WO2022249602A1 - 自動車用パネル構造 - Google Patents
自動車用パネル構造 Download PDFInfo
- Publication number
- WO2022249602A1 WO2022249602A1 PCT/JP2022/007782 JP2022007782W WO2022249602A1 WO 2022249602 A1 WO2022249602 A1 WO 2022249602A1 JP 2022007782 W JP2022007782 W JP 2022007782W WO 2022249602 A1 WO2022249602 A1 WO 2022249602A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- resin
- outer panel
- panel structure
- panel member
- automotive
- Prior art date
Links
- 229920005989 resin Polymers 0.000 claims abstract description 233
- 239000011347 resin Substances 0.000 claims abstract description 233
- 239000000853 adhesive Substances 0.000 claims description 47
- 239000000463 material Substances 0.000 claims description 47
- 230000001070 adhesive effect Effects 0.000 claims description 45
- 230000002093 peripheral effect Effects 0.000 claims description 13
- 229920001187 thermosetting polymer Polymers 0.000 claims description 11
- 238000000034 method Methods 0.000 claims description 10
- 229920005992 thermoplastic resin Polymers 0.000 claims description 8
- 238000010276 construction Methods 0.000 claims 3
- 238000012986 modification Methods 0.000 description 37
- 230000004048 modification Effects 0.000 description 37
- 239000004088 foaming agent Substances 0.000 description 20
- 238000010586 diagram Methods 0.000 description 15
- 230000000694 effects Effects 0.000 description 12
- 238000005187 foaming Methods 0.000 description 10
- 239000013521 mastic Substances 0.000 description 10
- -1 polyethylene Polymers 0.000 description 10
- 229920003051 synthetic elastomer Polymers 0.000 description 10
- 239000005061 synthetic rubber Substances 0.000 description 10
- 238000000465 moulding Methods 0.000 description 6
- 229910000831 Steel Inorganic materials 0.000 description 5
- 239000006260 foam Substances 0.000 description 5
- 229910052751 metal Inorganic materials 0.000 description 5
- 239000002184 metal Substances 0.000 description 5
- 239000007921 spray Substances 0.000 description 5
- 239000010959 steel Substances 0.000 description 5
- 239000013585 weight reducing agent Substances 0.000 description 5
- UIIMBOGNXHQVGW-UHFFFAOYSA-M Sodium bicarbonate Chemical compound [Na+].OC([O-])=O UIIMBOGNXHQVGW-UHFFFAOYSA-M 0.000 description 4
- 230000003247 decreasing effect Effects 0.000 description 4
- 239000000047 product Substances 0.000 description 4
- 230000006866 deterioration Effects 0.000 description 3
- 230000003014 reinforcing effect Effects 0.000 description 3
- 238000005507 spraying Methods 0.000 description 3
- NBOCQTNZUPTTEI-UHFFFAOYSA-N 4-[4-(hydrazinesulfonyl)phenoxy]benzenesulfonohydrazide Chemical compound C1=CC(S(=O)(=O)NN)=CC=C1OC1=CC=C(S(=O)(=O)NN)C=C1 NBOCQTNZUPTTEI-UHFFFAOYSA-N 0.000 description 2
- 239000004156 Azodicarbonamide Substances 0.000 description 2
- BVKZGUZCCUSVTD-UHFFFAOYSA-M Bicarbonate Chemical compound OC([O-])=O BVKZGUZCCUSVTD-UHFFFAOYSA-M 0.000 description 2
- MWRWFPQBGSZWNV-UHFFFAOYSA-N Dinitrosopentamethylenetetramine Chemical compound C1N2CN(N=O)CN1CN(N=O)C2 MWRWFPQBGSZWNV-UHFFFAOYSA-N 0.000 description 2
- 229920001890 Novodur Polymers 0.000 description 2
- 229920002292 Nylon 6 Polymers 0.000 description 2
- 229920002302 Nylon 6,6 Polymers 0.000 description 2
- 239000004696 Poly ether ether ketone Substances 0.000 description 2
- 239000004698 Polyethylene Substances 0.000 description 2
- 239000004743 Polypropylene Substances 0.000 description 2
- 239000004793 Polystyrene Substances 0.000 description 2
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 description 2
- 125000003118 aryl group Chemical group 0.000 description 2
- XOZUGNYVDXMRKW-AATRIKPKSA-N azodicarbonamide Chemical compound NC(=O)\N=N\C(N)=O XOZUGNYVDXMRKW-AATRIKPKSA-N 0.000 description 2
- 235000019399 azodicarbonamide Nutrition 0.000 description 2
- 238000005452 bending Methods 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 238000013016 damping Methods 0.000 description 2
- 238000004070 electrodeposition Methods 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 239000003822 epoxy resin Substances 0.000 description 2
- RTZKZFJDLAIYFH-UHFFFAOYSA-N ether Substances CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 description 2
- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 description 2
- 239000013067 intermediate product Substances 0.000 description 2
- 229920006287 phenoxy resin Polymers 0.000 description 2
- 239000013034 phenoxy resin Substances 0.000 description 2
- 229920001643 poly(ether ketone) Polymers 0.000 description 2
- 229920001652 poly(etherketoneketone) Polymers 0.000 description 2
- 229920006122 polyamide resin Polymers 0.000 description 2
- 229920001230 polyarylate Polymers 0.000 description 2
- 229920001707 polybutylene terephthalate Polymers 0.000 description 2
- 229920000515 polycarbonate Polymers 0.000 description 2
- 239000004417 polycarbonate Substances 0.000 description 2
- 229920000647 polyepoxide Polymers 0.000 description 2
- 229920000728 polyester Polymers 0.000 description 2
- 229920002530 polyetherether ketone Polymers 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- 229920000139 polyethylene terephthalate Polymers 0.000 description 2
- 239000005020 polyethylene terephthalate Substances 0.000 description 2
- 229920000098 polyolefin Polymers 0.000 description 2
- 229920001955 polyphenylene ether Polymers 0.000 description 2
- 229920001155 polypropylene Polymers 0.000 description 2
- 229920005990 polystyrene resin Polymers 0.000 description 2
- 229920006395 saturated elastomer Polymers 0.000 description 2
- 229910000030 sodium bicarbonate Inorganic materials 0.000 description 2
- 235000017557 sodium bicarbonate Nutrition 0.000 description 2
- 229920001169 thermoplastic Polymers 0.000 description 2
- 239000004416 thermosoftening plastic Substances 0.000 description 2
- 229920006337 unsaturated polyester resin Polymers 0.000 description 2
- 229920001567 vinyl ester resin Polymers 0.000 description 2
- 230000001747 exhibiting effect Effects 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 230000013011 mating Effects 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 230000002265 prevention Effects 0.000 description 1
- 230000000630 rising effect Effects 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
- B62D29/001—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material
- B62D29/004—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material the metal being over-moulded by the synthetic material, e.g. in a mould
-
- 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
- B62D25/08—Front or rear portions
- B62D25/10—Bonnets or lids, e.g. for trucks, tractors, busses, work vehicles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D27/00—Connections between superstructure or understructure sub-units
- B62D27/02—Connections between superstructure or understructure sub-units rigid
- B62D27/026—Connections by glue bonding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
- B62D29/001—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material
- B62D29/005—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material preformed metal and synthetic material elements being joined together, e.g. by adhesives
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
- F16B5/00—Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them
- F16B5/08—Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them by means of welds or the like
-
- 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
- B62D25/06—Fixed roofs
-
- 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
- B62D25/08—Front or rear portions
- B62D25/10—Bonnets or lids, e.g. for trucks, tractors, busses, work vehicles
- B62D25/105—Bonnets or lids, e.g. for trucks, tractors, busses, work vehicles for motor cars
Definitions
- the present invention relates to an automotive panel structure.
- This application claims priority based on Japanese Patent Application No. 2021-88089 filed in Japan on May 26, 2021, the content of which is incorporated herein.
- the tension stiffness is a characteristic that expresses the resistance of the outer panel to bending. For example, when the outer panel of an automobile is touched, the outer panel is less likely to bend if the tension rigidity of the outer panel is high.
- Patent Document 1 discloses a reinforcing structure in which an inner plate is provided on an outer plate via a foam layer, and the foam layer has an expansion ratio of 1.03 to 1.30 times.
- Patent Document 1 According to the technology of Patent Document 1, it is said that both high tension rigidity and prevention of distortion can be achieved. However, in the technique of Patent Document 1, if the adhesion to the outer panel is insufficient, high tension rigidity cannot be sufficiently exhibited, which is also a factor that hinders weight reduction.
- the present disclosure has been made in view of the above problems, and the purpose of the present disclosure is to provide an automotive panel structure that is lightweight yet capable of exhibiting excellent tension rigidity.
- the present invention employs the following configuration.
- a plate-like outer panel member, an inner member disposed facing the inner surface of the outer panel member, and a resin are made of resin, and the resin is bonded to the inner surface of the outer panel member. and a member, wherein at least part of the inner member is embedded in the resin member.
- the inner member may extend along one in-plane direction of the outer panel member.
- the inner member has a plate-like main body portion arranged to face the inner surface of the outer panel member, and the main body portion A cross-sectional portion having a protruding portion that protrudes toward the outer panel member, the cross-sectional portion being perpendicular to the in-plane direction of the outer panel member, the tip of the protruding portion being buried in the resin member. good.
- the cross-sectional portion perpendicular to the in-plane direction of the outer panel member, and the entire surface of the protruding portion near the outer panel member is the resin member. It may have a cross-section that is filled.
- the inner member has a plate-like main body portion arranged to face the inner surface of the outer panel member, and the main body portion a protruding portion including a peripheral wall portion rising toward an outer panel member;
- a cross-sectional portion perpendicular to the in-plane direction of the outer panel member may have a cross-sectional portion in which at least a portion of the top portion is buried in the resin member.
- the cross-sectional portion perpendicular to the in-plane direction of the outer panel member has a cross-sectional portion in which the entire top portion is buried in the resin member.
- the resin member may be a thermosetting resin.
- the resin member may be a thermoplastic resin.
- the automotive panel structure according to any one of (1) to (10) above includes a plurality of the resin members, and the plurality of the resin members extend along the in-plane direction of the outer panel member. They may be connected to each other.
- the plurality of resin members may be connected to each other with an adhesive.
- the plurality of resin members may be connected to each other by fitting.
- a bonding portion that joins the outer panel member and the resin member, and the outer panel member and the inner member are The same material as the bonding portion to be joined may be used.
- the outer panel member may have a tensile strength of 440 MPa or more.
- the outer panel member may have a plate thickness of 0.30 mm or more and 0.55 mm or less.
- a portion of the resin member having a maximum dimension in a direction perpendicular to the in-plane direction of the outer panel member may have a thickness of 3 mm or more and 60 mm or less.
- the resin member is joined to the inner surface of the outer panel member while being firmly held by the inner member.
- FIG. 1 is a perspective view of a panel structure according to a first embodiment of the present disclosure, viewed from the outside of a vehicle; FIG. It is the perspective view which looked at the panel structure which concerns on 1st embodiment from the vehicle inside.
