been made in view of such problems, and is a plate material having improved rigidity by providing uneven portions, and a plate material having a pattern of uneven portions having a higher rigidity improving effect than before, and this It is an object of the present invention to provide a used vehicle panel and a laminated structure.
- One aspect of the present invention is a plate material having increased rigidity by forming an uneven portion
- the concavo-convex portion is based on a first reference surface, an intermediate reference surface, and a second reference surface, which are virtual three surfaces sequentially arranged in parallel at intervals, Assuming that the intermediate reference plane is laid out with a first unit region and a second unit region made of a virtual rectangle of the same size, A direction parallel to one side of a virtual rectangle forming the first unit region and the second unit region is defined as an X direction, and a direction perpendicular to the X direction is defined as a Y direction.
- the first unit region and the second unit region are partitioned by a grid that divides the side arranged in the X direction into three equal parts and divides the side arranged in the Y direction into five equal parts.
- a column that is adjacent to the second column to the fifth column is a column, and a column composed of the cells arranged in the Y direction including the reference cell is a column A, and is sequentially Adjacent columns are the B and C columns,
- all ridges arranged in the first column and the fifth column are defined as the first ridge, and in the second column to the fourth column, they are arranged in the A column and the C column.
- the kite is the second kite and the kite arranged in the B row is the first kite.
- all the ridges arranged in the first column and the fifth column are the second ridges, and in the second column to the fourth column, they are arranged in the A column and the C column.
- the kite is the first kite and the kite arranged in the B-th row is the second kite.
- the first unit region and the second unit region are arranged in the same direction on the intermediate reference plane, and the first unit region and the second unit region are alternately arranged in a row in the Y direction.
- a plurality of unit region rows arranged in a The unit region rows adjacent in the X direction on the intermediate reference plane are arranged at positions moved by three squares in the Y direction.
- an icosahedral region composed of the first ridges adjacent to each other sharing a side is defined as a first reference region
- a decagonal region composed of the second ridges adjacent to each other sharing a side is defined as a first reference region.
- a second region protruding toward the second reference surface and a planar region formed on the intermediate reference surface based on the second reference region are provided.
- the first region includes a first top surface obtained by projecting the first reference region on the first reference surface with the same magnification or reduction, a contour of the first top surface, and a contour of the first reference region.
- the second region includes a second top surface obtained by projecting the second reference region on the first reference surface or the second reference surface with the same or reduced magnification, the outline of the second top surface, and the second top surface. It is in the board
- Another aspect of the present invention is a laminated structure formed by laminating a plurality of plate members, wherein at least one of the plate members is a plate member having the uneven portions.
- Still another aspect of the present invention is a vehicle panel having an outer panel and an inner panel joined to the back surface of the outer panel, wherein one or both of the outer panel and the inner panel has the uneven portion.
- the vehicle panel is characterized by comprising a plate material.
- the concavo-convex portion is defined on the intermediate reference plane and a first region protruding from the first reference region defined on the intermediate reference plane toward the first reference plane. Any one of a second region protruding from the second reference region to the first reference surface or the second reference surface and a planar region formed on the intermediate reference surface based on the second reference region Or both are provided.
- the plate material having the concavo-convex portion is a plate material excellent in bending rigidity and energy absorption characteristics.
- the reason why the rigidity is improved is considered as follows. That is, the first region includes the first top surface disposed on the first reference surface disposed at a position away from the neutral surface of the plate material, and the first side surface intersecting the thickness direction of the plate material. It consists of.
- the second region includes the second top surface disposed on the first reference surface or the second reference surface, and the second side surface intersecting the thickness direction of the plate material.
- the planar area is formed based on the second reference area disposed on the intermediate reference plane. Therefore, many materials can be arranged at positions away from the neutral surface of the plate material. Therefore, many materials can be used effectively, and the rigidity improvement effect can be enhanced.
- the first region and the second region are formed on the basis of the first reference region and the second reference region in which the shape and positional relationship are set as described above.
- the secondary moment of the cross section can be improved even in any cross section, and an uneven shape having an excellent rigidity improving effect and less rigidity anisotropy can be obtained.
- This makes it possible to reduce the weight of the material with a small thickness because the necessary rigidity can be obtained.
- the improvement in rigidity it is possible to obtain the effect of improving the vibration damping property and the effect of suppressing the sound echo due to the uneven shape.
- a laminated structure having very high rigidity can be easily obtained by using a plate member having an uneven portion having a rigidity improving effect as described above as a part of the laminated structure.
- the plate member having the uneven portion having the rigidity improving effect as described above for one or both of the outer panel and the inner panel, a vehicle panel having a very high rigidity can be easily obtained. be able to.
- FIG. 2 is a partially enlarged cross-sectional view taken along the line AA in FIG.
- FIG. 3 is an explanatory diagram illustrating a first unit region in the first embodiment.
- FIG. 6 is an explanatory diagram showing a second unit region in the first embodiment.
- FIG. 3 is an explanatory diagram illustrating an intermediate reference plane in the first embodiment.
- FIG. 8 is a partially enlarged cross-sectional view taken along the line BB in FIG.
- FIG. 10 is a partially enlarged cross-sectional view taken along the line CC in FIG. 9; Explanatory drawing which shows the cylindrical material which has an uneven
- FIG. Explanatory drawing of the laminated structure in Example 5.
- FIG. Explanatory drawing of the vehicle panel in Example 6.
- the icosahedron refers to a figure having 20 sides and 20 vertices, and the vertices are formed in a convex or concave shape.
- expressions of shapes such as icosagons and rectangles are not limited to geometrical concepts, and generally include shapes that can be recognized as the above shapes, and each side is slightly curved. Naturally, it is permissible to provide a so-called fillet that generates roundness necessary for molding at corners and surfaces.
- the expression of parallelism is not limited to a geometrically narrow concept, and may be anything that can be generally recognized as parallel.
- the configuration of the concavo-convex portion varies depending on which of the second region and the planar region is formed based on the second reference region.
- the concavo-convex portion is constituted by the first region and the second region.
- the second region is formed so as to protrude from the intermediate reference surface toward the first reference surface.
- the second region is formed on the second reference surface arranged on the first reference surface.
- a second side surface disposed between the first reference surface and the intermediate reference surface.
- the second region is the second apex arranged on the second reference surface.
- a second side surface disposed between the second reference surface and the intermediate reference surface.
- the uneven portion is constituted by the first region and the planar region. Further, both the second region and the planar region can be formed based on the second reference region. In this case, the uneven portion is constituted by the first region, the second region, and the planar region.
- the obtained rigidity and its anisotropy can be changed as appropriate.
- the shape of the concavo-convex portion formed by two or more regions among the first region, the second region, and the planar region to be formed is regularly formed.
- the uneven portion has an irregular shape, a local change in rigidity occurs, and the rigidity and its anisotropy may become unstable.
- first top surface may be configured by the surface of the first reference surface, or by a portion protruding from the first reference surface in a direction opposite to the direction in which the intermediate quasi-surface is arranged. It can also be configured.
