JP2013060060A - Vehicle structure member and vehicle floor using the same - Google Patents
Vehicle structure member and vehicle floor using the same Download PDFInfo
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Abstract
Description
本発明は、繊維強化樹脂で形成された車両構造部材及びこれを用いた車両フロアに関する。 The present invention relates to a vehicle structural member formed of a fiber reinforced resin and a vehicle floor using the vehicle structural member.
例えば、繊維強化樹脂を用いて車両の骨格を形成するという技術がある。一方、板状部材(基部材)において強度を高めるため、当該板状部材にリブ部(凸部)を設けるという技術がある。一般的に繊維強化樹脂は、強化繊維が含有されていない樹脂と比較して流動性が悪いため、繊維強化樹脂で形成される板状部材にリブ部を設ける場合、当該リブを形成するための凹部内に繊維強化樹脂が十分に充填されないという問題が生じる。 For example, there is a technique of forming a vehicle skeleton using a fiber reinforced resin. On the other hand, in order to increase the strength of the plate-like member (base member), there is a technique of providing rib portions (convex portions) on the plate-like member. In general, a fiber reinforced resin has poor fluidity compared to a resin containing no reinforced fiber. Therefore, when a rib portion is provided on a plate-like member formed of a fiber reinforced resin, the rib is formed. There arises a problem that the fiber reinforced resin is not sufficiently filled in the recess.
このため、特許文献1に記載の発明では、長繊維積層体で形成された構造体平面部(基部材)の下面に短繊維基材で形成されたリブを接着させた状態で金型内に配置し、加圧及び加熱することで、構造体平面部とリブとを一体化させ、当該構造体平面部を強化させている。 For this reason, in the invention described in Patent Document 1, the rib formed of the short fiber base material is bonded to the lower surface of the structure plane portion (base member) formed of the long fiber laminate in the mold. By arranging, pressing and heating, the structure plane portion and the rib are integrated, and the structure plane portion is strengthened.
しかしながら、この先行技術では、構造体平面部にリブを接着させる場合と比較して、製造時における作業工程が増えてしまう。このため、作業性の観点から改善の余地がある。 However, in this prior art, the number of work steps at the time of manufacture increases as compared with the case where the rib is bonded to the structure plane portion. For this reason, there is room for improvement from the viewpoint of workability.
本発明は、繊維強化樹脂を用いた基部材の強度及び剛性を向上させ、かつ製造時における作業性を向上させることができる車両構造部材及びこれを用いた車両フロアを得ることが目的である。 An object of the present invention is to obtain a vehicle structural member that can improve the strength and rigidity of a base member using a fiber reinforced resin, and can improve workability at the time of manufacture, and a vehicle floor using the vehicle structural member.
請求項1記載の発明に係る車両構造部材は、繊維強化樹脂によって板状に形成された基部材と、前記基部材の一方の面から突出する凸部と、前記基部材の他方の面に設けられ、前記凸部と対向する位置に形成された凹部と、を有している。 A vehicle structural member according to a first aspect of the present invention is provided on a base member formed in a plate shape by a fiber reinforced resin, a protrusion protruding from one surface of the base member, and the other surface of the base member And a concave portion formed at a position facing the convex portion.
請求項1記載の発明に係る車両構造部材では、繊維強化樹脂によって板状に形成された基部材の一方の面からはリブ等の凸部が突出しており、基部材の強度及び剛性を向上させている。また、基部材の他方の面には、凸部と対向する位置に凹部が形成されている。炭素繊維、ガラス繊維、アラミド繊維などの強化繊維が含有された繊維強化樹脂の場合、樹脂の流動方向(配向方向)に沿って繊維の配向が形成されるが、基部材における樹脂の配向方向と凸部における樹脂の配向方向は略直交することとなる。 In the vehicle structural member according to the first aspect of the present invention, a convex portion such as a rib protrudes from one surface of the base member formed in a plate shape by fiber reinforced resin, thereby improving the strength and rigidity of the base member. ing. Further, a concave portion is formed on the other surface of the base member at a position facing the convex portion. In the case of a fiber reinforced resin containing reinforcing fibers such as carbon fiber, glass fiber, and aramid fiber, fiber orientation is formed along the resin flow direction (orientation direction). The orientation direction of the resin in the convex portion is substantially orthogonal.