- FIG. 4 is a cross-sectional view of an inner member of the panel structure according to the first embodiment; It is a schematic diagram which shows the positional relationship of members in the panel structure which concerns on 1st embodiment. (a) is a cross-sectional view taken along arrow A in FIG. 4, and (b) is a cross-sectional view taken along arrow B in FIG. It is a schematic diagram which shows the positional relationship of members in the panel structure which concerns on the 1st modification of 1st embodiment.
- FIG. 14 is a cross-sectional view taken along line G in FIG. 13;
- FIG. Fig. 10 is an exploded perspective view showing a panel structure according to a second embodiment of the present disclosure; 15. It is H arrow directional cross-sectional view in FIG.
- FIG. 10 is a cross-sectional view for explaining the structure of a cross section perpendicular to the longitudinal direction of the projecting portion in the panel structure according to the first modified example of the second embodiment. It is an exploded perspective view showing the panel structure concerning the second modification of the second embodiment.
- FIG. 19 is a cross-sectional view taken along line I in FIG. 18; It is a sectional view of panel structure concerning the third modification of a second embodiment. It is a schematic diagram of the motor vehicle for demonstrating the example of application of a panel structure.
- panel structure 100 (hereinafter simply referred to as panel structure 100) according to the first embodiment of the present disclosure will be described.
- components having substantially the same functional configuration may be denoted by the same reference numerals, thereby omitting redundant description.
- the forward direction of the vehicle is indicated by an arrow Fr.
- a panel structure 100 according to this embodiment is a panel structure applied to the roof of an automobile 1000 shown in FIG.
- FIG. 1 is a perspective view showing the panel structure 100 seen from the outside of the vehicle
- FIG. 2 is a perspective view showing the panel structure 100 seen from the inside of the vehicle.
- the panel structure 100 includes an outer panel member 110, an inner member 120 arranged to face the inner surface of the outer panel member 110, and a resin member 130 joined to the inner surface of the outer panel member 110.
- the outer panel member 110 is a plate-like member having a curved surface that is convex toward the outside of the vehicle.
- the vehicle-exterior surface may be referred to as an outer surface
- the vehicle-interior surface may be referred to as an inner surface.
- the outer panel member 110 is formed by press forming a metal plate such as a steel plate. From the viewpoint of dent resistance, the tensile strength of the outer panel member 110 is preferably 440 MPa or more, more preferably 590 MPa or more.
- the thickness of the outer panel member 110 is preferably 0.55 mm or less, more preferably 0.50 mm or less. If the plate thickness of the outer panel member 110 is excessively thin, the reduction in tension rigidity becomes conspicuous. Further, if the thickness of the outer panel member 110 is excessively thin, the outer panel member 110 tends to resonate due to high-frequency vibration. For this reason, for example, when the outer panel 110 is applied to the roof of an automobile, sounds such as vibration noise due to raindrops from above and wind noise during driving are likely to enter the interior of the vehicle, resulting in a significant decrease in quietness. I have something to do.
- the thickness of the outer panel member 110 is preferably 0.30 mm or more, more preferably 0.35 mm or more.
- the tension rigidity of the outer panel member 110 can be increased by the configuration described later. Therefore, the outer panel member 110 can exhibit excellent tension rigidity while reducing the thickness of the outer panel member 110 .
- the inner member 120 is an elongated member arranged to face the inner surface of the outer panel member 110 .
- the inner member 120 is arranged to extend along one in-plane direction of the outer panel member 110 .
- the inner member 120 serves to reinforce the panel structure 100 by being attached to the outer panel member 110 with its longitudinal direction aligned with the vehicle width direction.
- FIG. 3 is a sectional view showing a section perpendicular to the longitudinal direction of the inner member 120.
- the inner member 120 includes a top plate portion 121, a pair of side wall portions 123, 123 bent and extending from both ends of the top plate portion 121, and a top plate portion of the pair of side wall portions 123, 123. It has a substantially hat-shaped cross-section consisting of a pair of flanges 125, 125 bending and extending outward from the end opposite to 121.
- the width direction of the inner member 120 means a direction parallel to the top plate portion 121 among directions perpendicular to the longitudinal direction of the inner member 120 .
- the inner member 120 can be obtained, for example, by press forming a metal plate such as a steel plate.
- Resin member 130 As shown in FIGS. 1 and 2 , the pair of resin members 130 , 130 are joined to the inner surface of the outer panel member 110 so as to partially fill the inner member 120 .
- "at least a portion of the inner member is buried in the resin member” means that at least a portion of the inner member enters the resin member and is held in surface contact.
- the thickness of the maximum thickness portion where the dimension in the direction perpendicular to the in-plane direction of the outer panel member 110 is maximum is preferably 3 mm or more and 60 mm or less. If the thickness of the thickest portion of the resin member 130 is 3 mm or more, the inner member 120 can be held more firmly. This is preferable because it is possible to compensate for the lack of rigidity due to the thinning of the outer panel member 110 . More preferably, the thickness of the thickest portion of the resin member 130 is 5 mm or more. On the other hand, even if the thickness of the thickest portion of the resin member 130 exceeds 60 mm, the effect is saturated. Therefore, the thickness of the thickest portion of the resin member 130 is preferably 60 mm or less. From the viewpoint of weight reduction, the thickness of the thickest portion of the resin member 130 is more preferably 10 mm or less.
- the material of the resin member 130 may be resin, and both thermosetting resin and thermoplastic resin can be used for the resin member 130 .
- thermosetting resins include epoxy resins, unsaturated polyester resins, and vinyl ester resins.
- thermoplastic resins include polyolefins (polyethylene, polypropylene, etc.) and acid-modified products thereof, polyamide resins such as nylon 6 and nylon 66, thermoplastic aromatic polyesters such as polyethylene terephthalate and polybutylene terephthalate, polycarbonates, poly Examples include ether sulfone, polyphenylene ether and modified products thereof, polyarylate, polyether ketone, polyether ether ketone, polyether ketone ketone, vinyl chloride, styrenic resins such as polystyrene, and phenoxy resins.
- the resin may be formed of a plurality of types of resin materials.
- the resin material forming the resin member 130 when the resin material forming the resin member 130 contains a foaming agent, the working efficiency when attaching the resin member 130 is improved. Therefore, the resin material forming the resin member 130 preferably contains a foaming agent.
- foaming agents include N,N'-dinitrosopentamethylenetetramine, azodicarbonamide, 4,4'-oxybis(benzenesulfonylhydrazide), hydrogencarbonate, sodium hydrogencarbonate and the like.
- a foaming agent when a foaming agent is contained in the resin material, it is preferable to adjust the content of the foaming agent so that the foaming ratio is 5 times or more and 50 times or less.
- the expansion ratio is 5 times or more, the flange portion 125 of the inner member 120 can be more reliably embedded in the resin member 130 . Therefore, the effect of improving the tension rigidity can be reliably exhibited. Further, when the foaming ratio is 5 times or more, the vibration is easily damped, so that the effect of improving quietness can be further enhanced.
- the expansion ratio is more preferably 10 times or more from the viewpoint of making up for the lack of rigidity while reducing the weight.
- the expansion ratio is 50 times or less, it is possible to prevent the density of the resin member 130 from excessively decreasing. Therefore, the effect of improving tension rigidity can be reliably exhibited.
- the foaming ratio is 50 times or less, the density of the resin member 130 can be prevented from being excessively decreased, so that the vibration characteristics can be improved, and the effect of improving quietness can be further enhanced.
- the expansion ratio is more preferably 20 times or less.
- FIG. 1 The positional relationship among the outer panel member 110, the inner member 120, and the resin member 130 will be described below with reference to FIGS. 4 and 5.
- FIG. 1 The positional relationship among the outer panel member 110, the inner member 120, and the resin member 130 will be described below with reference to FIGS. 4 and 5.
- FIG. 4 is a schematic diagram for explaining the positional relationship between members when the panel structure 100 is viewed from the inside of the vehicle. As shown in FIG. 4 , the pair of resin members 130 , 130 are arranged so as to partially fill the inner member 120 at the longitudinal center of the inner member 120 .
- FIG. 5(a) is a cross-sectional view taken along the arrow A in FIG. That is, (a) of FIG. 5 shows a cross section at the center of the inner member 120 in the longitudinal direction of the cross section perpendicular to the longitudinal direction of the inner member 120 in the panel structure 100 .
- the widthwise ends of the pair of flange portions 125 , 125 of the inner member 120 extend from the side surfaces of the pair of resin members 130 , 130 . of the resin members 130, 130. That is, part of the inner member 120 is buried in the resin member 130 .
- the upper surfaces of the pair of resin members 130 , 130 are joined to the inner surface of the outer panel member 110 via the adhesive portion 150 .
- the adhesive portion 150 may be any adhesive. When a mastic adhesive containing synthetic rubber as a main component is used as the material of the adhesive portion 150, the tensile rigidity of the outer panel member 110 can be further increased. In addition, if a mastic adhesive containing synthetic rubber as a main component is used as the material of the adhesive portion 150, it is possible to impart a vibration characteristic that facilitates damping of high-frequency vibrations. can be enhanced. Therefore, it is preferable to use a mastic adhesive containing synthetic rubber as a main component as the material of the adhesive portion 150 .
- the bonding portion 150 may be provided on the entire upper surface of the resin member 130 or may be provided only on a part thereof.
- the resin material forming the resin member 130 contains a foaming agent
- the resin material containing the foaming agent is spray-applied to the outer panel member 110 and/or the inner member 120, and the resin material is heated to foam.
- the resin member 130 can be formed.
- the bonding portion 150 can be omitted.
- FIG. 5(b) is a cross-sectional view taken along arrow B in FIG. That is, FIG. 5(b) shows a cross section on the longitudinal end side of the inner member 120 among the cross sections perpendicular to the longitudinal direction of the inner member 120 in the panel structure 100 .
- the pair of resin members 130, 130 are not arranged on the longitudinal end side of the inner member 120, and the pair of flange portions 125, 125 of the inner member 120 are bonded. It is joined to the outer panel member 110 via the portion 160 .
- the adhesion part 160 should just be an adhesive agent.
- a mastic adhesive containing synthetic rubber as a main component is used as the material of the adhesive portion 160, the tensile rigidity of the outer panel member 110 can be further increased.
- a mastic adhesive containing synthetic rubber as a main component is used as the material of the adhesive portion 160, it is possible to impart a vibration characteristic that facilitates damping of high-frequency vibrations. can be enhanced. Therefore, it is preferable to use a mastic adhesive containing synthetic rubber as a main component as the material of the adhesive portion 160 .
- the bonding portion 160 is provided only on the longitudinal end portion side of the inner member 120, but may also be provided on the longitudinal central portion.
- the adhesive portion 160 When the adhesive portion 160 is also provided in the central portion of the inner member 120 in the longitudinal direction, the adhesive portion 160 may be provided continuously along the longitudinal direction of the inner member 120, or may be provided along the longitudinal direction of the inner member 120 at a predetermined distance. It may be intermittently provided at a pitch.