- second top surface in the case where the second region is provided may be configured by the surface of the first reference surface or the second reference surface, or in the same direction as the protruding direction of the second region. It can also be constituted by a protruding part. Examples of the shape of the protruding portion include a dome shape, a ridge line shape, and a cone shape, but are not limited thereto.
- the length L (mm) of one side forming the ridge and the length M (mm) of a side orthogonal to the one side have a relationship of 0.5L ⁇ M ⁇ 2L.
- M is less than 0.5L and exceeds 2L, it is not preferable because molding may become difficult and anisotropy of bending rigidity may increase.
- the inclination angle ⁇ 1 (°) of the first side surface with respect to the intermediate reference plane is in the range of 10 ° to 90 °
- the inclination angle ⁇ 2 (°) of the second side surface with respect to the intermediate reference plane is It is preferably in the range of 10 ° to 90 °.
- grooved part shape which has the outstanding rigidity improvement effect can be obtained, ensuring a moldability.
- the protruding heights of the first region and the second region are increased. This makes it difficult to improve the rigidity.
- the upper limit values of the inclination angle ⁇ 1 (°) of the first side surface and the inclination angle ⁇ 2 (°) of the second side surface are 70 ° or less due to the problem of formability.
- a more preferable range is 10 ° to 70 °.
- the said 1st side surface and the said 2nd side surface are comprised by several surfaces, all of those surfaces do not need to be the same inclination angles, and you may change an inclination angle according to a site
- the plate material having the excellent uneven portion can be deformed into various shapes, and the application can be expanded.
- the concavo-convex portion is formed by press-molding the metal plate.
- the metal plate can be easily formed with uneven portions by performing plastic working such as press forming such as embossing or roll forming. Therefore, in the case of a metal plate, it is relatively easy to apply the above excellent uneven shape.
- various materials that can be plastically processed such as aluminum alloy, steel, and copper alloy can be applied.
- plate material has the said uneven
- it is effective also in materials other than a metal,
- it can also be set as the laminated material or composite material of a resin board, resin, and a metal. If it is a resin material or the like, the uneven portion can be formed by injection molding or hot pressing. Resin materials are less subject to molding restrictions than metal materials, and the degree of freedom in design is wider.
- the plate thickness t (mm) before forming the metal plate is preferably 0.03 to 6.0 mm.
- the thickness of the metal plate is less than 0.03 mm or more than 6.0 mm, there is little need to improve the rigidity for use.
- the ratio L / t between the length L (mm) of one side forming the ridge and the plate thickness t (mm) is preferably 10 to 2000. If the ratio L / t is less than 10, molding may be difficult. On the other hand, if the ratio L / t exceeds 2000, a sufficient uneven portion shape cannot be formed and rigidity is reduced. There is a risk of problems.
- the largest inclination angle ⁇ 1 formed by the ratio H 1 / t between the protrusion height H 1 (mm) of the first region and the plate thickness t (mm), and the first side surface and the intermediate reference surface. (°) has a relationship of 1 ⁇ (H 1 / t) ⁇ ⁇ 3 ⁇ 1 +272, and the ratio H 2 between the protrusion height H 2 (mm) of the second region and the plate thickness t (mm).
- / T and the largest inclination angle ⁇ 2 (°) formed by the second side surface and the intermediate reference surface preferably have a relationship of 1 ⁇ (H 2 / t) ⁇ ⁇ 3 ⁇ 2 +272.
- the ratio H 1 / t When the ratio H 1 / t is less than 1, there may be a problem that the effect of improving the rigidity by forming the first region cannot be sufficiently obtained. On the other hand, when the ratio H 1 / t exceeds ⁇ 3 ⁇ 1 +272, there is a possibility that a problem that molding becomes difficult may occur. Similarly, when the ratio H 2 / t is less than 1, there may be a problem that the rigidity improvement effect by forming the second region cannot be sufficiently obtained. On the other hand, when the ratio H 2 / t exceeds ⁇ 3 ⁇ 2 +272, there is a possibility that a problem that molding becomes difficult may occur.
- grooved part can be made into the core material of 1 sheet, and can be set as the laminated body of the three-layer structure which consists of a flat faceplate each arrange
- a structure in which such a basic structure is repeated that is, a multilayer structure in which a plurality of plate members having the above-described uneven portions are laminated on each other via a flat face plate.
- a structure in which a plate material having a plurality of uneven portions is directly laminated to form a core material, and a flat face plate is bonded to the surface of one side or both sides thereof can also be adopted.
- it can also be set as the laminated structure of the state which only laminated
- the number of laminated plate members can be changed according to the application and required characteristics.
- the vehicle panel is applicable not only to automobile hoods, but also to panels and reinforcing members such as doors, roofs, floors, and trunk lids, and energy absorbing members such as bumpers, crash boxes, and door beams.
- a steel plate, an aluminum alloy plate, etc. can be used as the outer panel and the inner panel.
- the outer panel is made of an aluminum alloy plate, for example, a 6000 series alloy is preferable because it is relatively inexpensive.
- the inner panel is made of an aluminum alloy plate, for example, a 5000 series alloy plate is preferable because of its relatively good formability.
- Example 1 Examples relating to a plate material having an uneven portion will be described with reference to FIGS.
- FIG. 1 shows a plan view of a plate 1 having an uneven portion 20 shown in this example, and a broken line shown in the drawing shows an intersection line between the intermediate reference plane K3 and the uneven portion 20.
- FIG. FIG. 6 shows the shape of the concavo-convex portion 20 of the plate 1 shown in this example by the arrangement of the first reference region 213 and the second reference region 223 on the intermediate reference surface K3.
- a thick solid line indicates the boundary between the first unit region 241 and the second unit region 242, and a thin solid line indicates the outline of the first reference region 213 and the second reference region 223. is there.
- the broken line shows the outline of the 1st cage
- the plate member 1 having the concavo-convex portion 20 of this example has increased rigidity by forming the concavo-convex portion 20.
- the uneven portion 20 is configured as follows. As shown in FIG. 2, the concavo-convex portion 20 is based on a first reference plane K1, an intermediate reference plane K3, and a second reference plane K2, which are three virtual planes arranged sequentially in parallel at intervals. As shown in FIG. 6, the intermediate reference plane K3 is assumed to be covered with a first unit area 241 and a second unit area 242 made up of virtual rectangles (squares) of the same size.
- a direction parallel to one side of a virtual rectangle forming the first unit region 241 and the second unit region 242 is defined as an X direction, and a direction perpendicular to the X direction is defined as a Y direction.
- the first unit region 241 and the second unit region 242 divide the side arranged in the X direction into three equal parts and divide the side arranged in the Y direction into five equal parts.
- the virtual cells divided by the arranged grids are classified into two types of first cells 243 or second cells 244.
- the column arranged in the Y direction including the reference cell is referred to as the A column, The columns that are sequentially adjacent to this are defined as a Bth column and a Cth column.