一方、基部材に凸部を設ける場合、基部材の表面に発生するヒケ等を防止するため、製品設計上、一般的には、凸部の肉厚は基部材の肉厚の略半分程度となるように設定される。車両構造部材を成形する金型において、凸部が形成される部分には、凸部形成用凹部が形成されるが、金型内を流動する繊維強化樹脂は、基部材が形成される空間から凸部形成用凹部内へ流動するに当たって、金型内の流路が略半分程度となってしまう。このため、強化繊維として長繊維が用いられた場合は特に、凸部形成用凹部の根元部で長繊維が引っ掛かり、繊維強化樹脂が凸部形成用凹部内へ流動し難くなる。つまり、当該凸部形成用凹部において繊維強化樹脂が充填され難くなる。 On the other hand, when providing a convex portion on the base member, in order to prevent sink marks and the like generated on the surface of the base member, the thickness of the convex portion is generally about half of the thickness of the base member in product design. Is set to be In a mold for molding a vehicle structural member, a convex forming concave portion is formed in a portion where the convex portion is formed, but the fiber reinforced resin flowing in the mold is from the space where the base member is formed. In flowing into the concave portion for forming the convex portion, the flow path in the mold becomes about half. For this reason, especially when a long fiber is used as the reinforcing fiber, the long fiber is caught at the root part of the concave part for forming the convex part, and the fiber reinforced resin hardly flows into the concave part for forming the convex part. That is, it becomes difficult to fill the fiber-reinforced resin in the concave portions for forming the convex portions.
しかし、本発明では、車両構造部材の凸部と対向する位置に凹部が形成されている。つまり、車両構造部材を成形する金型において、凸部が形成される部分には、凸部形成用凹部が形成され、凹部が形成される部分には、凹部形成用凸部が形成されることとなる。したがって、当該金型内の繊維強化樹脂は、凸部形成用凹部の上方において、凹部形成用凸部によって凸部形成用凹部側へ押し込まれ、当該繊維強化樹脂が凸部形成用凹部へ充填され易くなる。 However, in this invention, the recessed part is formed in the position facing the convex part of a vehicle structural member. In other words, in the mold for molding the vehicle structural member, the convex portion forming concave portion is formed in the portion where the convex portion is formed, and the concave portion forming convex portion is formed in the portion where the concave portion is formed. It becomes. Accordingly, the fiber reinforced resin in the mold is pushed into the convex portion forming concave portion by the concave portion forming convex portion above the convex portion forming concave portion, and the convex portion forming concave portion is filled with the fiber reinforced resin. It becomes easy.
このように、凸部形成用凹部と対向する位置に、凹部形成用凸部を形成することで、当該凸部形成用凹部へ繊維強化樹脂を充填され易くすることで、基部材の強度及び剛性を向上させるための凸部を基部材の成形時に基部材と一体に設けることができる。このため、接着などにより、基部材に凸部を接着させ当該基部材と凸部とを一体化させる場合と比較して製造工数を削減することができる。また、凹部が形成されることで、その分繊維強化樹脂の量が削減されることとなる。このため、車両構造部材において、軽量化及びコストの観点でも有効である。 In this way, by forming the concave portion forming convex portion at a position facing the convex portion forming concave portion, the concave portion for forming the convex portion can be easily filled with the fiber reinforced resin, so that the strength and rigidity of the base member are increased. A convex portion for improving the thickness can be provided integrally with the base member when the base member is molded. For this reason, a manufacturing process can be reduced compared with the case where a convex part is adhere | attached on a base member by adhesion | attachment etc., and the said base member and a convex part are integrated. Moreover, the amount of the fiber reinforced resin is reduced correspondingly by forming the recess. For this reason, in a vehicle structural member, it is effective also from a viewpoint of weight reduction and cost.
請求項2記載の発明に係る車両構造部材は、請求項1に記載の車両構造部材において、前記凹部の縁部間の幅が前記凸部の根元部のそれよりも狭くなるように設定されている。 The vehicle structural member according to a second aspect of the present invention is the vehicle structural member according to the first aspect, wherein the width between the edges of the concave portion is set to be narrower than that of the root portion of the convex portion. Yes.
請求項2記載の発明に係る車両構造部材では、凹部の縁部間の幅が凸部の根元部の幅よりも狭くなるように設定することで、車両構造部材を成形する金型が型締めされた状態で、平面視で凸部形成用凹部の内側に凹部形成用凸部が配置されることとなる。このため、金型内を流動する繊維強化樹脂は、凹部形成用凸部に当たると凸部形成用凹部側へ押し込まれ、そのまま凸部形成用凹部側へ案内される。 In the vehicle structural member according to the second aspect of the invention, the mold for molding the vehicle structural member is clamped by setting the width between the edge portions of the concave portion to be narrower than the width of the base portion of the convex portion. In this state, the concave portion forming convex portion is arranged inside the convex portion forming concave portion in plan view. For this reason, when the fiber reinforced resin flowing in the mold hits the concave portion forming convex portion, the fiber reinforced resin is pushed into the convex portion forming concave portion side and is guided as it is to the convex portion forming concave portion side.
請求項3記載の発明に係る車両フロアは、請求項1又は2に記載の車両構造部材を用いて中空構造に形成され、前記凸部が車両上下方向に沿って中空部内に突出するリブとして配設されている。 A vehicle floor according to a third aspect of the present invention is formed in a hollow structure using the vehicle structural member according to the first or second aspect, and the convex portion is arranged as a rib protruding into the hollow portion along the vehicle vertical direction. It is installed.