- the adhesive portion 150 that joins the outer panel member 110 and the resin member 130 and the adhesive portion 160 that joins the outer panel member 110 and the inner member 120 are made of the same material. It is preferable from the viewpoint of improving work efficiency when attaching 130 .
- ⁇ Pattern A for assembling after forming the resin member As a method of obtaining the panel structure 100, ⁇ Pattern A for assembling after forming the resin member, ⁇ Pattern B for assembling before forming the resin member, can be adopted. Details are described below.
- a molding die is set so as to surround a predetermined portion of the inner member 120, and a resin material is injected into the molding die and solidified to form the inner member 120 and the pair of resin members 130, 130 are integrated.
- the integrated inner member 120 and the pair of resin members 130, 130 are attached to the outer panel member 110 with an adhesive or the like.
- thermoplastic resin and a thermosetting resin can be used as the resin material used in the first step A11.
- the resin material may contain a foaming agent.
- a resin material is first injected into a molding die and solidified to form an intermediate product of a pair of resin members 130, 130, and slitting is performed on each intermediate product.
- the inner member 120 may be integrated by inserting the flange portion 125 of the inner member 120 .
- step B11 the outer panel member 110 and/or the inner member 120 are spray-coated with a resin material containing a foaming agent.
- step B12 the pair of flange portions 125, 125 of the inner member 120 are attached to the outer panel member 110 with an adhesive or the like.
- step B13 the resin material is foamed to form the resin member 130 in which the pair of flange portions 125, 125 of the inner member 120 are filled.
- thermosetting resin is used as the resin material to be spray-coated in the first step B11.
- the order of the first step B11 and the second step B12 may be reversed.
- the third step B13 it is preferable to adjust the content of the foaming agent so that the foaming ratio is 5 times or more and 50 times or less.
- the expansion ratio is 5 times or more
- the flange portion 125 of the inner member 120 can be more reliably embedded in the resin member 130, so that the effect of improving the tension rigidity can be reliably exhibited.
- the foaming ratio is 5 times or more, the vibration is easily damped, so that the effect of improving quietness can be further enhanced.
- the resin material may be foamed using heat generated during electrodeposition coating.
- the panel structure 100 described above a portion of the inner member 120 is embedded in the pair of resin members 130 , 130 . Therefore, the pair of resin members 130 , 130 are joined to the inner surface of the outer panel member 110 while being firmly held by the inner member 120 . Therefore, compared to the case where the resin member 130 is simply arranged only between the outer panel member 110 and the inner member 120, the tensional rigidity of the outer panel member 110 can be improved. Since the tensional rigidity can be improved in this way, it is possible to prevent the deterioration of the tensional rigidity which becomes apparent when the outer panel member 110 is thinned and lightened. Therefore, according to the panel structure 100 described above, it is possible to exhibit excellent tension rigidity while being lightweight.
- Characteristics can be improved and quietness can be improved. Since the quietness can be improved in this way, it is possible to prevent the deterioration of the quietness that becomes apparent when the outer panel member 110 is thinned and lightened. Therefore, according to the roof panel structure 100 described above, it is possible to exhibit excellent quietness while being lightweight.
- FIG. 6 is a schematic diagram for explaining the positional relationship between members when the panel structure 100A according to the first modification is viewed from the inside of the vehicle.
- FIG. 7(a) is a cross-sectional view taken along arrow C in FIG. 6, and
- FIG. 7(b) is a cross-sectional view taken along arrow D in FIG.
- the pair of flange portions 125, 125 and the pair of side wall portions 123 of the inner member 120 are partly filled with a single resin member 130A.
- the resin member 130A According to this panel structure 100A, a wider portion of the inner member 120 can be held by the resin member 130A. Furthermore, since the resin member 130A also exists in the region between the pair of flange portions 125, 125, a wide portion of the outer panel member 110 can be joined to the resin member 130A. Therefore, the tensile rigidity of the outer panel member 110 can be further increased. In addition, the vibration characteristics of the outer panel member 110 can be improved, and quietness can be further enhanced.
- the single resin member 130A may be configured by connecting a plurality of divided resin members.
- FIG. 8 is a schematic diagram for explaining the positional relationship between members when the panel structure 100B according to the second modification is viewed from the inside of the vehicle.
- FIG. 9(a) is a cross-sectional view taken along arrow E in FIG. 8
- FIG. 9(b) is a cross-sectional view taken along arrow F in FIG. In this panel structure 100B, as shown in FIG.
- the entire inner member 120 (that is, the top plate portion 121, the pair of side wall portions 123, 123, and a pair of flange portions 125, 125) are filled with a single resin member 130B.
- a single resin member 130B since the inner member 120 has a cross-sectional portion where the entire inner member 120 is buried in the single resin member 130B, a wider portion of the inner member 120 can be held by the resin member 130B.
- the resin member 130B exists also in the region between the pair of flange portions 125, 125, a wide portion of the outer panel member 110 can be joined to the resin member 130B. Therefore, the tensile rigidity of the outer panel member 110 can be further increased. In addition, the vibration characteristics of the outer panel member 110 can be improved, and quietness can be further enhanced.
- the single resin member 130B may be configured by connecting a plurality of divided resin members.
- the method for obtaining the panel structure 100A according to the first modified example or the panel structure 100B according to the second modified example is similar to the method for obtaining the panel structure 100.
- ⁇ Pattern A for assembling after forming the resin member, ⁇ Pattern B for assembling before forming the resin member, can be adopted.
- Pattern B when the order of the first step B11 and the second step B12 is reversed (that is, after the inner member 120 is attached to the outer panel member 110 with an adhesive or the like, a resin material containing a foaming agent is spray-coated. case), the adhesive may be sprayed from the gap between the flange portion 125 and the outer panel member 110 . However, if the gap is narrow, a hole for spray coating may be formed in the top plate portion 121 or the side wall portion 123 of the inner member 120 .
- FIG. 10 is a schematic diagram for explaining the positional relationship between the members when the panel structure 100C according to the third modification is viewed from the inside of the vehicle.
- the first inner member 120C1 and the second inner member 120C2 are arranged so as to be spaced apart in the longitudinal direction of the vehicle. More specifically, the first inner member 120C1 and the second inner member 120C2 are arranged such that the longitudinal direction of the first inner member 120C1 and the longitudinal direction of the second inner member 120C2 are parallel.
- a pair of first resin members 130C1 and 130C1 and a pair of second resin members 130C2 and 130C2 that fill the pair of flange portions 125 and 125 are provided in each of the first inner member 120C1 and the second inner member 120C2. It is The first inner member 120C1 and the second inner member 120C2 have the same configuration as the inner member 120, and the first resin member 130C1 and the second resin member 130C2 have the same configuration as the resin member 130. , the description is omitted. According to the panel structure 100C according to the third modified example, even when the outer panel member 110 has a large dimension, it is possible to increase the tensional rigidity of a desired portion.
- vibration characteristics can be improved and quietness can be enhanced even when the outer panel member 110 has a large dimension.
- three or more inner members 120 may be provided, or a plurality of inner members 120 may be provided such that their longitudinal directions cross each other.
- the first resin member 130C1 and the second resin member 130C2 are arranged apart from each other at the center in the longitudinal direction of the vehicle, but they may be integrated with each other. . That is, at least part of each of a pair of inner members 120 adjacent in the longitudinal direction of the vehicle may be embedded in a single (common) resin member 130 .
- each resin member 130 of the pair of resin members 130, 130 is composed of a single member, but each resin member 130 is divided into a plurality of parts.
- the members may be connected along the in-plane direction of the outer panel member 110 .
- FIG. 11 is a schematic diagram for explaining the positional relationship between the members when the panel structure 100D according to the fourth modification is viewed from the inside of the vehicle.
- This panel structure 100D has a first resin member 130D1 and a second resin member 130D2 that are divided into two in the longitudinal direction (vehicle width direction) of the inner member 120 in the in-plane direction of the outer panel member 110. As shown in FIG.
- the first resin member 130D1 and the second resin member 130D2 are connected by bonding the end face 131D1 of the first resin member 130D1 and the end face 131D2 of the second resin member 130D2 with an adhesive. . Since the first resin member 130D1 and the second resin member 130D2 have the same configuration as the resin member 130, description thereof is omitted. According to the panel structure 100D according to the fourth modification, even when the outer panel member 110 has a large dimension, it is possible to increase the tensional rigidity of a desired portion. Further, according to the roof panel structure 100D according to the fourth modification, vibration characteristics can be improved and quietness can be enhanced even when the outer panel member 110 has a large dimension.
- FIG. 12 is a schematic diagram for explaining the positional relationship between the members when the panel structure 100E according to the fifth modification is viewed from the inside of the vehicle.
- This panel structure 100E has a first resin member 130E1 and a second resin member 130E2 that are divided into two in the longitudinal direction (vehicle width direction) of the inner member 120 in the in-plane direction of the outer panel member 110. As shown in FIG.
- the first resin member 130E1 and the second resin member 130E2 are connected to each other by fitting together the end surface 131E1 of the first resin member 130E1 and the end surface 131E2 of the second resin member 130E2. .
- each of the end surface 131E1 and the end surface 131E2 facing each other has convex portions and concave portions alternately, and the convex portions and concave portions of the end surface 131E1 are the end surfaces.
- the first resin member 130E1 and the second resin member 130E2 are connected by fitting the concave and convex portions of 131E2. Since the first resin member 130E1 and the second resin member 130E2 have the same configuration as the resin member 130, redundant description will be omitted. According to the panel structure 100D according to the fifth modification, even when the outer panel member 110 has a large dimension, it is possible to increase the tensional rigidity of a desired portion.
- the roof panel structure 100D according to the fifth modification vibration characteristics can be improved and quietness can be enhanced even when the outer panel member 110 has a large dimension.
- it is not essential to bond the end surfaces with an adhesive, so workability during installation is improved.
- the fitting portions of the projection and the recess are joined with an adhesive, it is possible to more reliably prevent the first resin member 130E1 and the second resin member 130E2 from coming off. Therefore, it is preferable to bond the mating portions of the convex portion and the concave portion with an adhesive.
- FIG. 13 is a schematic diagram showing the positional relationship between members in the panel structure 100F according to the sixth modification.
- 14 is a cross-sectional view taken along arrow G in FIG. 13.
- FIG. 1 In this panel structure 100F, a pair of side frames 170, 170 are provided near the edges of the outer panel member 110 in the vehicle width direction so as to extend in the longitudinal direction of the vehicle.
- the side frame 170 may be, for example, a hollow elongated member made of a metal plate such as a steel plate.
- the inner member 120 is fixed at both ends in the longitudinal direction to a pair of side frames 170, 170 by welding or the like.
- both ends of the inner member 120 in the longitudinal direction are buried in the resin member 130F as shown in FIG.
- the pair of resin members 130 ⁇ /b>F, 130 ⁇ /b>F are joined to the inner surface of the outer panel member 110 while both ends thereof are firmly held by the inner member 120 fixed to the pair of side frames 170 , 170 . be. Therefore, the vibration characteristics of the outer panel member 110 can be improved, and quietness can be further improved.