- a column arranged in the X direction including the reference cell is a first column, and columns adjacent to the first column are a second column to a fifth column.
- all ridges arranged in the first column and the fifth column are defined as the first ridge 243, and the A-th column and the C-th column in the second to fourth columns.
- the basket arranged in the row is referred to as a second basket 244, and the basket arranged in the B-th row is referred to as a first basket 243.
- the first unit regions 241 arranged in this way are arranged in the first direction and the fifth direction in the Y direction arranged in the first row 243 and the third row 243 connected to the B row in the second to fourth rows.
- a substantially I-type region composed of three continuous first rods 243, and three second rods 244 that are arranged in the Y direction in the second column to the fourth column, respectively.
- all ridges arranged in the first column and the fifth column are defined as the second ridge 244, and in the second to fourth columns, the A column and the The basket arranged in the C-th row is referred to as a first basket 243, and the basket arranged in the B-th column is referred to as a second basket 244.
- the second unit region 242 arranged in this way has three second rods 244 continuous in the X direction in the first row and the fifth row, and the Y direction arranged in the B row in the second to fourth rows.
- a substantially I-type region composed of three continuous second rods 244, and three first rods 243 that are arranged in the Y direction in the second to fourth columns, respectively, arranged in the A and C columns.
- the first unit region 241 and the second unit region 242 are arranged in the same direction on the intermediate reference plane K3, and the first unit region 241 and the second unit region are arranged in the Y direction.
- a plurality of unit region rows L1 and L2 in which 242 and 242 are alternately arranged in a row are formed.
- the unit region rows L1 and the unit region rows L2 are alternately arranged, and the adjacent unit region rows L1 and L2 are moved by three squares in the Y direction. It is placed in the position.
- an icosahedral area composed of first ridges 243 sharing adjacent sides is defined as a first reference area 213, and an icosahedral area composed of second ridges 244 sharing adjacent sides is defined as The second reference area 223 is assumed.
- the first reference region 213 arranged on the intermediate reference plane K3 includes the substantially I-shaped region formed by the first ribs 243 in the first unit region 241 and the first reference region 213 in the substantially I-shaped region.
- Combining the three first rods 243 connected in the X direction arranged in one row or the fifth row with a rectangular region composed of the first ribs 243 of the second unit regions 242 arranged on both sides in the X direction It becomes an area.
- the second reference region 223 includes a substantially I-type region formed by the second ridge 244 in the second unit region 242 and X arranged in the first row or the fifth row in the substantially I-shaped region. This is a combined region of the three second rods 244 connected in the direction and the rectangular region formed of the first ribs 243 of the second unit regions 242 arranged on both sides in the X direction.
- the concavo-convex portion 20 is a first region that protrudes from the first reference region 213 (FIG. 6) defined on the intermediate reference surface K3 (FIG. 6) toward the first reference surface K1.
- the first region 21 connects the first top surface 211 obtained by reducing and projecting the first reference region 213 onto the first reference surface K1, and the contour of the first top surface 211 and the contour of the first reference region 213. It consists of the first side surface 212.
- the second region 22 connects the second top surface 221 obtained by reducing and projecting the second reference region 223 onto the second reference surface K2, and the contour of the second top surface 221 and the contour of the second reference region 223.
- the second side 222 is formed.
- the first reference plane K1, the intermediate reference plane K3, and the second reference plane K2 in this example are planes parallel to each other.
- the first top surface 211 is configured such that the plate thickness center thereof overlaps with the first reference surface K1
- the second top surface 221 is configured so that the plate thickness center thereof overlaps with the second reference surface K2. Yes.
- the distance to the projection height H 1 between the first reference surface K1 and the intermediate reference plane K3, in the present embodiment, the protruding height H 1 of the first region 21 was set to 1.5 mm.
- the distance to the protruding height H 2 of between the second reference plane K2 and the intermediate reference plane K3, in the present embodiment, the protruding height H 2 of the second region 22 was set to 1.5 mm.
- the length L (mm) of the sides arranged in parallel to the X direction in the first mesh 243 and the second mesh 244 are arranged in parallel to the Y direction.
- the length M (mm) of the sides is 8 mm, and the squares are square.
- the inclination angle ⁇ 1 of the first side surface 212 with respect to the intermediate reference plane K3 and the inclination angle ⁇ 2 of the second side surface 222 with respect to the intermediate reference plane K3 are both 30 °.
- the concavo-convex portion 20 is formed by press molding using a pair of molds.
- molding method can also employ
- the ratio L / t between the length L (mm) of the side arranged parallel to the X direction and the thickness t (mm) of the aluminum plate is 26.67, and is within the range of 10 to 2000. is there.
- the ratio H 1 / t between the protrusion height H 1 (mm) of the first region 21 and the plate thickness t (mm) is 5.
- the ratio H 2 / t between the protrusion height H 2 (mm) of the second region 22 and the plate thickness t (mm) is 5.
- the concavo-convex portion 20 includes the first region 21 projecting from the first reference region 213 defined on the intermediate reference surface K3 toward the first reference surface K1, and the first region 21 defined on the intermediate reference surface K3. And a second region 22 projecting from the second reference region 223 toward the second reference plane K2.
- the first region 21 includes a first top surface 211, and a first side surface 212 that connects the contour of the first top surface 211 and the contour of the first reference region 213. It consists of a top surface 221 and a second side surface 222 that connects the contour of the second top surface 221 and the contour of the second reference region 223.
- grooved part 20 of this example becomes excellent in the energy absorption characteristic while being excellent in bending rigidity.
- the reason why the rigidity is improved is considered as follows. That is, as shown in FIG. 2, the first region 21 includes a first top surface 211 disposed on the first reference surface K ⁇ b> 1 disposed at a position away from the neutral surface of the plate material 1, and the thickness direction of the plate material 1. And a first side surface 212 intersecting with.
- the second region 22 includes a second top surface 221 disposed on the second reference surface K2 disposed at a position away from the neutral surface of the plate 1 and a second side surface that intersects the thickness direction of the plate 1. 222. Therefore, many materials can be arranged at positions away from the neutral surface of the plate 1. Therefore, many materials can be used effectively, and the rigidity improvement effect can be enhanced.
- the first region 21 and the second region 22 are formed on the basis of the first reference region 213 and the second reference region 223 in which the shape and positional relationship are set as described above.
- the cross-sectional secondary moment can be improved even in an arbitrary cross-section, and an uneven shape having an excellent bending rigidity improvement effect and little rigidity anisotropy can be obtained.
- the improvement in rigidity it is possible to obtain the effect of improving the vibration damping property and the effect of suppressing the sound echo due to the uneven shape.
- the improvement in rigidity it is possible to obtain the effect of improving the vibration damping property and the effect of suppressing the sound echo due to the uneven shape.