繊維強化樹脂で形成された基部材の強度及び剛性を向上させることで、本発明の車両構造部材で車両フロアを形成することができる。つまり、請求項3記載の発明に係る車両フロアでは、当該車両構造部材を用いて中空構造に形成され、凸部が車両上下方向に沿って中空部内に突出するリブとして配設されている。このように、車両フロアにおいて、本発明の車両構造部材が用いられることで、鋼板と比較して車両の軽量化及び低コスト化を図ることができる。 By improving the strength and rigidity of the base member formed of fiber reinforced resin, the vehicle floor can be formed with the vehicle structural member of the present invention. That is, in the vehicle floor according to the third aspect of the present invention, the vehicle structural member is used to form a hollow structure, and the convex portion is disposed as a rib protruding into the hollow portion along the vehicle vertical direction. As described above, by using the vehicle structural member of the present invention on the vehicle floor, the vehicle can be reduced in weight and cost as compared with the steel plate.
本発明は上記構成としたので、請求項1に記載の車両構造部材は、繊維強化樹脂を用いた基部材の強度及び剛性を向上させ、かつ製造時における作業性を向上させることができる、という優れた効果を有する。 Since the present invention is configured as described above, the vehicle structural member according to claim 1 can improve the strength and rigidity of the base member using the fiber reinforced resin, and can improve the workability at the time of manufacture. Has an excellent effect.
請求項2に記載の車両構造部材は、基部材に設けられた凸部に繊維強化樹脂を充填させ易くすることができる、という優れた効果を有する。 The vehicle structural member according to the second aspect has an excellent effect that the convex portions provided on the base member can be easily filled with the fiber reinforced resin.
請求項3に記載の車両フロアは、軽量化及び低コスト化を図ることができる、という優れた効果を有する。 The vehicle floor according to claim 3 has an excellent effect that weight reduction and cost reduction can be achieved.
本発明の実施形態に係る車両構造部材が用いられた車両フロアについて、図1〜図3に基づいて説明する。なお、図中に適宜記す矢印FRは車両前後方向の前方向を、矢印UPは車両上下方向の上方向を、矢印Wは車両幅方向をそれぞれ示す。 A vehicle floor in which a vehicle structural member according to an embodiment of the present invention is used will be described with reference to FIGS. Note that an arrow FR appropriately shown in the figure indicates a forward direction in the vehicle longitudinal direction, an arrow UP indicates an upward direction in the vehicle vertical direction, and an arrow W indicates a vehicle width direction.
(車両フロアの構成)
図1には、車両構造部材が用いられた車両フロアとしてのアンダーボディ12が示されている。アンダーボディ12は繊維強化樹脂で形成されており、基部材としてのアッパパネル20とロアパネル22とを含んで構成されている。そして、これらのアッパパネル20とロアパネル22とが、上下に重なり互いに接合されることで中空構造のアンダーボディ12が構成される。なお、繊維強化樹脂として、例えば、炭素繊維、ガラス繊維、アラミド繊維などの強化繊維を含有する繊維強化プラスチックが挙げられる。
(Vehicle floor configuration)
FIG. 1 shows an underbody 12 as a vehicle floor in which vehicle structural members are used. The underbody 12 is formed of a fiber reinforced resin, and includes an upper panel 20 and a lower panel 22 as base members. The upper panel 20 and the lower panel 22 are vertically overlapped and joined to each other to form the hollow underbody 12. Examples of the fiber reinforced resin include fiber reinforced plastics containing reinforced fibers such as carbon fibers, glass fibers, and aramid fibers.
ロアパネル22は、平面視で略矩形状を成しアンダーボディ12のフロア部14の一部を構成するフロア下部14Aを備えている。このフロア下部14Aの前端部からは、アンダーボディ12のダッシュ部16の一部を構成するダッシュフロントパネル16Aが上向きに立設しており、フロア下部14Aの後端部からは、アンダーボディ12のバック部18の一部を構成するバックリアパネル18Aが上向きに立設している。 The lower panel 22 includes a floor lower portion 14 </ b> A that has a substantially rectangular shape in plan view and constitutes a part of the floor portion 14 of the underbody 12. A dash front panel 16A constituting a part of the dash portion 16 of the underbody 12 is erected upward from the front end portion of the floor lower portion 14A, and the underbody 12 is extended from the rear end portion of the floor lower portion 14A. A back rear panel 18A that constitutes a part of the back portion 18 is erected upward.