- the inner member 120 may be a member with a U-shaped cross section or a T-shaped cross section.
- the resin member 130 is provided only on a part of the inner member 120 in the longitudinal direction, the resin member 130 may be provided over the entire length of the inner member 120 in the longitudinal direction.
- the resin member 130 can be provided in a manner that completely surrounds and fills the inner member 120 by spraying a resin material over the entire inner member 120 .
- panel structure 200 (Second embodiment)
- panel structure 200 an automotive panel structure 200 (hereinafter simply referred to as panel structure 200) according to the second embodiment of the present disclosure will be described.
- a panel structure 200 according to this embodiment is a panel structure applied to the hood of an automobile 1000 shown in FIG. 15 is an exploded perspective view of the panel structure 200.
- FIG. 15 is an exploded perspective view of the panel structure 200.
- the panel structure 200 has an outer panel member 210, an inner member 220 arranged to face the inner surface of the outer panel member 210, and a resin member 230 joined to the inner surface of the outer panel member 210. .
- the outer panel member 210 is a plate-like member having a curved surface that is convex toward the outside of the vehicle.
- the vehicle-exterior surface may be referred to as an outer surface
- the vehicle-interior surface may be referred to as an inner surface.
- the outer panel member 210 is formed by press forming a metal plate such as a steel plate. From the viewpoint of dent resistance, the tensile strength of the outer panel member 210 is preferably 440 MPa or more, more preferably 590 MPa or more.
- the thickness of the outer panel member 210 is preferably 0.55 mm or less, more preferably 0.50 mm or less. If the plate thickness of the outer panel member 210 is excessively thin, the tensile rigidity will be lowered. Therefore, in order to reliably exhibit excellent tension rigidity, the thickness of the outer panel member 210 is preferably 0.30 mm or more, more preferably 0.35 mm or more. In addition, according to the panel structure 200 according to the present embodiment, the tension rigidity of the outer panel member 210 can be increased by the configuration described later. Therefore, the outer panel member 210 can exhibit excellent tension rigidity while reducing the thickness of the outer panel member 210 .
- the inner member 220 is composed of a plate-shaped main body portion 221 arranged to face the inner surface of the outer panel member 210 .
- the body portion 221 has a protruding portion 221a protruding toward the outer panel member 210 at the center in the in-plane direction.
- the projecting portion 221a has a role of reinforcing the panel structure 200 by being formed in the inner member 220 in such a manner that the longitudinal direction of the projecting portion 221a coincides with the vehicle width direction.
- the protruding portion 221a may be formed on the inner member 220 such that its longitudinal direction intersects the vehicle width direction when viewed from a direction perpendicular to the in-plane direction of the outer panel member 210 . Moreover, when viewed from a direction perpendicular to the in-plane direction of the outer panel member 210, the projecting portion 221a may have a circular shape, an elliptical shape, or a polygonal shape.
- the inner member 220 can be obtained, for example, by press forming a metal plate such as a steel plate.
- the resin member 230 has a bottom surface 231 facing the body portion 221 of the inner member 220 .
- a groove 231a having a shape corresponding to the protrusion 221a is formed in the bottom surface 231 .
- the resin member 230 is joined to the inner surface of the outer panel member 210 in such a manner as to fill the tip of the projecting portion 221a on the outer panel member 210 side.
- the thickness of the maximum thickness portion where the dimension in the direction perpendicular to the in-plane direction of the outer panel member 210 is maximum is preferably 3 mm or more and 60 mm or less. If the thickness of the thickest portion of the resin member 230 is 3 mm or more, the inner member 220 can be held more firmly. Since this makes it possible to compensate for the lack of rigidity due to the thinning of the outer panel member 210, the thickness of the thickest portion of the resin member 230 is preferably 3 mm or more. On the other hand, even if the thickness of the thickest portion of the resin member 230 exceeds 60 mm, the effect is saturated, so the thickness of the thickest portion of the resin member 230 is preferably 60 mm or less.
- the material of the resin member 230 may be resin, and both thermosetting resin and thermoplastic resin can be used as the material of the resin member 230 .
- thermosetting resins include epoxy resins, unsaturated polyester resins, and vinyl ester resins.
- thermoplastic resins include polyolefins (polyethylene, polypropylene, etc.) and acid-modified products thereof, polyamide resins such as nylon 6 and nylon 66, thermoplastic aromatic polyesters such as polyethylene terephthalate and polybutylene terephthalate, polycarbonates, poly Examples include ether sulfone, polyphenylene ether and modified products thereof, polyarylate, polyether ketone, polyether ether ketone, polyether ketone ketone, vinyl chloride, styrenic resins such as polystyrene, and phenoxy resins.
- the resin may be formed of a plurality of types of resin materials.
- the resin material forming the resin member 230 contains a foaming agent
- the working efficiency when attaching the resin member 230 is improved. Therefore, it is preferable that the resin material forming the resin member 230 contains a foaming agent.
- foaming agents include N,N'-dinitrosopentamethylenetetramine, azodicarbonamide, 4,4'-oxybis(benzenesulfonylhydrazide), hydrogencarbonate, sodium hydrogencarbonate and the like.
- a foaming agent is contained in the resin material, it is preferable to adjust the content of the foaming agent so that the foaming ratio is 5 times or more and 50 times or less.
- FIG. 16 is a cross-sectional view taken along arrow H in FIG. 15.
- FIG. 16 shows a cross section at the center of the projection 221a in the longitudinal direction of the cross section perpendicular to the longitudinal direction of the projection 221a in the panel structure 200.
- the tip of the protrusion 221 a of the inner member 220 on the outer panel member 210 side enters the groove 231 a of the resin member 230 . That is, part of the inner member 220 is buried in the resin member 230 .
- the upper surface of the resin member 230 is joined to the inner surface of the outer panel member 210 via the adhesive portion 250 .
- the adhesion part 250 should just be an adhesive agent.
- a mastic adhesive containing synthetic rubber as a main component is used as the material of the adhesive portion 250, the tension rigidity of the outer panel member 210 can be further increased. Therefore, it is preferable to use a mastic adhesive containing synthetic rubber as a main component as the material of the adhesive portion 250 .
- the bonding portion 250 may be provided on the entire upper surface of the resin member 230, or may be provided only on a part thereof.
- the resin material forming the resin member 230 contains a foaming agent
- the resin material containing the foaming agent is spray-applied to the outer panel member 210 and/or the inner member 220, and the resin material is heated to foam.
- the resin member 230 can be formed.
- the bonding portion 250 can be omitted.
- ⁇ Pattern A for assembling after forming the resin member As a method of obtaining the panel structure 200, ⁇ Pattern A for assembling after forming the resin member, ⁇ Pattern B for assembling before forming the resin member, can be adopted. Details are described below.
- a molding die is set so as to surround a predetermined portion of the projecting portion 221a of the inner member 220, and a resin material is injected into the molding die and solidified to form the inner member 220 and the resin member. 230 are integrated.
- the integrated inner member 220 and resin member 230 are attached to the outer panel member 210 with an adhesive or the like.
- thermoplastic resin and a thermosetting resin can be used as the resin material used in the first step A21.
- the resin material may contain a foaming agent.
- the resin material 230 and the inner member 220 may be integrated by bonding the resin member 230, which has been previously formed with a molding die, to the inner member 220 with an adhesive or the like.
- step B21 the outer panel member 210 and/or the inner member 220 are spray-coated with a resin material containing a foaming agent.
- step B22 the inner member 220 is attached to the outer panel member 210 with an adhesive or the like.
- step B23 the resin material is foamed to form the resin member 230 in which the tips of the projecting portions 221a of the inner member 220 are buried.
- thermosetting resin is used as the resin material to be spray-coated in the first step B21.
- the order of the first step B21 and the second step B22 may be reversed. However, it is necessary to devise a method such as forming a hole in the inner member 220 for spray coating.
- the third step B23 it is preferable to heat so that the foaming ratio is 5 times or more and 50 times or less.
- the foaming ratio is 5 times or more, the projecting portion 221a of the inner member 220 can be more reliably embedded in the resin member 230, so that the effect of improving the tension rigidity can be reliably exhibited.
- the expansion ratio is more preferably 10 times or more from the viewpoint of making up for the lack of rigidity while reducing the weight.
- the expansion ratio is 50 times or less, it is possible to prevent the density of the resin member 230 from being excessively lowered, so that the effect of improving the tension rigidity can be reliably exhibited.
- the expansion ratio is more preferably 20 times or less.
- foaming may be performed using the heat generated during electrodeposition coating.
- the tip of the projecting portion 221 a of the inner member 220 is buried in the resin member 230 . Therefore, the resin member 230 is joined to the inner surface of the outer panel member 210 while being firmly held by the inner member 220 . Therefore, compared to the case where the resin member 230 is simply arranged only between the outer panel member 210 and the inner member 220, the tensional rigidity of the outer panel member 210 can be improved. Since the tensional rigidity can be improved in this way, it is possible to prevent deterioration of the tensional rigidity that becomes apparent when the outer panel member 210 is thinned and lightened. Therefore, according to the panel structure 200 described above, it is possible to exhibit excellent tension rigidity while being lightweight.
- the panel structure 200 according to the second embodiment has a cross-sectional portion in which the tip of the protruding portion 221a of the inner member 220 is buried in the resin member 230.
- a configuration having a cross-sectional portion entirely buried in the resin member 230 may be employed.
- FIG. 17 shows a cross section at the center in the longitudinal direction of the protrusion 221a among the cross sections perpendicular to the longitudinal direction of the protrusion 221a in the panel structure 200A according to the first modified example of the second embodiment. As shown in FIG.
- the bottom surface 231A of the resin member 230A is in surface contact with the main body portion 221 of the inner member 220 (that is, the portion other than the projecting portion 221a).
- the panel structure 200A has a cross-sectional portion in which the entire surface of the projecting portion 221a of the inner member 220 on the outer panel member 210 side is filled with the resin member 230A.
- the resin member 230A is joined to the outer panel member 210 while the resin member 230A is held more firmly by the inner member 220, so that the tensional rigidity of the outer panel member 210 can be further improved.
- FIG. 18 is an exploded perspective view of a panel structure 200B according to a second modified example of the second embodiment.
- the inner member 220B is composed of a plate-shaped main body portion 221B arranged to face the inner surface of the outer panel member 210 .
- the body portion 221B is formed with a plurality of overhanging portions 221b and a bottom portion 221c continuous with the overhanging portions 221b at the center in the in-plane direction.
- the protruding portion 221b is formed in a manner that rises toward the outer panel member 210.
- the bottom portion 221c is arranged continuously with the projecting portion 221b on the inner member 220B side. A plurality of such projecting portions 221b and bottom portions 221c are provided so as to line up in the in-plane direction of the main body portion 221B.
- FIG. 19 is a cross-sectional view taken along arrow I in FIG. That is, FIG. 19 shows a cross section of the panel structure 200B that is perpendicular to one in-plane direction (vehicle front direction Fr) of the outer panel member 210 and includes the projecting portion 221b and the bottom portion 221c.