- FEM analysis In order to quantitatively determine the rigidity improvement effect of the plate material 1 of this example, bending rigidity evaluation by a cantilever beam using FEM analysis was performed. In the FEM analysis, bending rigidity was evaluated in three directions of 0 °, 45 °, and 90 ° by changing the formation direction of the uneven portion 20 in the test piece.
- the shape of the test piece used for the FEM analysis has a rectangular shape of 120 mm ⁇ 120 mm, and an uneven portion 20 is formed on the entire surface.
- one end was used as a fixed end, and the end arranged opposite to the fixed end was used as a free end.
- a 1N load was applied to the central portion of the side forming the free end, and the amount of deflection of the plate 1 was determined by performing FEM analysis. The evaluation was performed by comparing the amount of deflection obtained by performing the same FEM analysis on a flat base plate on which the uneven portion 20 was not formed.
- the plate 1 having the concavo-convex portion 20 shown in this example has a rigidity magnification G of 14.26 times that of the flat plate even in the 45 ° direction where the bending rigidity improvement effect is the lowest, and the weight reduction rate W (%) Is expected to be at least 58%.
- the shape of the uneven portion 20 in the 135 ° direction is the same as the 45 ° direction
- the shape of the uneven portion 20 in the 180 ° direction is the same as the 0 ° direction. Therefore, as a result of the FEM analysis, the 135 ° direction and the 45 ° direction are the same, and the 180 ° direction and the 0 ° direction are the same.
- Example 2 The board
- This example shows an example in which the configuration of the concavo-convex portion 20 is changed using an intermediate reference plane K3 (FIG. 6) similar to that of the first embodiment.
- the first reference plane K1 and the intermediate reference plane K3 are used as a reference, and the second reference plane K2 is not used.
- the plate member 1 has a concavo-convex portion 20 constituted by a first region 21 and a second region 22 protruding toward the first reference plane K1.
- the second region 22 of the present example includes a second top surface 221 obtained by projecting the second reference region 223 (FIG. 6) on the first reference plane K1, and the second top surface 221.
- the second side surface 222 connects the contour of the top surface 221 and the contour of the second reference region 223.
- the second region 22 of this example is formed so as to protrude from the intermediate reference surface K3 to the first reference surface K1, and the protruding direction is opposite to that of the first embodiment. Therefore, the protrusion height H 2 of the second region 22 in this example is the same as the protrusion height H 1 of the first region 21.
- Other configurations of the first region 21 and the second region 22 are the same as those in the first embodiment.
- FEM analysis In order to quantitatively determine the rigidity improvement effect of the plate material 1 of this example, bending rigidity evaluation by a cantilever beam using FEM analysis was performed. In the FEM analysis, bending rigidity was evaluated in three directions of 0 °, 45 °, and 90 ° by changing the formation direction of the uneven portion 20 in the test piece.
- the shape of the test piece used for the FEM analysis has a rectangular shape of 120 mm ⁇ 120 mm, and an uneven portion 20 is formed on the entire surface.
- one end was used as a fixed end, and the end arranged opposite to the fixed end was used as a free end.
- a 1N load was applied to the central portion of the side forming the free end, and the amount of deflection of the plate 1 was determined by performing FEM analysis. The evaluation was performed by comparing the amount of deflection obtained by performing the same FEM analysis on a flat base plate on which the uneven portion 20 was not formed.
- the shape of the uneven portion 20 in the 135 ° direction is the same as the 45 ° direction
- the shape of the uneven portion 20 in the 180 ° direction is the same as the 0 ° direction. Therefore, as a result of the FEM analysis, the 135 ° direction and the 45 ° direction are the same, and the 180 ° direction and the 0 ° direction are the same.
- Example 3 The board
- This example shows an example in which the configuration of the concavo-convex portion 20 is changed using the same intermediate reference plane K3 (FIG. 6) as in the first and second embodiments.
- the first reference plane K1 and the intermediate reference plane K3 are used as a reference, and the second reference plane K2 is not used.
- the plate material 1 shown in FIG. 9 has a concavo-convex portion 20 composed of a first region 21 and a planar region 23.
- the planar region 23 is formed by the outline of the second reference region 223 (FIG. 6) on the intermediate reference plane K3 (FIG. 6).
- the configuration of the first region 21 is the same as that in the first embodiment.
- FEM analysis In order to quantitatively determine the rigidity improvement effect of the plate material 1 of this example, bending rigidity evaluation by a cantilever beam using FEM analysis was performed. In the FEM analysis, bending rigidity was evaluated in three directions of 0 °, 45 °, and 90 ° by changing the formation direction of the uneven portion 20 in the test piece.
- the shape of the test piece used for the FEM analysis has a rectangular shape of 120 mm ⁇ 120 mm, and an uneven portion 20 is formed on the entire surface.
- one end was used as a fixed end, and the end arranged opposite to the fixed end was used as a free end.
- a 1N load was applied to the central portion of the side forming the free end, and the amount of deflection of the plate 1 was determined by performing FEM analysis. The evaluation was performed by comparing the amount of deflection obtained by performing the same FEM analysis on a flat base plate on which the uneven portion 20 was not formed.
- the plate 1 having the concavo-convex portion 20 shown in this example has an excellent bending rigidity improvement effect and extremely little bending rigidity anisotropy in any direction of 0 °, 45 °, and 90 °. It became.
- grooved part 20 shown in this example has the rigidity magnification G 5.54 times compared with a flat plate also in the 45 degree direction where the bending rigidity improvement effect is the lowest, and the weight reduction rate W (%). Is expected to be at least 43%.
- the shape of the uneven portion 20 in the 135 ° direction is the same as the 45 ° direction
- the shape of the uneven portion 20 in the 180 ° direction is the same as the 0 ° direction. Therefore, as a result of the FEM analysis, the 135 ° direction and the 45 ° direction are the same, and the 180 ° direction and the 0 ° direction are the same.
- Example 4 the concavo-convex portion 20 is provided in the cylindrical material 11.
- the first reference plane K1, the intermediate reference plane K3, and the second reference plane K2 are formed of cylindrical curved surfaces arranged in parallel.
- the intermediate reference plane K3 of this example is obtained by curving the intermediate reference plane K3 having a flat shape described in any of the first to third embodiments into a cylindrical shape.
- the configurations of the first region 21, the second region 22, and the planar region 23 that form the uneven portion 20 are the same as those in the first and second embodiments.
- the plate member 1 having the concavo-convex portion 20 having excellent characteristics can be deformed into various shapes, and the application can be expanded.
- the rigidity can be increased without increasing the thickness of the material.
- the cylindrical material 11 of this example has excellent energy absorption characteristics. Therefore, high rigidity and excellent energy absorption characteristics can be imparted by using it in a vehicle body such as an automobile.
- the laminated structure 5 is configured using the plate material 1 having the uneven portion 20 of Example 1 as a core material. That is, the laminated structure 5 is formed by bonding the face plates 42 and 43 to the surfaces on both sides of the core material made of one plate material 1 having the uneven portion 20.
- the face plates 42 and 43 are made of an aluminum alloy plate having a material of 3000 series and a thickness of 1.0 mm.