ダッシュフロントパネル16Aの車両幅方向両端部には、車両後方へ向かって前側壁下部22Aが延出しており、バックリアパネル18Aの車両幅方向両端部には、車両前方へ向かって後側壁下部22Bが延出している。アンダーボディ12の側壁は切欠き部24が設けられた状態となっているが、ロアパネル22の前側壁下部22Aの下部と後側壁下部22Bの下部は、下壁26によって架け渡されている。 A front side wall lower portion 22A extends toward the vehicle rear side at both ends of the dash front panel 16A in the vehicle width direction, and a rear side wall lower portion 22B extends toward the vehicle front side at both ends of the back rear panel 18A in the vehicle width direction. It is extended. The side wall of the underbody 12 is provided with a notch 24, but the lower part of the front side wall lower part 22 </ b> A and the lower part of the rear side wall lower part 22 </ b> B of the lower panel 22 are bridged by the lower wall 26.
また、ダッシュフロントパネル16A及び前側壁下部22Aの先端部からは、車両前方側へ向かって下フランジ28が張り出しており、バックリアパネル18A及び後側壁下部22Bの先端部からは、車両後方側へ向かって下フランジ30が張り出している。 Further, a lower flange 28 projects toward the vehicle front side from the front end portions of the dash front panel 16A and the front side wall lower portion 22A, and from the front end portions of the back rear panel 18A and the rear side wall lower portion 22B toward the vehicle rear side. The lower flange 30 protrudes.
一方、アッパパネル20は、平面視で略矩形状を成しアンダーボディ12のフロア部14の一部を構成するフロア上部14Bを備えている。フロア上部14Bの前端部からは、斜め前方上側へ向かって傾斜する傾斜前壁32が延出しており、傾斜前壁32の前端部からは、アンダーボディ12のダッシュ部16の一部を構成するダッシュリアパネル16Bが上向きに立設している。また、フロア上部14Bの後端部からは、斜め後方上側へ向かって傾斜する傾斜後壁34が延出しており、傾斜後壁34の後端部からは、アンダーボディ12のバック部18の一部を構成するバックフロントパネル18Bが上向きに立設している。 On the other hand, the upper panel 20 includes a floor upper portion 14 </ b> B that has a substantially rectangular shape in plan view and constitutes a part of the floor portion 14 of the underbody 12. An inclined front wall 32 that inclines obliquely forward and upward extends from the front end portion of the floor upper portion 14B, and a part of the dash portion 16 of the underbody 12 is formed from the front end portion of the inclined front wall 32. A dash rear panel 16B is erected upward. In addition, an inclined rear wall 34 that inclines obliquely rearward and upward extends from the rear end portion of the floor upper portion 14B, and a rear portion 18 of the underbody 12 extends from the rear end portion of the inclined rear wall 34. The back front panel 18B which comprises a part is standing upright.
ダッシュリアパネル16Bの車両幅方向両端部からは、車両後方へ向かって前側壁上部20Aが延出しており、バックリアパネル18Aの車両幅方向両端部からは、車両前方へ向かって後側壁上部20Bが延出している。ダッシュリアパネル16B及び前側壁上部20Aの先端部からは、車両前方側へ向かって上フランジ50が張り出しており、バックフロントパネル18B及び後側壁上部20Bの先端部からは、車両後方側へ向かって上フランジ52が張り出している。 A front side wall upper portion 20A extends toward the rear of the vehicle from both ends of the dash rear panel 16B in the vehicle width direction, and a rear side wall upper portion 20B extends toward the front of the vehicle from both ends of the back rear panel 18A in the vehicle width direction. I'm out. An upper flange 50 projects from the front end of the dash rear panel 16B and the front side wall upper portion 20A toward the vehicle front side, and from the front end portion of the back front panel 18B and the rear side wall upper portion 20B, the top flange 50 The flange 52 is overhanging.
そして、ロアパネル22の下フランジ28とアッパパネル20の上フランジ50とは面接触可能とされており、ロアパネル22の下フランジ30とアッパパネル20の上フランジ52とは面接触可能とされている。 The lower flange 28 of the lower panel 22 and the upper flange 50 of the upper panel 20 can be brought into surface contact, and the lower flange 30 of the lower panel 22 and the upper flange 52 of the upper panel 20 can be brought into surface contact.
図2には、図1に示すアンダーボディ12におけるトンネル部38(後述する)に沿って切断された側断面図が示されている。図2に示されるように、ロアパネル22の下フランジ28とアッパパネル20の上フランジ50との間には接着剤54が設けられ、ロアパネル22の下フランジ30とアッパパネル20の上フランジ52との間には接着剤54が設けられる。そして、アッパパネル20とロアパネル22とが上下に重なり合った状態でアッパパネル20とロアパネル22との間には中空部15が設けられるが、当該接着剤54を介して、ロアパネル22とアッパパネル20とが互いに接合(接着)される。 FIG. 2 shows a side sectional view taken along a tunnel portion 38 (described later) in the underbody 12 shown in FIG. As shown in FIG. 2, an adhesive 54 is provided between the lower flange 28 of the lower panel 22 and the upper flange 50 of the upper panel 20, and between the lower flange 30 of the lower panel 22 and the upper flange 52 of the upper panel 20. Is provided with an adhesive 54. A hollow portion 15 is provided between the upper panel 20 and the lower panel 22 in a state where the upper panel 20 and the lower panel 22 overlap each other. The lower panel 22 and the upper panel 20 are joined to each other via the adhesive 54. (Glued).