- vehicle front direction Fr vehicle front direction
- the projecting portion 221b has a peripheral wall portion 221b1 and a top portion 221b2.
- the peripheral wall portion 221b1 is a portion formed in a manner that rises from the main body portion 221B toward the outer panel member 210.
- the peripheral wall portion 221b1 is arranged between the top portion 221b2 and the bottom portion 221c, and connects the top portion 221b2 and the bottom portion 221c.
- the peripheral wall portion 221b1 has a substantially hexagonal outer shape as shown in FIG. 18, but may be polygonal, circular, or elliptical.
- the top portion 221b2 is a portion of the protruding portion 221b that bends and extends from the edge on the outer panel member 210 side. .
- a substantially hexagonal opening penetrating in a direction perpendicular to the in-plane direction of the outer panel member 210 is formed in the center of the top portion 221b2.
- the opening may be polygonal, circular, or elliptical.
- the weight reduction of the inner member 220B is realized by the opening portion, and the rigidity that is reduced by the opening portion is reduced by the three-dimensionally formed peripheral wall portion. This can be supplemented by the portion 221b1.
- the bottom portion 221c is continuous with the peripheral wall portion 221b1 and is arranged apart from the top portion 221b2.
- the bottom portion 221c is continuous with the peripheral wall portion 221b1 on the side opposite to the top portion 221b2.
- the bottom portion 221c has a substantially hexagonal outer shape as shown in FIG. 18, but may be polygonal, circular, or elliptical.
- the bottom portion 221c continuous with one top portion 221b2 is mated with the bottom portion 221c continuous with the other top portion 221b2.
- this panel structure 200B has a cross-sectional portion in which a portion of the top portion 221b2 is buried in the resin member 230B.
- the tension rigidity can be further increased by embedding a part of the peripheral wall portion 221b1 in the resin member 230B.
- the adhesive portion 250B may be an adhesive.
- a mastic adhesive containing synthetic rubber as a main component is used as the material of the adhesive portion 250, the tension rigidity of the outer panel member 210 can be further increased. Therefore, it is preferable to use a mastic adhesive containing synthetic rubber as a main component as the material of the adhesive portion 250 .
- the bonding portions 250B may be provided continuously in a ring shape along the upper surface of the top portion 221b2, or may be provided in a ring shape at a predetermined pitch.
- the top 221b2 may be entirely buried in the resin member 230C. According to this structure, it is possible to further increase the tension rigidity as compared with the panel structure 200B according to the second modified example.
- the panel structure of the present disclosure has been described above based on the first embodiment, the second embodiment, and their modifications, the panel structure of the present disclosure is not limited thereto.
- the roof panel structure 100 can also be applied to panel structures such as hoods, side doors, and back doors.
- the inner member 120 may be attached to the outer panel member 110 in such a manner that its longitudinal direction matches the longitudinal direction of the vehicle. Thereby, the panel structure 100 can be reinforced.
- the number of inner members 120 may be one or plural. When a plurality of inner members 120 are arranged with their longitudinal directions aligned with the front-rear direction of the vehicle, each inner member 120 may have a different shape or the same shape.
- each inner member 120 may have different lengths, or may have the same length.
- the arrangement of each inner member 120 is not particularly limited.
- the inner members 120 may be arranged at equal intervals in the vehicle width direction, or may be arranged at different intervals.
- each inner member 120 may be arranged, for example, shifted in the front-rear direction of the vehicle.
- each inner member 120 may be arranged side by side in the vehicle front-rear direction at the same position in the vehicle width direction.
- the inner member 120 may have an opening extending longitudinally thereof. When the inner member 120 is attached to the outer panel member 110 with its longitudinal direction aligned with the longitudinal direction of the vehicle, the longitudinally extending opening of the inner member 120 extends in the longitudinal direction of the vehicle.
- the hood panel structure 200 can also be applied to panel structures such as roofs, side doors, and back doors. Also, the modifications described in the first embodiment and the second embodiment may be applied to panel structures according to other embodiments.
- Automotive panel structure 110 Outer panel member 120 Inner member 130 Resin member 150 Adhesive portion 160 Adhesive portion 170 Side frame 200 Automotive panel structure 210 Outer panel member 220 Inner member 221 Body portion 221a Protruding portion 221b Peripheral wall portion 221c Bottom portion 230 Resin member 250 Adhesion Part 1000 Automobile
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Abstract
Description
(1)本発明の一態様は、板状のアウタパネル部材と、前記アウタパネル部材の内面に対向して配置されるインナ部材と、材料が樹脂であり、前記アウタパネル部材の前記内面に接合される樹脂部材と、を有し、前記インナ部材の少なくとも一部が前記樹脂部材に埋められている自動車用パネル構造である。
(2)上記(1)に記載の自動車用パネル構造においては、前記インナ部材が、前記アウタパネル部材の面内方向における一方向に沿って延在してもよい。
(3)上記(2)に記載の自動車用パネル構造においては、前記インナ部材が延在する方向に垂直な断面部であって、前記インナ部材の全体が前記樹脂部材に埋められている断面部を有してもよい。
(4)上記(2)又は(3)に記載の自動車用パネル構造においては、前記インナ部材を複数有し、複数の前記インナ部材が、前記アウタパネル部材の面内方向のうち前記一方向に垂直な方向に離間して平行に配置されてもよい。
(5)上記(1)に記載の自動車用パネル構造においては、前記インナ部材が、前記アウタパネル部材の前記内面に対向して配置される板状の本体部を有し、前記本体部が、前記アウタパネル部材に向かって突出する突出部を有し、前記アウタパネル部材の面内方向に垂直な断面部であって、前記突出部の先端が前記樹脂部材に埋められている断面部を有してもよい。
(6)上記(5)に記載の自動車用パネル構造においては、前記アウタパネル部材の面内方向に垂直な断面部であって、前記突出部の前記アウタパネル部材に近い面の全体が前記樹脂部材に埋められている断面部を有してもよい。