- the laminated structure 5 of the present example uses the plate material 1 having the uneven portion 20 having excellent rigidity as described above as a core material, and the first top surface 211 of the first region 21 and the second region 22 of the second region 22.
- the laminated structure 5 having a remarkably higher rigidity than the case of the plate material 1 having the concavo-convex portion 20 can be obtained.
- both the plate material 1 and the face plates 42 and 43 are made of an aluminum alloy plate, the weight can be reduced.
- the face plates 42 and 43 it is also possible to apply a metal plate other than the aluminum alloy, for example, a steel plate, a titanium plate, a resin plate, or the like.
- the plate 1 described in any one of the first to third embodiments is used as an inner panel, and the surface on the first reference plane K1 side of the plate 1 is on the back side of the outer panel 61. It is an example of the vehicle panel 6 arrange
- the inner panel is joined to the outer panel 61 by hem processing or the like at the outer peripheral portion thereof.
- grooved part 20 is not limited,
- plate material 1 is arrange
- the plate 1 having the concavo-convex portion 20 constituting the inner panel is excellent in the rigidity improving effect as described above, the energy of the primary collision and the secondary collision when the pedestrian collides. It is excellent in the property of absorbing the energy. In addition, it is possible to obtain the effect of improving the vibration damping property accompanying the improvement of the rigidity and the effect of improving the sound absorption by enclosing the air layer.
- grooved part 20 was used as an inner panel, it can be used for any one or both of an inner panel and the outer panel 61.
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Abstract
Description
これまで、板材の板厚を厚くすることなく剛性を向上させるために、板材に波形形状や、凹凸形状を設けて形状的に剛性を向上させることが検討されてきた。
上記凹凸部は、間隔をあけて順次平行に配された仮想の3つの面である第1基準面、中間基準面及び第2基準面を基準とし、
上記中間基準面を、同じ大きさの仮想の矩形からなる第1単位領域及び第2単位領域を敷き詰めたものと仮定し、
上記第1単位領域及び上記第2単位領域をなす仮想の矩形の一辺と平行な方向をX方向とし、該X方向に垂直な方向をY方向とし、
上記第1単位領域及び上記第2単位領域は、上記X方向に配される辺を3等分すると共に、上記Y方向に配される辺を5等分するように配した格子によって区画される仮想の枡目を第1枡又は第2枡の2種類に分類し、
上記第1単位領域及び上記第2単位領域の任意の1つの角に存在する上記枡目を基準枡目として、上記基準枡目を含む上記X方向に配された枡目からなる列を第1列とするとともにこれに順次隣接する列を第2列~第5列とし、かつ該基準枡目を含む上記Y方向に配された枡目からなる列を第A列とすると共に、これに順次隣接する列を第B列及び第C列とし、
上記第1単位領域においては、第1列及び第5列に配される全ての枡を上記第1枡とし、第2列~第4列においては、第A列及び第C列に配される枡を上記第2枡とすると共に第B列に配される枡を上記第1枡とし、
上記第2単位領域においては、第1列及び第5列に配される全ての枡を上記第2枡とし、第2列~第4列においては、第A列及び第C列に配される枡を上記第1枡とすると共に第B列に配される枡を上記第2枡とし、
上記中間基準面上には、上記第1単位領域及び上記第2単位領域が同じ向きで配列されており、上記Y方向においては、上記第1単位領域と上記第2単位領域とを交互に一列に配列した単位領域列が複数形成され、
上記中間基準面上のX方向において隣接する上記単位領域列は、互いにY方向に3つの枡目分移動した位置に配されて、
上記中間基準面上において、隣接し辺を共有する上記第1枡からなる二十角形の領域を第1基準領域とし、隣接し辺を共有する上記第2枡からなる二十角形の領域を第2基準領域として、
上記中間基準面上において定められた上記第1基準領域から上記第1基準面に向かって突出する第1領域と、上記中間基準面上において定められた上記第2基準領域から上記第1基準面又は第2基準面に向かって突出する第2領域及び上記中間基準面上に上記第2基準領域を基に形成される平面領域のいずれか一方又は両方、とを設け、
上記第1領域は、上記第1基準領域を上記第1基準面上に等倍又は縮小して投影した第1頂面と、該第1頂面の輪郭と上記第1基準領域の輪郭とをつなぐ第1側面とからなり、
上記第2領域は、上記第2基準領域を上記第1基準面上又は上記第2基準面上に等倍又は縮小して投影した第2頂面と、該第2頂面の輪郭と上記第2基準領域の輪郭とをつなぐ第2側面とからなるよう構成したことを特徴とする凹凸部を有する板材にある。
剛性が向上する理由は、次のように考えられる。即ち、上記第1領域は、上記板材の中立面から離れた位置に配される上記第1基準面上に配置した上記第1頂面と、板材の厚さ方向に交差した上記第1側面とからなる。また、第2領域は、上記第1基準面又は上記第2基準面上に配置した上記第2頂面と、板材の厚さ方向に交差した上記第2側面とからなる。また、上記平面領域は、上記中間基準面上に配された上記第2基準領域を基に形成される。そのため、上記板材の中立面から離れた位置に多くの材料を配置できる。したがって、多くの材料を効果的に使用することができ、剛性向上効果を高めることができる。