ところで、アッパパネル20のフロア上部14Bの車両幅方向両端側には、断面形状が略逆U字状を成すロッカー部36が車両前後方向の略全域に亘って突設されている。また、フロア上部14Bの車両幅方向中央部には、断面形状が略逆U字状を成すトンネル部38が車両前後方向の略全域に亘って突設されている。 By the way, rocker portions 36 having a substantially inverted U-shaped cross section project from substantially the entire area in the vehicle front-rear direction on both ends of the upper floor 14B of the upper panel 20 in the vehicle width direction. In addition, a tunnel portion 38 having a substantially inverted U-shaped cross-section is provided at the center of the floor upper portion 14B in the vehicle width direction so as to protrude over substantially the entire vehicle longitudinal direction.
ロッカー部36とトンネル部38とは略同等の高さとなるように設定されており、ロッカー部36及びトンネル部38の車両前後方向中央部には、ロッカー部36の上壁36Aとトンネル部38の上壁38Aとの間を架け渡す架設壁40が設けられている。なお、ここでは上壁36A、上壁38A及び架設壁40がいわゆる基部材となる。また、ロッカー部36及びトンネル部38は、フロア下部14Aとの間で接着されており、正面断面視において矩形枠状となる閉断面構造を成している。 The rocker portion 36 and the tunnel portion 38 are set to have substantially the same height, and the upper wall 36A of the rocker portion 36 and the tunnel portion 38 are located at the center of the rocker portion 36 and the tunnel portion 38 in the vehicle front-rear direction. An erection wall 40 is provided between the upper wall 38A. Here, the upper wall 36A, the upper wall 38A, and the installation wall 40 are so-called base members. Further, the rocker portion 36 and the tunnel portion 38 are bonded to the floor lower portion 14A, and form a closed cross-sectional structure having a rectangular frame shape when viewed from the front cross-section.
ここで、図1及び図2に示されるように、基部材55としてのロッカー部36の上壁36A、トンネル部38の上壁38A及び架設壁40における下面42からは、凸部としての板状のリブ44が、中空部15内でロアパネル22側へ向かってそれぞれ垂下している(なお、図2には、ロッカー部36及び架設壁40は図示されていない)。 Here, as shown in FIGS. 1 and 2, the upper wall 36 </ b> A of the rocker portion 36 as the base member 55, the upper wall 38 </ b> A of the tunnel portion 38, and the lower surface 42 of the erected wall 40 are plate-like as convex portions. The ribs 44 respectively hang down toward the lower panel 22 in the hollow portion 15 (note that the rocker portion 36 and the erection wall 40 are not shown in FIG. 2).
このリブ44は、ロッカー部36を構成する縦壁36B及びトンネル部38を構成する縦壁38Bを除く車両幅方向の略全域に亘って設けられている。また、架設壁40が設けられている領域では、ロッカー部36の上壁36Aとトンネル部38の上壁38Aとが架設壁40によって架け渡されているため、ロッカー部36の縦壁36B及びトンネル部38の縦壁38Bは存在しない。このため、架設壁40に設けられたリブ44は、ロッカー部36及びトンネル部38に設けられたリブ44と連続して車両幅方向の略全域に亘って設けられている。 The ribs 44 are provided over substantially the entire region in the vehicle width direction excluding the vertical wall 36B constituting the rocker portion 36 and the vertical wall 38B constituting the tunnel portion 38. Further, in the region where the erection wall 40 is provided, the upper wall 36A of the locker part 36 and the upper wall 38A of the tunnel part 38 are bridged by the erection wall 40. The vertical wall 38B of the part 38 does not exist. For this reason, the ribs 44 provided on the construction wall 40 are provided over substantially the entire region in the vehicle width direction continuously with the ribs 44 provided on the rocker portion 36 and the tunnel portion 38.