(7)上記(1)に記載の自動車用パネル構造においては、前記インナ部材が、前記アウタパネル部材の前記内面に対向して配置される板状の本体部を有し、前記本体部が、前記アウタパネル部材に向かって立ち上がる周壁部と、前記周壁部のうち前記アウタパネル部材側の端縁から屈曲して延在するとともに中央に開口部が形成された頂部とを含む張出部を有し、前記アウタパネル部材の面内方向に垂直な断面部であって、前記頂部の少なくとも一部が前記樹脂部材に埋められている断面部を有してもよい。
(8)上記(7)に記載の自動車用パネル構造においては、前記アウタパネル部材の面内方向に垂直な断面部であって、前記頂部の全体が前記樹脂部材に埋められている断面部を有してもよい。
(9)上記(1)~(8)のいずれか一項に記載の自動車用パネル構造においては、前記樹脂部材が熱硬化性樹脂であってもよい。
(10)上記(1)~(8)のいずれか一項に記載の自動車用パネル構造においては、前記樹脂部材が熱可塑性樹脂であってもよい。
(11)上記(1)~(10)のいずれか一項に記載の自動車用パネル構造においては、前記樹脂部材を複数有し、複数の前記樹脂部材が前記アウタパネル部材の面内方向に沿って互いに接続されていてもよい。
(12)上記(11)に記載の自動車用パネル構造においては、複数の前記樹脂部材が接着剤により互いに接続されていてもよい。
(13)上記(11)又は(12)に記載の自動車用パネル構造においては、複数の前記樹脂部材が嵌合により互いに接続されていてもよい。
(14)上記(1)~(13)のいずれか一項に記載の自動車用パネル構造においては、前記アウタパネル部材と前記樹脂部材とを接合する接着部と、前記アウタパネル部材と前記インナ部材とを接合する接着部とが同じ材質であってもよい。
(15)上記(1)~(14)のいずれか一項に記載の自動車用パネル構造においては、前記アウタパネル部材は、引張強さが440MPa以上であってもよい。
(16)上記(1)~(15)のいずれか一項に記載の自動車用パネル構造においては、前記アウタパネル部材は、板厚が0.30mm以上0.55mm以下であってもよい。(17)上記(1)~(16)のいずれか一項に記載の自動車用パネル構造においては、前記樹脂部材のうち、前記アウタパネル部材の面内方向に垂直な方向の寸法が最大となる部位の厚さが3mm以上60mm以下であってもよい。
以下、本開示の第一実施形態に係る自動車用パネル構造100(以下、単にパネル構造100と呼称する)について説明する。
なお、本明細書及び図面において、実質的に同一の機能構成を有する構成要素については、同一の符号を付することにより重複説明を省略する場合がある。なお、図面において、車両前方向を矢印Frで示す。
図1は、パネル構造100を車外側から見た状態を示す斜視図であり、図2はパネル構造100を車内側から見た状態を示す斜視図である。
アウタパネル部材110は、車外側に向けて凸の曲面を有する板状の部材である。本開示においては、車外側の面を外面、車内側の面を内面と呼称する場合がある。
アウタパネル部材110は、鋼板などの金属板をプレス成形することにより形成される。
アウタパネル部材110の引張強度は、耐デント性の観点から、440MPa以上であることが好ましく、590MPa以上であることがより好ましい。
アウタパネル部材110の板厚は、過度に薄い場合には張り剛性の低下が顕在化する。また、アウタパネル部材110の板厚が過度に薄い場合には、アウタパネル部材110が高周波の振動で共振しやすくなる。このため、例えば、自動車のルーフにアウタパネル110が適用される場合、上空からの雨粒による加振音や走行時の風切り音といったような音が車内に侵入しやすくなり、静粛性の低下が顕在化することがある。従って、優れた張り剛性及び静粛性を確実に発揮するためには、アウタパネル部材110の板厚は0.30mm以上であることが好ましく、0.35mm以上であることがより好ましい。尚、本実施形態に係るパネル構造100によれば、後述する構成によりアウタパネル部材110の張り剛性を高めることができる。このため、アウタパネル部材110の板厚を薄くしながらも優れた張り剛性を発揮することができる。
インナ部材120は、アウタパネル部材110の内面に対向して配置される長尺部材である。インナ部材120は、アウタパネル部材110の面内方向における一方向に沿って延在する態様で配置される。インナ部材120は、その長手方向が車幅方向に一致する態様でアウタパネル部材110に取り付けられることにより、パネル構造100を補強する役割を有する。
尚、本開示において、インナ部材120の幅方向は、インナ部材120の長手方向に垂直な方向のうち、天板部121に平行な方向を意味する。
図1及び図2に示すように、一対の樹脂部材130,130は、インナ部材120の一部を埋める態様で、アウタパネル部材110の内面に接合されている。
尚、本開示において「インナ部材の少なくとも一部が樹脂部材に埋められる」とは、インナ部材の少なくとも一部が樹脂部材に入り込み、面接触した状態で保持されていることを意味する。
樹脂部材130の厚さ最大部位の厚さが3mm以上であれば、インナ部材120をより強固に保持することができる。これにより、アウタパネル部材110の薄肉化に伴う剛性不足を補うことができるため好ましい。樹脂部材130の厚さ最大部位の厚さは、より好ましくは、5mm以上である。
一方、樹脂部材130の厚さ最大部位の厚さが60mm超であっても効果が飽和する。そのため、樹脂部材130の厚さ最大部位の厚さは、60mm以下であることが好ましい。樹脂部材130の厚さ最大部位の厚さは、軽量化の観点から、より好ましくは、10mm以下である。
熱硬化性樹脂としては、例えば、エポキシ樹脂、不飽和ポリエステル樹脂、並びにビニルエステル樹脂等があげられる。
熱可塑性樹脂としては、例えば、ポリオレフィン(ポリエチレン、ポリプロピレン等)およびその酸変性物、ナイロン6およびナイロン66等のポリアミド樹脂、ポリエチレンテレフタラートおよびポリブチレンテレフタラート等の熱可塑性芳香族ポリエステル、ポリカーボネート、ポリエーテルスルホン、ポリフェニレンエーテルおよびその変性物、ポリアリレート、ポリエーテルケトン、ポリエーテルエーテルケトン、ポリエーテルケトンケトン、塩化ビニル、ポリスチレン等のスチレン系樹脂、並びにフェノキシ樹脂等があげられる。
なお、樹脂は、複数種類の樹脂材料により形成されていてもよい。
発泡剤としては、N,N´-ジニトロソペンタメチレンテトラミン、アゾジカルボンアミド、4,4´-オキシビス(ベンゼンスルホニルヒドラジド)、炭酸水素塩、炭酸水素ナトリウム等が挙げられる。
樹脂材料に発泡剤を含有させる場合、発泡倍率が5倍以上50倍以下となるように発泡剤の含有量を調整することが好ましい。発泡倍率が5倍以上である場合、より確実にインナ部材120のフランジ部125を樹脂部材130に埋めることができる。このため、張り剛性の向上効果を確実に発揮することができる。また、発泡倍率が5倍以上であると、振動が減衰しやすくなるため、静粛性の向上効果をより一層高めることができる。発泡倍率は、より好ましくは、軽量化しながら剛性不足を補うという観点から、10倍以上である。一方、発泡倍率が50倍以下である場合、樹脂部材130の密度が過度に低下することを防ぐことができる。そのため、張り剛性の向上効果を確実に発揮することができる。また、発泡倍率が50倍以下である場合、樹脂部材130の密度が過度に低下することを防ぐことができるため、振動特性を改善し、静粛性の向上効果をより一層高めることができる。発泡倍率は、より好ましくは20倍以下である。
図5の(a)に示すように、インナ部材120の長手方向中央においては、インナ部材120の一対のフランジ部125,125の幅方向端部は、一対の樹脂部材130,130の側面から一対の樹脂部材130,130の内部に入り込んでいる。すなわち、インナ部材120の一部が樹脂部材130に埋められている。
更に、一対の樹脂部材130,130の上面は、接着部150を介してアウタパネル部材110の内面に接合されている。
接着部150は、樹脂部材130の上面の全体に設けられてもよく、一部のみに設けられてもよい。
図5の(b)に示すように、インナ部材120の長手方向端部側においては、一対の樹脂部材130,130は配置されておらず、インナ部材120の一対のフランジ部125,125が接着部160を介してアウタパネル部材110に接合されている。
接着部160は、インナ部材120の長手方向端部側にのみ設けられているが、長手方向中央部にも設けられてもよい。接着部160をインナ部材120の長手方向中央部にも設ける場合、接着部160は、インナ部材120の長手方向に沿って連続的に設けられてもよく、インナ部材120の長手方向に沿って所定ピッチで断続的に設けられてもよい。
・樹脂部材を形成した後に組み付けを行うパターンAと、
・樹脂部材を形成する前に組み付けを行うパターンBと、
のいずれかを採用することができる。詳細について以下に説明する。
第一工程A11として、インナ部材120の所定の部位を取り囲むように成型金型を設置し、成型金型の内部に樹脂材料を注入して固めることにより、インナ部材120と一対の樹脂部材130,130を一体化させる。
第二工程A12として、一体化させたインナ部材120と一対の樹脂部材130,130とを接着剤等によりアウタパネル部材110に取り付ける。
第一工程A11においては、先に成型金型の内部に樹脂材料を注入して固めることにより、一対の樹脂部材130,130の中間品を成型し、それぞれの中間品にスリット加工を行い、スリットにインナ部材120のフランジ部125を挿し込むことで一体化させてもよい。
第一工程B11として、アウタパネル部材110及び/又はインナ部材120に発泡剤を含む樹脂材料をスプレー塗布する。
第二工程B12として、インナ部材120の一対のフランジ部125,125を接着剤等によりアウタパネル部材110に取り付ける。
第三工程B13として、樹脂材料を発泡させ、インナ部材120の一対のフランジ部125,125を埋めた状態の樹脂部材130を形成する。
第一工程B11と第二工程B12は順序が逆であってもよい。
第三工程B13においては、発泡倍率が5倍以上50倍以下となるように発泡剤の含有量を調整することが好ましい。発泡倍率が5倍以上である場合、より確実にインナ部材120のフランジ部125を樹脂部材130に埋めることができるため、張り剛性の向上効果を確実に発揮することができる。また、発泡倍率が5倍以上であると、振動が減衰しやすくなるため、静粛性の向上効果をより一層高めることができる。一方、発泡倍率が50倍以下である場合、樹脂部材130の密度が過度に低下することを防ぐことができる。そのため、張り剛性の向上効果を確実に発揮することができる。また、発泡倍率が50倍以下である場合、樹脂部材130の密度が過度に低下することを防ぐことができるため、振動特性を改善し、静粛性の向上効果をより一層高めることができる。
第三工程B13においては、電着塗装時の熱を利用して樹脂材料を発泡してもよい。
従って、樹脂部材130を単にアウタパネル部材110とインナ部材120との間のみに配置する場合に比べ、アウタパネル部材110の張り剛性を向上させることができる。このように、張り剛性を向上させることができるため、アウタパネル部材110を薄肉化して軽量化する際に顕在化する張り剛性の低下を防ぐことができる。
従って、上記のパネル構造100によれば、軽量でありながらも優れた張り剛性を発揮することができる。
しかしながら、上記のルーフパネル構造100によれば、インナ部材120の一部が一対の樹脂部材130,130に埋められている。従って、一対の樹脂部材130,130がインナ部材120に強固に保持された状態で、アウタパネル部材110の内面に接合されている。これにより、樹脂部材130を単にアウタパネル部材110とインナ部材120との間のみに配置する場合に比べ、高周波の振動が減衰し易くなるような振動特性に改善することができ、アウタパネル部材110の振動特性を改善し、静粛性を向上させることができる。
このように、静粛性を向上させることができるため、アウタパネル部材110を薄肉化して軽量化する際に顕在化する静粛性の低下を防ぐことができる。
従って、上記のルーフパネル構造100によれば、軽量でありながらも優れた静粛性を発揮することができる。
上記の第一実施形態に係るパネル構造100は、一対の樹脂部材130を有する構成であった。しかし、第一変形例に係るパネル構造100Aは、単一の樹脂部材130Aを有する構成である。
図6は、第一変形例に係るパネル構造100Aを車内側から見た状態における部材同士の位置関係を説明するための模式図である。図7の(a)は図6のC矢視断面図であり、図7の(b)は図6のD矢視断面図である。
このパネル構造100Aにおいては、単一の樹脂部材130Aにより、インナ部材120の一対のフランジ部125,125と、一対の側壁部123の一部が埋められている。このパネル構造100Aによれば、インナ部材120におけるより広い部位を樹脂部材130Aにより保持することができる。さらには、一対のフランジ部125,125の間の領域にも樹脂部材130Aが存在するため、アウタパネル部材110の広い部位を樹脂部材130Aに接合させることができる。
従って、アウタパネル部材110の張り剛性を更に高めることができる。また、アウタパネル部材110の振動特性を改善し、静粛性を更に高めることができる。
尚、単一の樹脂部材130Aは、複数に分割された樹脂部材を接続することにより構成されていてもよい。
更には、第二変形例に係るパネル構造100Bのように、インナ部材120の全体が単一の樹脂部材130Bにより埋められる断面部を有していてもよい。