また、平行の表現は幾何学上の狭義の概念に止まらず、一般的に平行と認識できるものであればよい。
上記第2基準領域を基に上記第2領域を形成した場合、上記凹凸部は上記第1領域と上記第2領域とによって構成される。このとき、上記第2領域を上記中間基準面から上記第1基準面上に向かって突出するように形成した場合、上記第2領域は、上記第1基準面上に配された上記第2頂面と、上記第1基準面と上記中間基準面の間に配される上記第2側面とからなる。また、上記第2領域を、上記中間基準面から上記第2基準面上に向かって突出するように形成した場合、上記第2領域は、上記第2基準面上に配された上記第2頂面と、上記第2基準面と上記中間基準面の間に配される上記第2側面とからなる。
また、上記第2基準領域を基に上記第2領域と上記平面領域の両方を形成することもできる。この場合、上記凹凸部は、上記第1領域、上記第2領域及び上記平面領域によって構成される。
また、上記第2領域を設ける場合における上記第2頂面は、上記第1基準面又は第2基準面の面によって構成することもできるし、あるいは、上記第2領域の突出方向と同じ方向に突出した部位によって構成することもできる。突出した部位の形状例としては、ドーム形状、稜線形状、錐形状等があるがこれに限定するものではない。
Mが0.5L未満の場合及び2Lを超える場合、成形が困難となったり、曲げ剛性の異方性が大きくなることがあり好ましくない。
尚、金属板をプレス成型する場合において上記第1側面の傾斜角度θ1(°)及び上記第2側面の傾斜角度θ2(°)の上限値は、成形性の問題から、70°以下であることがより好ましい。したがってより好ましい範囲としては10°~70°である。
また、上記第1側面及び上記第2側面は複数の面により構成されるが、それらの面が全て同じ傾斜角度である必要はなく、部位によって傾斜角度を変えてもよい。但し、いずれの面においても、上記好ましい傾斜角度の範囲内とすることが好ましい。
この場合には、優れた上記凹凸部を有する板材を様々な形状に変形させることができ、用途を拡大することができる。
また、上記板材は、上記凹凸部を有する限り、金属以外の材料においても有効であり、例えば、樹脂板、樹脂と金属との積層材又は複合材等とすることもできる。樹脂材料等であれば射出成形あるいはホットプレス等によって凹凸部を形成することができる。樹脂材料においては、金属材料の場合よりも成形上の制約を受けにくく、設計の自由度もより広くなる。
上記比L/tが10未満の場合には成形が困難となるおそれがあり、一方、上記比L/tが2000を超える場合には、十分な凹凸部形状を形成できなくなり、剛性が低下するという問題が生じるおそれがある。
また、複数枚の凹凸部を有する板材を直接積層してコア材とし、その片側又は両側の表面に平坦な面板を接合してなる構造を取ることもできる。
また、複数枚の凹凸部を有する板材を直接積層しただけの状態の積層構造体とすることもできる。
上記板材の積層枚数としては、用途及び要求特性に応じて変更することができる。
上記アウターパネルをアルミニウム合金板により構成する場合には、たとえば、比較的安価であるという理由により6000系合金が好適である。また、上記インナーパネルをアルミニウム合金板により構成する場合には、たとえば、比較的成形性が良いという理由により5000系合金板が好適である。
凹凸部を有する板材にかかる実施例につき、図1~図6を参照して説明する。
また、図6は、本例に示す板材1が有する凹凸部20の形状を、中間基準面K3における第1基準領域213及び第2基準領域223の配置によって表したものである。同図中において、太実線は、第1単位領域241と第2単位領域242の境界を示すものであり、細実線は、第1基準領域213及び第2基準領域223の輪郭線を示すものである。また、同図中において、破線は、仮想の枡である第1枡243及び第2枡244の輪郭線を示すものである。
凹凸部20は、次のように構成される。
凹凸部20は、図2に示すごとく、間隔をあけて順次平行に配された仮想の3つの面である第1基準面K1、中間基準面K3及び第2基準面K2を基準とする。中間基準面K3は、図6に示すごとく、同じ大きさの仮想の矩形(正方形)からなる第1単位領域241及び第2単位領域242を敷き詰めたものと仮定する。
また、図4及び図5に示すごとく、第1枡243及び第2枡244をなす上記枡目におけるX方向と平行に配された辺の長さL(mm)及びY方向と平行に配された辺の長さM(mm)は、共に8mmとし、上記枡目は正方形をなしている。
また、本例の凹凸部20を有する板材1は、板厚t=0.3mmの1000系のアルミニウム板である。凹凸部20は、一対の金型を用いたプレス成形により形成される。尚、この成形方法は、表面に所望の凹凸形状を付けた一対の成形ロールによって成形するロール成形等の他の塑性加工方法を採用することも可能である。
また、第1領域21の突出高さH1(mm)と板厚t(mm)との比H1/tは、5である。また、第1側面212と中間基準面K3とがなす傾斜角度θ1=30°であり、-3θ1+272=182である。したがって、1≦H1/t≦182の関係を満たしている。同様に、第2領域22の突出高さH2(mm)と板厚t(mm)との比H2/tは、5である。また、第2側面222と中間基準面K3とがなす傾斜角度θ2=30°であり、-3θ2+272=182である。したがって、1≦H2/t≦182の関係を満たしている。
凹凸部20は、上記のごとく、中間基準面K3上において定められた第1基準領域213から第1基準面K1に向かって突出する第1領域21と、中間基準面K3上において定められた第2基準領域223から第2基準面K2に向かって突出する第2領域22とを設けてなる。そして、第1領域21は、第1頂面211と、該第1頂面211の輪郭と第1基準領域213の輪郭とをつなぐ第1側面212とからなり、第2領域22は、第2頂面221と、該第2頂面221の輪郭と第2基準領域223の輪郭とをつなぐ第2側面222とからなる。
剛性が向上する理由は、次のように考えられる。即ち、図2に示すごとく、第1領域21は、板材1の中立面から離れた位置に配される第1基準面K1上に配置した第1頂面211と、板材1の厚さ方向に交差した第1側面212とからなる。また、第2領域22は、板材1の中立面から離れた位置に配される第2基準面K2上に配置した第2頂面221と、板材1の厚さ方向に交差した第2側面222とからなる。そのため、板材1の中立面から離れた位置に多くの材料を配置できる。したがって、多くの材料を効果的に使用することができ、剛性向上効果を高めることができる。
本例の板材1の剛性向上効果を定量的に判断するために、FEM解析を用いた片持ち梁による曲げ剛性評価を行った。
上記FEM解析は、試験片における凹凸部20の形成方向を変化させることにより、0°、45°、90°の3方向における曲げ剛性評価を行った。
上記試験片の端部において、一端を固定端とし、該固定端と対向して配される端部を自由端とした。該自由端をなす辺の中央部に1Nの負荷を加え、FEM解析を行うことで板材1のたわみ量を求めた。
評価は、凹凸部20を形成していない平板状の元板について、同様のFEM解析を行い得られたたわみ量と比較することで行った。
図1に示すごとく、中間基準面K3(図6)におけるX方向と板材1のなす辺とが平行となるよう凹凸部20を形成した試験片において、同図中の上方に位置する端部Z1を固定端とし、端部Z1と対向する端部Z2を自由端とする方向を0°方向とした。
実施例1の凹凸部20を有する板材1は、前述した0°方向において、平板状の元板と比べて、曲げ剛性が20.82倍に向上することが明らかとなった。
中間基準面K3(図6)におけるX方向と板材1のなす辺とが45°となるよう凹凸部20を形成した試験片において、一つの端部を固定端とし、固定端と対向する端部を自由端とする方向を45°方向とした。
実施例1の凹凸部20を有する板材1は、前述した45°方向において、平板状の元板と比べて、曲げ剛性が14.26倍に向上することが明らかとなった。