また、基部材55としてのロッカー部36の上壁36A、トンネル部38の上壁38A及び架設壁40における上面46には、当該リブ44が設けられた位置に対向して平面視で略一致する位置に断面形状が略半円状を成す凹部48が形成されている。つまり、凹部48の中心がリブ44の板厚方向の中心線上に設けられ、当該凹部48はリブ44の板厚方向の中心線に対して対称形状とされている。図3には、基部材55に形成されたリブ44及び凹部48が拡大された斜視図が示されている。図3に示されるように、凹部48の縁部間の幅(W1)は、凸部としてのリブ44の根元部の幅(W2)よりも狭くなるように設定されている。また、凹部48の深さtは、基部材55の肉厚Tの1/2程度(約0.4〜0.6T)となるように設定されている。 Further, the upper wall 36A of the rocker portion 36 serving as the base member 55, the upper wall 38A of the tunnel portion 38, and the upper surface 46 of the erection wall 40 are substantially coincident with each other in plan view, facing the position where the rib 44 is provided. A concave portion 48 having a substantially semicircular cross-sectional shape is formed at the position. That is, the center of the recess 48 is provided on the center line of the rib 44 in the plate thickness direction, and the recess 48 is symmetrical with respect to the center line of the rib 44 in the plate thickness direction. FIG. 3 shows a perspective view in which the ribs 44 and the recesses 48 formed in the base member 55 are enlarged. As shown in FIG. 3, the width (W1) between the edges of the concave portion 48 is set to be narrower than the width (W2) of the root portion of the rib 44 as the convex portion. Further, the depth t of the recess 48 is set to be about ½ (about 0.4 to 0.6 T) of the thickness T of the base member 55.
(車両フロアの作用・効果)
本実施形態では、図1に示されるように、基部材55としてのロッカー部36の上壁36A、トンネル部38の上壁38A及び架設壁40における下面42からは、板状のリブ44がそれぞれ垂下している。これにより、アッパパネル20の強度及び剛性を向上させることができる。
(Operation / effect of vehicle floor)
In this embodiment, as shown in FIG. 1, plate-like ribs 44 are respectively formed from the upper wall 36 </ b> A of the rocker portion 36 as the base member 55, the upper wall 38 </ b> A of the tunnel portion 38, and the lower surface 42 of the installation wall 40. It is drooping. Thereby, the strength and rigidity of the upper panel 20 can be improved.
ここで、図4(A)、(B)及び図5にはアンダーボディ12の成形方法を説明するための断面図が示されている。図4(A)には後述する金型60の型開きの状態が示されており、図4(B)及び図5には当該金型60の型締めの状態が示されている。図4(A)に示されるように、強化繊維56が含有された繊維強化樹脂58の場合、繊維強化樹脂58の流動方向(配向方向)に沿って強化繊維56が配向される。 Here, FIGS. 4A, 4 </ b> B, and 5 are cross-sectional views for explaining a method of forming the underbody 12. 4A shows a state of mold opening of a mold 60 described later, and FIGS. 4B and 5 show a state of mold clamping of the mold 60. FIG. As shown in FIG. 4A, in the case of the fiber reinforced resin 58 containing the reinforced fiber 56, the reinforced fiber 56 is oriented along the flow direction (orientation direction) of the fiber reinforced resin 58.
一般的に、熱可塑性繊維強化樹脂の成形方法として、例えばスタンピング成形が挙げられるが、この成形方法では、所定の大きさに形成されたシート状の繊維強化樹脂58が、約200℃に加熱された状態で、アッパパネル20を成形する金型60内に配置される。金型60は上型62と下型64を含んで構成されており、下型64内にシート状の繊維強化樹脂58が配置された状態で、上型62が下型64側へ移動し、図4(B)に示されるように、金型60が型締めされる。 In general, as a molding method of the thermoplastic fiber reinforced resin, for example, stamping molding may be mentioned. In this molding method, the sheet-like fiber reinforced resin 58 formed in a predetermined size is heated to about 200 ° C. In this state, the upper panel 20 is placed in a mold 60 for molding. The mold 60 is configured to include an upper mold 62 and a lower mold 64. With the sheet-like fiber reinforced resin 58 disposed in the lower mold 64, the upper mold 62 moves to the lower mold 64 side, As shown in FIG. 4B, the mold 60 is clamped.
このように、金型60が型締めされた状態で、溶融された繊維強化樹脂58が上型62と下型64との間で圧縮されることとなるが、上型62及び下型64に形成された凹凸に合わせて車両構造部材が成形される(図5参照)。ここでは、車両構造部材としてのアッパパネル20(図1参照)が成形される。 As described above, the melted fiber reinforced resin 58 is compressed between the upper mold 62 and the lower mold 64 in a state where the mold 60 is clamped. A vehicle structural member is formed according to the formed irregularities (see FIG. 5). Here, an upper panel 20 (see FIG. 1) as a vehicle structural member is molded.
図5に示されるように、基部材55における強化繊維56の配向方向とリブ44における強化繊維56の配向方向は略直交する。一方、図6に示されるように、基部材100にリブ102を設ける際、基部材100の表面に発生するヒケ等を防止するため、製品設計上、一般的には、リブ102の肉厚t1は基部材100の肉厚T1の略半分程度となるように設定される。つまり、図3に示すリブ44では、肉厚W2は基部材55の肉厚Tの略半分程度となるように設定される。 As shown in FIG. 5, the orientation direction of the reinforcing fibers 56 in the base member 55 and the orientation direction of the reinforcing fibers 56 in the rib 44 are substantially orthogonal. On the other hand, as shown in FIG. 6, when the rib 102 is provided on the base member 100, the thickness t1 of the rib 102 is generally used in product design in order to prevent sink marks and the like generated on the surface of the base member 100. Is set to be approximately half the thickness T1 of the base member 100. That is, in the rib 44 shown in FIG. 3, the thickness W <b> 2 is set to be approximately half of the thickness T of the base member 55.