図8は、第二変形例に係るパネル構造100Bを車内側から見た状態における部材同士の位置関係を説明するための模式図である。図9の(a)は図8のE矢視断面図であり、図9の(b)は図8のF矢視断面図である。
このパネル構造100Bでは、図9の(a)に示すように、インナ部材120の長手方向中央における断面部において、インナ部材120の全体(すなわち、天板部121、一対の側壁部123,123、及び一対のフランジ部125,125)が単一の樹脂部材130Bにより埋められている。
このパネル構造100Bによれば、インナ部材120の全体が単一の樹脂部材130Bに埋められている断面部を有するため、インナ部材120におけるより広い部位を樹脂部材130Bにより保持することができる。さらには、一対のフランジ部125,125の間の領域にも樹脂部材130Bが存在するため、アウタパネル部材110の広い部位を樹脂部材130Bに接合させることができる。
従って、アウタパネル部材110の張り剛性を更に高めることができる。また、アウタパネル部材110の振動特性を改善し、静粛性を更に高めることができる。
尚、単一の樹脂部材130Bは、複数に分割された樹脂部材を接続することにより構成されていてもよい。
・樹脂部材を形成した後に組み付けを行うパターンAと、
・樹脂部材を形成する前に組み付けを行うパターンBと、
のいずれかを採用することができる。
上記の第一実施形態に係るパネル構造100においては、単一のインナ部材120を有する構成であったが、複数のインナ部材120を有する構成であってもよい。
図10は、第三変形例に係るパネル構造100Cを車内側から見た状態における部材同士の位置関係を説明するための模式図である。
このパネル構造100Cにおいては、第一のインナ部材120C1と第二のインナ部材120C2が、車両の前後方向に離間する態様で配置されている。より具体的には、第一のインナ部材120C1の長手方向と、第二のインナ部材120C2の長手方向とが平行となる態様で第一のインナ部材120C1と第二のインナ部材120C2が配置されている。
第一のインナ部材120C1及び第二のインナ部材120C2のそれぞれには、一対のフランジ部125,125を埋める一対の第一の樹脂部材130C1,130C1と一対の第二の樹脂部材130C2,130C2が設けられている。
第一のインナ部材120C1及び第二のインナ部材120C2は、インナ部材120と同様の構成であり、第一の樹脂部材130C1と第二の樹脂部材130C2は、樹脂部材130と同様の構成であるため、説明を省略する。
第三変形例に係るパネル構造100Cによれば、アウタパネル部材110の寸法が大きい場合にも所望の部位の張り剛性を高めることができる。また、第三変形例に係るルーフパネル構造100Cによれば、アウタパネル部材110の寸法が大きい場合にも振動特性を改善し、静粛性を高めることができる。
尚、アウタパネル部材110の形状や寸法に応じて、3つ以上のインナ部材120が設けられてもよく、長手方向が互いに交差する態様で複数のインナ部材120が設けられてもよい。
また、図10に示す例では、第一の樹脂部材130C1と第二の樹脂部材130C2とが、車両の前後方向の中央で互いに離間して配置されているが、互いに一体化されていてもよい。すなわち、車両の前後方向に隣り合う一対のインナ部材120のそれぞれの少なくとも一部が、単一の(共通の)樹脂部材130に埋められている構成であってもよい。
上記の第一実施形態に係るパネル構造100においては、一対の樹脂部材130,130のそれぞれの樹脂部材130が単一の部材で構成されているが、それぞれの樹脂部材130は複数に分断された部材がアウタパネル部材110の面内方向に沿って接続された構成であってもよい。
図11は、第四変形例に係るパネル構造100Dを車内側から見た状態における部材同士の位置関係を説明するための模式図である。このパネル構造100Dは、アウタパネル部材110の面内方向においてインナ部材120の長手方向(車幅方向)に二つに分断された第一の樹脂部材130D1及び第二の樹脂部材130D2を有する。そして、第一の樹脂部材130D1及び第二の樹脂部材130D2は、第一の樹脂部材130D1の端面131D1と第二の樹脂部材130D2の端面131D2とが接着剤で接合されることによって接続されている。
第一の樹脂部材130D1及び第二の樹脂部材130D2は、樹脂部材130と同様の構成であるため説明を省略する。
第四変形例に係るパネル構造100Dによれば、アウタパネル部材110の寸法が大きい場合にも所望の部位の張り剛性を高めることができる。また、第四変形例に係るルーフパネル構造100Dによれば、アウタパネル部材110の寸法が大きい場合にも振動特性を改善し、静粛性を高めることができる。
第一の樹脂部材130E1及び第二の樹脂部材130E2は、樹脂部材130と同様の構成であるため重複する説明を省略する。
第五変形例に係るパネル構造100Dによれば、アウタパネル部材110の寸法が大きい場合にも所望の部位の張り剛性を高めることができる。また、第五変形例に係るルーフパネル構造100Dによれば、アウタパネル部材110の寸法が大きい場合にも振動特性を改善し、静粛性を高めることができる。また、第五変形例に係るパネル構造100Dでは、第四変形例に係るパネル構造100のように端面同士を接着剤で接合することが必須ではないため、取り付け時の作業性が向上する。ただし、凸部と凹部との嵌合部位を接着剤で接合すると、第一の樹脂部材130E1と第二の樹脂部材130E2が脱落することをより確実に防止することができる。そのため、凸部と凹部との嵌合部位を接着剤で接合することが好ましい。
図13は第六変形例に係るパネル構造100Fにおける部材同士の位置関係を示す模式図である。図14は図13におけるG矢視断面図である。
このパネル構造100Fにおいては、一対のサイドフレーム170,170が車両の前後方向に延在する態様でアウタパネル部材110の車両幅方向端縁の近傍に設けられている。
サイドフレーム170は、例えば、鋼板などの金属板から形成された中空の長尺部材であればよい。
このパネル構造100Fにおいては、インナ部材120が、その長手方向の両端部が一対のサイドフレーム170,170に溶接等により固定されている。
更に、インナ部材120の長手方向の両端部は、図14に示すように、樹脂部材130Fに埋められている。
この態様によれば、一対の樹脂部材130F,130Fは、その両端部が一対のサイドフレーム170,170に固定されたインナ部材120に強固に保持された状態で、アウタパネル部材110の内面に接合される。従って、アウタパネル部材110の振動特性を改善し、静粛性を更に向上させることができる。
上記以外にも種々の変形例を採用することができる。
例えば、インナ部材120としてハット型断面の部材を用いているが、インナ部材120は、U字型断面の部材やT字型断面の部材であってもよい。
また、樹脂部材130はインナ部材120の長手方向の一部にのみ設ける構成とされているが、樹脂部材130はインナ部材120の長手方向の全長に亘って設ける構成とされてもよい。例えば、インナ部材120の全体に樹脂材料のスプレー塗布することにより、インナ部材120を完全に包囲して埋める態様で樹脂部材130を設けることができる。
以下、本開示の第二実施形態に係る自動車用パネル構造200(以下、単にパネル構造200と呼称する)について説明する。
図15は、パネル構造200の分解斜視図である。
アウタパネル部材210は、車外側に向けて凸の曲面を有する板状の部材である。本開示においては、車外側の面を外面、車内側の面を内面と呼称する場合がある。
アウタパネル部材210は、鋼板などの金属板をプレス成形することにより形成される。
アウタパネル部材210の引張強度は、耐デント性の観点から、440MPa以上であることが好ましく、590MPa以上であることがより好ましい。
アウタパネル部材210の板厚は、過度に薄い場合には張り剛性の低下が顕在化する。従って、優れた張り剛性を確実に発揮するためには、アウタパネル部材210の板厚は0.30mm以上であることが好ましく、0.35mm以上であることがより好ましい。尚、本実施形態に係るパネル構造200によれば、後述する構成によりアウタパネル部材210の張り剛性を高めることができる。このため、アウタパネル部材210の板厚を薄くしながらも優れた張り剛性を発揮することができる。
インナ部材220は、アウタパネル部材210の内面に対向して配置される板状の本体部221により構成される。
本体部221は、その面内方向の中央において、アウタパネル部材210に向かって突出する突出部221aを有する。
このパネル構造200においては、突出部221aは、その長手方向が車幅方向に一致する態様でインナ部材220に形成されていることにより、パネル構造200を補強する役割を有する。
図15に示すように、樹脂部材230は、インナ部材220の本体部221に対向する底面231を有する。底面231には、突出部221aに対応する形状の溝231aが形成されている。樹脂部材230は、突出部221aの、アウタパネル部材210側の先端を埋める態様で、アウタパネル部材210の内面に接合されている。
樹脂部材230の厚さ最大部位の厚さが3mm以上であれば、インナ部材220をより強固に保持することができる。これにより、アウタパネル部材210の薄肉化に伴う剛性不足を補うことができるため、樹脂部材230の厚さ最大部位の厚さは3mm以上であることが好ましい。
一方、樹脂部材230の厚さ最大部位の厚さが60mm超であっても効果が飽和するため、樹脂部材230の厚さ最大部位の厚さは60mm以下であることが好ましい。
熱硬化性樹脂としては、例えば、エポキシ樹脂、不飽和ポリエステル樹脂、並びにビニルエステル樹脂等があげられる。
熱可塑性樹脂としては、例えば、ポリオレフィン(ポリエチレン、ポリプロピレン等)およびその酸変性物、ナイロン6およびナイロン66等のポリアミド樹脂、ポリエチレンテレフタラートおよびポリブチレンテレフタラート等の熱可塑性芳香族ポリエステル、ポリカーボネート、ポリエーテルスルホン、ポリフェニレンエーテルおよびその変性物、ポリアリレート、ポリエーテルケトン、ポリエーテルエーテルケトン、ポリエーテルケトンケトン、塩化ビニル、ポリスチレン等のスチレン系樹脂、並びにフェノキシ樹脂等があげられる。
なお、樹脂は、複数種類の樹脂材料により形成されていてもよい。
発泡剤としては、N,N´-ジニトロソペンタメチレンテトラミン、アゾジカルボンアミド、4,4´-オキシビス(ベンゼンスルホニルヒドラジド)、炭酸水素塩、炭酸水素ナトリウム等が挙げられる。
樹脂材料に発泡剤を含有させる場合、発泡倍率が5倍以上50倍以下となるように発泡剤の含有量を調整することが好ましい。
図16に示すように、インナ部材220の突出部221aの長手方向中央においては、インナ部材220の突出部221aの、アウタパネル部材210側の先端は、樹脂部材230の溝231aに入り込んでいる。すなわち、インナ部材220の一部が樹脂部材230に埋められている。
更に、樹脂部材230の上面は、接着部250を介してアウタパネル部材210の内面に接合されている。
接着部250は、樹脂部材230の上面の全体に設けられてもよく、一部のみに設けられてもよい。
・樹脂部材を形成した後に組み付けを行うパターンAと、
・樹脂部材を形成する前に組み付けを行うパターンBと、
のいずれかを採用することができる。詳細について以下に説明する。
第一工程A21として、インナ部材220の突出部221aの所定の部位を取り囲むように成型金型を設置し、成型金型の内部に樹脂材料を注入して固めることにより、インナ部材220と樹脂部材230を一体化させる。
第二工程A22として、一体化させたインナ部材220と樹脂部材230とを接着剤等によりアウタパネル部材210に取り付ける。
第一工程A21においては、先に成型金型で作成した樹脂部材230をインナ部材220に接着剤等で接合することで、樹脂材料230とインナ部材220とを一体化させてもよい。
第一工程B21として、アウタパネル部材210及び/又はインナ部材220に発泡剤を含む樹脂材料をスプレー塗布する。
第二工程B22として、インナ部材220を接着剤等によりアウタパネル部材210に組み付ける。
第三工程B23として、樹脂材料を発泡させ、インナ部材220の突出部221aの先端を埋めた状態の樹脂部材230を形成する。
第一工程B21と第二工程B22は順序が逆であってもよい。ただし、スプレー塗布するための孔をインナ部材220に形成する等の工夫が必要である。
第三工程B23においては、発泡倍率が5倍以上50倍以下となるように加熱することが好ましい。発泡倍率が5倍以上である場合、より確実にインナ部材220の突出部221aを樹脂部材230に埋めることができるため、張り剛性の向上効果を確実に発揮することができる。発泡倍率は、より好ましくは、軽量化しながら剛性不足を補うという観点から、10倍以上である。一方、発泡倍率が50倍以下である場合、樹脂部材230の密度が過度に低下することを防ぐことができるため、張り剛性の向上効果を確実に発揮することができる。発泡倍率は、より好ましくは20倍以下である。
第三工程B23においては、電着塗装時の熱を利用して発泡してもよい。
従って、樹脂部材230を単にアウタパネル部材210とインナ部材220との間のみに配置する場合に比べ、アウタパネル部材210の張り剛性を向上させることができる。このように、張り剛性を向上させることができるため、アウタパネル部材210を薄肉化して軽量化する際に顕在化する張り剛性の低下を防ぐことができる。
従って、上記のパネル構造200によれば、軽量でありながらも優れた張り剛性を発揮することができる。