図1に示すごとく、中間基準面K3(図6)におけるX方向と板材1のなす辺とが平行となるよう凹凸部20を形成した試験片において、同図中の左側に位置する端部Z3を固定端とし、端部Z3と対向する端部Z4を自由端とする方向を90°方向とした。
実施例1の凹凸部20を有する板材1は、前述した90°方向において、平板状の元板と比べて、曲げ剛性が15.73倍に向上することが明らかとなった。
また、本例においては、135°方向における凹凸部20の形状は、45°方向と同様であり、180°方向における凹凸部20の形状は、0°方向と同様である。したがって、FEM解析の結果は、135°方向と45°方向とが同一となり、180°方向と0°方向とが同一となる。
本例にかかる凹凸部20を有する板材1について、図7及び図8を参照して説明する。
本例は、実施例1と同様の中間基準面K3(図6)を用いて、凹凸部20の構成を変更した例を示すものである。尚、本例においては、第1基準面K1及び中間基準面K3の2つの面を基準とし、第2基準面K2は用いない。
板材1は、図8に示すごとく、第1領域21及び第1基準面K1に向かって突出した第2領域22により構成される凹凸部20を有するものである。本例の第2領域22は、図7及び図8に示すごとく、第2基準領域223(図6)を第1基準面K1上に縮小して投影した第2頂面221と、該第2頂面221の輪郭と第2基準領域223の輪郭とをつなぐ第2側面222とからなる。本例の第2領域22は、上記のごとく中間基準面K3から第1基準面K1に対して突出するように形成されており、突出方向が実施例1とは反対となる。したがって、本例における、第2領域22の突出高さH2は第1領域21の突出高さH1と同一となる。その他の第1領域21及び第2領域22の構成については実施例1と同様である。
本例の板材1の剛性向上効果を定量的に判断するために、FEM解析を用いた片持ち梁による曲げ剛性評価を行った。
上記FEM解析は、試験片における凹凸部20の形成方向を変化させることにより、0°、45°、90°の3方向における曲げ剛性評価を行った。
上記試験片の端部において、一端を固定端とし、該固定端と対向して配される端部を自由端とした。該自由端をなす辺の中央部に1Nの負荷を加え、FEM解析を行うことで板材1のたわみ量を求めた。
評価は、凹凸部20を形成していない平板状の元板について、同様のFEM解析を行い得られたたわみ量と比較することで行った。
図7に示すごとく、中間基準面K3(図6)におけるX方向と板材1のなす辺とが平行となるよう凹凸部20を形成した試験片において、同図中の上方に位置する端部Z1を固定端とし、端部Z1と対向する端部Z2を自由端とする方向を0°方向とした。
実施例2の凹凸部20を有する板材1は、前述した0°方向において、平板状の元板と比べて、曲げ剛性が5.65倍に向上することが明らかとなった。
中間基準面K3(図6)におけるX方向と板材1のなす辺とが45°となるよう凹凸部20を形成した試験片において、一つの端部を固定端とし、固定端と対向する端部を自由端とする方向を45°方向とした。
実施例1の凹凸部20を有する板材1は、前述した45°方向において、平板状の元板と比べて、曲げ剛性が4.08倍に向上することが明らかとなった。
図7に示すごとく、中間基準面K3(図6)におけるX方向と板材1のなす辺とが平行となるよう凹凸部20を形成した試験片において、同図中の左側に位置する端部Z3を固定端とし、端部Z3と対向する端部Z4を自由端とする方向を90°方向とした。
実施例2の凹凸部20を有する板材1は、前述した90°方向において、平板状の元板と比べて、曲げ剛性が5.35倍に向上することが明らかとなった。
また、本例においては、135°方向における凹凸部20の形状は、45°方向と同様であり、180°方向における凹凸部20の形状は、0°方向と同様である。したがって、FEM解析の結果は、135°方向と45°方向とが同一となり、180°方向と0°方向とが同一となる。
本例にかかる凹凸部20を有する板材1について、図9及び図10を参照して説明する。
本例は、実施例1及び実施例2と同様の中間基準面K3(図6)を用いて、凹凸部20の構成を変更した例を示すものである。尚、本例においては、実施例2と同様に、第1基準面K1及び中間基準面K3の2つの面を基準とし、第2基準面K2は用いない。
図9に示す板材1は、図10に示すごとく、第1領域21及び平面領域23からなる凹凸部20を有するものである。平面領域23は、図9及び図10に示すごとく、中間基準面K3(図6)上において第2基準領域223(図6)の輪郭により形成される。また、第1領域21の構成については実施例1と同様である。
本例の板材1の剛性向上効果を定量的に判断するために、FEM解析を用いた片持ち梁による曲げ剛性評価を行った。
上記FEM解析は、試験片における凹凸部20の形成方向を変化させることにより、0°、45°、90°の3方向における曲げ剛性評価を行った。
上記試験片の端部において、一端を固定端とし、該固定端と対向して配される端部を自由端とした。該自由端をなす辺の中央部に1Nの負荷を加え、FEM解析を行うことで板材1のたわみ量を求めた。
評価は、凹凸部20を形成していない平板状の元板について、同様のFEM解析を行い得られたたわみ量と比較することで行った。
図9に示すごとく、中間基準面K3(図6)におけるX方向と板材1のなす辺とが平行となるよう凹凸部20を形成した試験片において、同図中の上方に位置する端部Z1を固定端とし、端部Z1と対向する端部Z2を自由端とする方向を0°方向とした。
実施例3の凹凸部20を有する板材1は、前述した0°方向において、平板状の元板と比べて、曲げ剛性が6.34倍に向上することが明らかとなった。
中間基準面K3(図6)におけるX方向と板材1のなす辺とが45°となるよう凹凸部20を形成した試験片において、一つの端部を固定端とし、固定端と対向する端部を自由端とする方向を45°方向とした。
実施例1の凹凸部20を有する板材1は、前述した45°方向において、平板状の元板と比べて、曲げ剛性が5.54倍に向上することが明らかとなった。
図9に示すごとく、中間基準面K3(図6)におけるX方向と板材1のなす辺とが平行となるよう凹凸部20を形成した試験片において、同図中の左側に位置する端部Z3を固定端とし、端部Z3と対向する端部Z4を自由端とする方向を90°方向とした。
実施例3の凹凸部20を有する板材1は、前述した90°方向において、平板状の元板と比べて、曲げ剛性が6.42倍に向上することが明らかとなった。
また、本例においては、135°方向における凹凸部20の形状は、45°方向と同様であり、180°方向における凹凸部20の形状は、0°方向と同様である。したがって、FEM解析の結果は、135°方向と45°方向とが同一となり、180°方向と0°方向とが同一となる。
本例は、図11に示すごとく、凹凸部20を円筒材11に設けた例である。本例においては、第1基準面K1、中間基準面K3及び第2基準面K2は、平行に配された円筒状の曲面からなる。本例の中間基準面K3は、実施例1~実施例3のいずれかに記載の平面状をなす中間基準面K3を円筒状に湾曲させたものである。凹凸部20をなす第1領域21、第2領域22及び平面領域23の構成は、実施例1及び実施例2と同様である。
本例に示すごとく、優れた特性を備えた凹凸部20を有する板材1を様々な形状に変形させることができ、用途を拡大することができる。
本例は、図12に示すごとく、実施例1の凹凸部20を有する板材1をコア材として用いて積層構造体5を構成した例である。
即ち、積層構造体5は、凹凸部20を有する1枚の板材1よりなるコア材の両側の表面に面板42,43を接合してなる。
面板42,43は、材質3000系、板厚1.0mmのアルミニウム合金板よりなる。