この場合、基部材100を成形する金型では、図示はしないが、リブ102が形成される部分には、凸部形成用凹部が形成される。金型内を流動する繊維強化樹脂は、基部材100が形成される空間から凸部形成用凹部内へ流動するに当たって、金型内の流路が略半分程度となってしまう。このため、強化繊維として長繊維が用いられた場合は特に、凸部形成用凹部の根元部で長繊維が引っ掛かり、繊維強化樹脂が凸部形成用凹部内へ流動し難くなる。つまり、当該凸部形成用凹部において繊維強化樹脂が充填され難くなる。 In this case, in the mold for molding the base member 100, although not shown, a convex forming recess is formed in a portion where the rib 102 is formed. When the fiber reinforced resin flowing in the mold flows from the space in which the base member 100 is formed into the convex forming recess, the flow path in the mold becomes approximately half. For this reason, especially when a long fiber is used as the reinforcing fiber, the long fiber is caught at the root part of the concave part for forming the convex part, and the fiber reinforced resin hardly flows into the concave part for forming the convex part. That is, it becomes difficult to fill the fiber-reinforced resin in the concave portions for forming the convex portions.
しかし、本実施形態では、図3に示されるように、基部材55において、リブ44と対向する位置に凹部48が形成されている。図4(A)に示されるように、アッパパネル20を成形する金型60は、上型62及び下型64で構成されているが、下型64には、リブ44が形成される部分にリブ形成用凹部66が形成されている。また、上型62には、凹部48が形成される部分に凹部形成用凸部68が形成されている。 However, in the present embodiment, as shown in FIG. 3, a recess 48 is formed in the base member 55 at a position facing the rib 44. As shown in FIG. 4A, the mold 60 for molding the upper panel 20 is composed of an upper mold 62 and a lower mold 64. The lower mold 64 has ribs on the portion where the ribs 44 are formed. A forming recess 66 is formed. Further, the upper mold 62 is provided with a concave portion forming convex portion 68 at a portion where the concave portion 48 is formed.
したがって、図4(B)に示されるように、上型62と下型64との間で構成される空間70内を流動する繊維強化樹脂58は、リブ形成用凹部66の上方では凹部形成用凸部68によってリブ形成用凹部66側へ押し込まれるため、リブ形成用凹部66へ充填され易くなる。 Accordingly, as shown in FIG. 4B, the fiber reinforced resin 58 flowing in the space 70 formed between the upper mold 62 and the lower mold 64 is used for forming a recess above the rib forming recess 66. Since the rib 68 is pushed toward the rib forming recess 66 by the protrusion 68, the rib forming recess 66 is easily filled.
このように、リブ形成用凹部66と対向する位置に、凹部形成用凸部68を形成することで、当該リブ形成用凹部66へ繊維強化樹脂58を充填され易くすることで、アッパパネル20(図1参照)の強度及び剛性を向上させるためのリブ44をアッパパネル20(基部材55)の成形時に当該アッパパネル20と一体に設けることができる(図5参照)。 Thus, by forming the concave portion forming convex portion 68 at a position facing the rib forming concave portion 66, the rib forming concave portion 66 can be easily filled with the fiber reinforced resin 58. 1) can be provided integrally with the upper panel 20 when the upper panel 20 (base member 55) is molded (see FIG. 5).
このため、接着などにより、基部材55にリブ44を接着させ当該基部材55とリブ44とを一体化させる場合と比較して製造工数を削減することができる。つまり、本実施形態では、繊維強化樹脂58を用いたアッパパネル20の強度及び剛性を向上させ、かつ製造時における作業性を向上させることができる。 Therefore, the number of manufacturing steps can be reduced as compared with the case where the rib 44 is bonded to the base member 55 by bonding or the like and the base member 55 and the rib 44 are integrated. That is, in this embodiment, the strength and rigidity of the upper panel 20 using the fiber reinforced resin 58 can be improved, and workability at the time of manufacturing can be improved.
また、図3に示されるように、基部材55の上面46に凹部48が形成されることで、その分繊維強化樹脂58の量が削減されることとなる。具体的には、二点鎖線で示される繊維強化樹脂59分が削減される。このため、アッパパネル20(図1参照)において軽量化及びコストの観点でも有効である。 Further, as shown in FIG. 3, the concave portion 48 is formed on the upper surface 46 of the base member 55, whereby the amount of the fiber reinforced resin 58 is reduced accordingly. Specifically, 59 minutes of fiber reinforced resin indicated by a two-dot chain line is reduced. Therefore, the upper panel 20 (see FIG. 1) is also effective from the viewpoint of weight reduction and cost.