第二実施形態に係るパネル構造200は、インナ部材220の突出部221aの先端が樹脂部材230に埋められている断面部を有する構成であったが、突出部221aにおけるアウタパネル部材210側の面の全体が樹脂部材230に埋められている断面部を有有する構成であってもよい。
図17は、第二実施形態の第一変形例に係るパネル構造200Aにおける、突出部221aの長手方向に垂直な断面部のうち、突出部221aの長手方向中央における断面部を示す。図17に示すように、パネル構造200Aでは、樹脂部材230Aの底面231Aがインナ部材220の本体部221(すなわち、突出部221a以外の部位)に面接触する構成とされている。このような構成により、パネル構造200Aは、インナ部材220の突出部221aのアウタパネル部材210側の表面の全体が樹脂部材230Aにより埋められる断面部を有している。
この構成によれば、樹脂部材230Aがインナ部材220によって更に強固に保持された状態で、樹脂部材230Aがアウタパネル部材210に接合されるため、アウタパネル部材210の張り剛性を更に向上させることができる。
第二実施形態に係るパネル構造200は、インナ部材220に形成された突出部221aが樹脂部材230に埋められる断面部を有する構成であったが、インナ部材220を貫通する開口部の近傍が樹脂部材230に埋められている断面部を有する構成であってもよい。
図18は、第二実施形態の第二変形例に係るパネル構造200Bの分解斜視図である。図18に示すように、パネル構造200Bにおいては、インナ部材220Bが、アウタパネル部材210の内面に対向して配置される板状の本体部221Bにより構成される。本体部221Bには、その面内方向の中央において、複数の張出部221bと、張出部221bに連続した底部221cが形成されている。張出部221bは、アウタパネル部材210に向かって立ち上がる態様で形成されている。底部221cは、インナ部材220B側で張出部221bに連続して配置されている。このような張出部221b及び底部221cが、複数個、本体部221Bの面内方向に並ぶように設けられる。
周壁部221b1は、本体部221Bからアウタパネル部材210に向かって立ち上がる態様で形成される部位である。周壁部221b1は、頂部221b2と底部221cの間に配置されており、頂部221b2と底部221cとを接続している。周壁部221b1は、図18に示すように、略六角形の外形を有しているが、多角形、円形、又は楕円形であってもよい。
頂部221b2は、張出部221bのうち、アウタパネル部材210側の端縁から屈曲して延在する部位である、頂部221b2の上面は、接着部250Bを介してアウタパネル部材210の内面に接合される。
このように、張出部221bが、周壁部221b1と頂部221b2とを有する場合、開口部によりインナ部材220Bの軽量化を実現しつつ、開口部により低下する剛性を、立体的に形成された周壁部221b1により補うことができる。
また、図19に示すように、一の頂部221b2に連続する底部221cは、他の頂部221b2に連続する底部221cと付き合わされている。
接着部250Bは、頂部221b2の上面に沿って環状に連続的に設けられてもよく、環状に所定ピッチで設けられてもよい。
更には、図20に示す第三変形例に係るパネル構造200Cのように、頂部221b2の全体が樹脂部材230Cに埋められている断面部を有する構成であってもよい。この構造によれば、第二変形例に係るパネル構造200Bよりも張り剛性を更に高めることができる。
上記以外にも種々の変形例を採用することができる。
例えば、第二変形例に係るパネル構造200B及び第三変形例に係るパネル構造200Cにおいては、複数の張出部221bが形成されているが、張出部221bは少なくとも一つ形成されていればよい。
例えば、ルーフのパネル構造100は、フード、サイドドア、及びバックドア等のパネル構造にも適用できる。例えば、パネル構造100がフードに適用される場合、インナ部材120は、その長手方向が車両の前後方向に一致する態様でアウタパネル部材110に取り付けられてもよい。これにより、パネル構造100を補強することができる。インナ部材120は、1つであってもよいし、複数であってもよい。複数のインナ部材120が、それらの長手方向が車両の前後方向に一致する態様で配される場合、各インナ部材120は、互いに異なる形状であってもよいし、同一形状であってもよい。また、各インナ部材120は、互いに異なる長さであってもよいし、同一の長さであってもよい。更に、各インナ部材120の配置も特段制限されない。各インナ部材120は、例えば、車幅方向に等間隔に配されてもよいし、異なる間隔で配されてもよい。また、各インナ部材120は、例えば、車両の前後方向にずれて配されてもよい。また、各インナ部材120は、車幅方向に等しい位置で、車両前後方向に並んで配されてもよい。
更に、インナ部材120は、その長手方向に延びた開口部を有していてもよい。インナ部材120がその長手方向が車両の前後方向に一致する態様でアウタパネル部材110に取付けられている場合は、インナ部材120の長手方向に延びた開口部は、車長前後方向に延在する。
また、フードのパネル構造200は、ルーフ、サイドドア、及びバックドア等のパネル構造にも適用できる。
また、第一実施形態と第二実施形態でそれぞれ説明した変形例は、他の実施形態に係るパネル構造に適用してもよい。
110 アウタパネル部材
120 インナ部材
130 樹脂部材
150 接着部
160 接着部
170 サイドフレーム
200 自動車用パネル構造
210 アウタパネル部材
220 インナ部材
221 本体部
221a 突出部
221b 周壁部
221c 底部
230 樹脂部材
250 接着部
1000 自動車
Claims (17)
- 板状のアウタパネル部材と、
前記アウタパネル部材の内面に対向して配置されるインナ部材と、
材料が樹脂であり、前記アウタパネル部材の前記内面に接合される樹脂部材と、
を有し、
前記インナ部材の少なくとも一部が前記樹脂部材に埋められている
ことを特徴とする自動車用パネル構造。 - 前記インナ部材が、前記アウタパネル部材の面内方向における一方向に沿って延在することを特徴とする請求項1に記載の自動車用パネル構造。
- 前記インナ部材が延在する方向に垂直な断面部であって、前記インナ部材の全体が前記樹脂部材に埋められている断面部を有する
ことを特徴とする請求項2に記載の自動車用パネル構造。 - 前記インナ部材を複数有し、
複数の前記インナ部材が、前記アウタパネル部材の面内方向のうち前記一方向に垂直な方向に離間して平行に配置される
ことを特徴とする請求項2又は3に記載の自動車用パネル構造。 - 前記インナ部材が、前記アウタパネル部材の前記内面に対向して配置される板状の本体部を有し、
前記本体部が、前記アウタパネル部材に向かって突出する突出部を有し、
前記アウタパネル部材の面内方向に垂直な断面部であって、前記突出部の先端が前記樹脂部材に埋められている断面部を有する
ことを特徴とする請求項1に記載の自動車用パネル構造。 - 前記アウタパネル部材の面内方向に垂直な断面部であって、前記突出部の前記アウタパネル部材に近い面の全体が前記樹脂部材に埋められている断面部を有する
ことを特徴とする請求項5に記載の自動車用パネル構造。 - 前記インナ部材が、前記アウタパネル部材の前記内面に対向して配置される板状の本体部を有し、
前記本体部が、前記アウタパネル部材に向かって立ち上がる周壁部と、前記周壁部のうち前記アウタパネル部材側の端縁から屈曲して延在するとともに中央に開口部が形成された頂部とを含む張出部を有し、
前記アウタパネル部材の面内方向に垂直な断面部であって、前記頂部の少なくとも一部が前記樹脂部材に埋められている断面部を有する
ことを特徴とする請求項1に記載の自動車用パネル構造。 - 前記アウタパネル部材の面内方向に垂直な断面部であって、前記頂部の全体が前記樹脂部材に埋められている断面部を有する
ことを特徴とする請求項7に記載の自動車用パネル構造。 - 前記樹脂部材が熱硬化性樹脂である
ことを特徴とする請求項1~8のいずれか一項に記載の自動車用パネル構造。 - 前記樹脂部材が熱可塑性樹脂である
ことを特徴とする請求項1~8のいずれか一項に記載の自動車用パネル構造。 - 前記樹脂部材を複数有し、
複数の前記樹脂部材が前記アウタパネル部材の面内方向に沿って互いに接続されていることを特徴とする請求項1~10のいずれか一項に記載の自動車用パネル構造。 - 複数の前記樹脂部材が接着剤により互いに接続されている
ことを特徴とする請求項11に記載の自動車用パネル構造。 - 複数の前記樹脂部材が嵌合により互いに接続されている
ことを特徴とする請求項11又は12に記載の自動車用パネル構造。 - 前記アウタパネル部材と前記樹脂部材とを接合する接着部と、前記アウタパネル部材と前記インナ部材とを接合する接着部とが同じ材質である
ことを特徴とする請求項1~13のいずれか一項に記載の自動車用パネル構造。 - 前記アウタパネル部材は、引張強さが440MPa以上である
ことを特徴とする請求項1~14のいずれか一項に記載の自動車用パネル構造。 - 前記アウタパネル部材は、板厚が0.30mm以上0.55mm以下である
ことを特徴とする請求項1~15のいずれか一項に記載の自動車用パネル構造。 - 前記樹脂部材のうち、前記アウタパネル部材の面内方向に垂直な方向の寸法が最大となる部位の厚さが3mm以上60mm以下である
ことを特徴とする請求項1~16のいずれか一項に記載の自動車用パネル構造。
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JPS5885762A (ja) * | 1981-11-16 | 1983-05-23 | Nissan Motor Co Ltd | 自動車用天井内装材の取付方法 |
JPS63258274A (ja) | 1987-04-16 | 1988-10-25 | Nitto Electric Ind Co Ltd | 自動車車体の補強構造 |
JP2006257993A (ja) * | 2005-03-17 | 2006-09-28 | Tokai Rubber Ind Ltd | 防音カバー |
JP2009073406A (ja) * | 2007-09-21 | 2009-04-09 | Toyota Motor Corp | 車両ボディー用パネルとこれを備えた車両 |
JP2013078985A (ja) * | 2011-10-03 | 2013-05-02 | Sanwa Kogyo Kk | 車両用天井成形材及びその製造方法 |
JP2015164840A (ja) * | 2014-02-07 | 2015-09-17 | 株式会社神戸製鋼所 | 異材パネル構造体 |
JP2021088089A (ja) | 2019-12-03 | 2021-06-10 | いすゞ自動車株式会社 | 中空体の成形装置 |
-
2022
- 2022-02-25 JP JP2023524002A patent/JPWO2022249602A1/ja active Pending
- 2022-02-25 EP EP22810883.3A patent/EP4350158A1/en active Pending
- 2022-02-25 CN CN202280027811.3A patent/CN117120326A/zh active Pending
- 2022-02-25 US US18/284,810 patent/US20240182121A1/en active Pending
- 2022-02-25 WO PCT/JP2022/007782 patent/WO2022249602A1/ja active Application Filing
Patent Citations (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS5885762A (ja) * | 1981-11-16 | 1983-05-23 | Nissan Motor Co Ltd | 自動車用天井内装材の取付方法 |
JPS63258274A (ja) | 1987-04-16 | 1988-10-25 | Nitto Electric Ind Co Ltd | 自動車車体の補強構造 |
JP2006257993A (ja) * | 2005-03-17 | 2006-09-28 | Tokai Rubber Ind Ltd | 防音カバー |
JP2009073406A (ja) * | 2007-09-21 | 2009-04-09 | Toyota Motor Corp | 車両ボディー用パネルとこれを備えた車両 |
JP2013078985A (ja) * | 2011-10-03 | 2013-05-02 | Sanwa Kogyo Kk | 車両用天井成形材及びその製造方法 |
JP2015164840A (ja) * | 2014-02-07 | 2015-09-17 | 株式会社神戸製鋼所 | 異材パネル構造体 |
JP2021088089A (ja) | 2019-12-03 | 2021-06-10 | いすゞ自動車株式会社 | 中空体の成形装置 |
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CN117120326A (zh) | 2023-11-24 |
US20240182121A1 (en) | 2024-06-06 |
JPWO2022249602A1 (ja) | 2022-12-01 |
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