尚、面板42,43としては、アルミニウム合金以外の金属の板、たとえば、鋼板、チタン板等や、樹脂板等を適用することも可能である。
本例は、図13に示すごとく、実施例1~実施例3のいずれかに記載の板材1をインナーパネルとして用い、板材1における第1基準面K1側の面をアウターパネル61の裏面側に向けて配置して構成する車両パネル6の例である。上記インナーパネルは、その外周部においてアウターパネル61とヘム加工等により接合されている。尚、前述したインナーパネルにおいて、凹凸部20の形成方向を限定するものではなく、板材1における第1基準面K1と反対側の面をアウターパネル61の裏面側に向けて配置して構成することもできる。
尚、本例においては、凹凸部20を有する板材1をインナーパネルとして用いたが、インナーパネルとアウターパネル61のいずれか一方又は両方に用いることができる。
Claims (10)
- 凹凸部を形成することによって剛性を高めた板材であって、
上記凹凸部は、間隔をあけて順次平行に配された仮想の3つの面である第1基準面、中間基準面及び第2基準面を基準とし、
上記中間基準面を、同じ大きさの仮想の矩形からなる第1単位領域及び第2単位領域を敷き詰めたものと仮定し、
上記第1単位領域及び上記第2単位領域をなす仮想の矩形の一辺と平行な方向をX方向とし、該X方向に垂直な方向をY方向とし、
上記第1単位領域及び上記第2単位領域は、上記X方向に配される辺を3等分すると共に、上記Y方向に配される辺を5等分するように配した格子によって区画される仮想の枡目を第1枡又は第2枡の2種類に分類し、
上記第1単位領域及び上記第2単位領域の任意の1つの角に存在する上記枡目を基準枡目として、上記基準枡目を含む上記X方向に配された枡目からなる列を第1列とするとともにこれに順次隣接する列を第2列~第5列とし、かつ該基準枡目を含む上記Y方向に配された枡目からなる列を第A列とすると共に、これに順次隣接する列を第B列及び第C列とし、
上記第1単位領域においては、第1列及び第5列に配される全ての枡を上記第1枡とし、第2列~第4列においては、第A列及び第C列に配される枡を上記第2枡とすると共に第B列に配される枡を上記第1枡とし、
上記第2単位領域においては、第1列及び第5列に配される全ての枡を上記第2枡とし、第2列~第4列においては、第A列及び第C列に配される枡を上記第1枡とすると共に第B列に配される枡を上記第2枡とし、
上記中間基準面上には、上記第1単位領域及び上記第2単位領域が同じ向きで配列されており、上記Y方向においては、上記第1単位領域と上記第2単位領域とを交互に一列に配列した単位領域列が複数形成され、
上記中間基準面上のX方向において隣接する上記単位領域列は、互いにY方向に3つの枡目分移動した位置に配されて、
上記中間基準面上において、隣接し辺を共有する上記第1枡からなる二十角形の領域を第1基準領域とし、隣接し辺を共有する上記第2枡からなる二十角形の領域を第2基準領域として、
上記中間基準面上において定められた上記第1基準領域から上記第1基準面に向かって突出する第1領域と、上記中間基準面上において定められた上記第2基準領域から上記第1基準面又は第2基準面に向かって突出する第2領域及び上記中間基準面上に上記第2基準領域を基に形成される平面領域のいずれか一方又は両方、とを設け、
上記第1領域は、上記第1基準領域を上記第1基準面上に等倍又は縮小して投影した第1頂面と、該第1頂面の輪郭と上記第1基準領域の輪郭とをつなぐ第1側面とからなり、
上記第2領域は、上記第2基準領域を上記第1基準面上又は上記第2基準面上に等倍又は縮小して投影した第2頂面と、該第2頂面の輪郭と上記第2基準領域の輪郭とをつなぐ第2側面とからなるよう構成したことを特徴とする凹凸部を有する板材。 - 請求項1に記載の凹凸部を有する板材において、上記枡をなす一辺の長さL(mm)と、該一辺と直交する辺の長さM(mm)は、0.5L≦M≦2Lの関係にあることを特徴とする凹凸部を有する板材。
- 請求項1又は2に記載の凹凸部を有する板材において、上記第2基準面に対する上記第1側面の傾斜角度θ1(°)は、10°~90°の範囲にあり、上記第2基準面に対する上記第2側面の傾斜角度θ2(°)は、10°~90°の範囲にあることを特徴とする凹凸部を有する板材。
- 請求項1~3のいずれか1項に記載の凹凸部を有する板材において、上記第1基準面及び上記第2基準面の少なくとも一部がそれぞれ平行な曲面からなることを特徴とする凹凸部を有する板材。
- 請求項1~4のいずれか1項に記載の凹凸部を有する板材において、上記板材は金属板をプレス成形することにより上記凹凸部を形成したものであることを特徴とする凹凸部を有する板材。
- 請求項5に記載の凹凸部を有する板材において、上記金属板の成形前の板厚t(mm)が0.03~6.0mmであることを特徴とする凹凸部を有する板材。
- 請求項5又は6に記載の凹凸部を有する板材において、上記枡の一辺の長さL(mm)と、上記板厚t(mm)との比L/tは10~2000であることを特徴とする凹凸部を有する板材。
- 請求項1~7のいずれか一項に記載の凹凸部を有する板材において、上記第1領域の突出高さH1(mm)と上記板厚t(mm)との比H1/tと、上記第1側面と上記中間基準面とがなす最も大きい傾斜角θ1(°)とは、1≦(H1/t)≦-3θ1+272の関係にあり、上記第2領域の突出高さH2(mm)と上記板厚t(mm)との比H2/tと、上記第2側面と上記中間基準面とがなす最も大きい傾斜角θ2(°)とは、1≦(H2/t)≦-3θ2+272の関係にあることを特徴とする凹凸部を有する板材。
- 複数の板材を積層してなる積層構造体であって、上記板材の少なくとも1枚は請求項1~8のいずれか1項に記載の凹凸部を有する板材であることを特徴とする積層構造体。
- アウターパネルと該アウターパネルの裏面に接合されたインナーパネルとを有する車両パネルであって、上記アウターパネルと上記インナーパネルのいずれか一方又は両方が請求項1~8のいずれか1項に記載の凹凸部を有する板材よりなることを特徴とする車両パネル。
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JP2012553578A JP5901542B2 (ja) | 2011-01-17 | 2011-12-13 | 凹凸部を有する板材並びにこれを用いた車両パネル及び積層構造体 |
US13/979,188 US8920908B2 (en) | 2011-01-17 | 2011-12-13 | Sheet material having a concave-convex part, and vehicle panel and laminated structure using the same |
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US8714631B2 (en) | 2011-01-17 | 2014-05-06 | Sumitomo Light Metal Industries, Ltd. | Raised and recessed sheet material, and vehicle panel and laminated structure using the same |
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US9090288B2 (en) | 2010-09-08 | 2015-07-28 | Sumitomo Light Metal Industries, Ltd. | Sheet material having a concave-convex part, and vehicle panel and laminated structure using the same |
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