さらに、凹部48の縁部間の幅(W1)が、リブ44の根元部の幅(W2)よりも狭くなるように設定されている。このため、図4(B)に示されるように、金型60が型締めされた状態で、凹部形成用凸部68及びリブ形成用凹部66を側面視した場合、リブ形成用凹部66の内側に凹部形成用凸部68が配置されることとなる。 Further, the width (W 1) between the edges of the recess 48 is set to be narrower than the width (W 2) of the root portion of the rib 44. For this reason, as shown in FIG. 4B, when the concave portion forming convex portion 68 and the rib forming concave portion 66 are viewed from the side with the mold 60 being clamped, the inside of the rib forming concave portion 66 is shown. The concave portion forming convex portion 68 is disposed on the surface.
したがって、基部材55が形成される空間70内を流動する繊維強化樹脂58は、凹部形成用凸部68が当たるとリブ形成用凹部66の外側へ押し広げられることなく、リブ形成用凹部66側へ押し込まれ、そのままリブ形成用凹部66内へ案内される。つまり、繊維強化樹脂58をリブ形成用凹部66内へ充填させ易くすることができる。 Therefore, the fiber reinforced resin 58 flowing in the space 70 in which the base member 55 is formed does not spread outwardly from the rib forming recess 66 when the recess forming projection 68 hits, but the rib forming recess 66 side. And is directly guided into the rib forming recess 66. That is, the fiber reinforced resin 58 can be easily filled into the rib forming recess 66.
なお、図3に示されるように、凹部48の深さtは、基部材55の肉厚Tの1/2程度となるように設定されている。凹部48の深さtが浅すぎると、繊維強化樹脂58をリブ形成用凹部66内へ押し込む力が小さくなり、凹部48の深さtが深すぎると、基部材55の肉厚が薄くなる。このため、リブ44の剛性を考慮すると、凹部48の深さtは、基部材55の肉厚Tの1/2程度となるように設定することが望ましい。 As shown in FIG. 3, the depth t of the recess 48 is set to be about ½ of the thickness T of the base member 55. If the depth t of the concave portion 48 is too shallow, the force for pushing the fiber reinforced resin 58 into the rib forming concave portion 66 becomes small, and if the depth t of the concave portion 48 is too deep, the thickness of the base member 55 becomes thin. For this reason, in consideration of the rigidity of the rib 44, it is desirable that the depth t of the recess 48 is set to be about ½ of the thickness T of the base member 55.
ところで、図4(A)に示されるように、ここではシート状の繊維強化樹脂58がリブ形成用凹部66の上方に当該リブ形成用凹部66を覆うようにして配置されている。ここで、繊維強化樹脂58のリブ形成用凹部66への充填性を考慮すると、図7(A)に示されるように、リブ形成用凹部66の周辺部に、シート状の繊維強化樹脂58の端部が配置されるように、当該繊維強化樹脂58が下型64に配置されるようにしても良い。 By the way, as shown in FIG. 4A, here, a sheet-like fiber reinforced resin 58 is disposed above the rib forming recess 66 so as to cover the rib forming recess 66. Here, considering the filling property of the fiber reinforced resin 58 into the rib forming recess 66, as shown in FIG. 7A, the sheet-like fiber reinforced resin 58 is formed around the rib forming recess 66. The fiber reinforced resin 58 may be disposed on the lower mold 64 so that the end portion is disposed.
つまり、リブ形成用凹部66の周辺部に、繊維強化樹脂58の端部が配置されるようにシート状の繊維強化樹脂58を配置した場合、図7(B)に示されるように、当該繊維強化樹脂58の端部がリブ形成用凹部66内へ徐々に充填されていくことになるため、リブ形成用凹部66内の空気が徐々に押し出され、繊維強化樹脂58のリブ形成用凹部66内への充填性が向上する。 That is, in the case where the sheet-like fiber reinforced resin 58 is arranged so that the end of the fiber reinforced resin 58 is arranged around the rib forming recess 66, as shown in FIG. Since the end portion of the reinforcing resin 58 is gradually filled into the rib forming recess 66, the air in the rib forming recess 66 is gradually pushed out, and the inside of the rib forming recess 66 of the fiber reinforced resin 58. Improves filling properties.
また、図4(A)に示されるように、繊維強化樹脂58がリブ形成用凹部66の上方に当該リブ形成用凹部66を覆うようにして配置された場合、図4(B)に示されるように、繊維強化樹脂58及び強化繊維56の流動方向(配向方向)に対して略直交する方向へ繊維強化樹脂58を押圧することとなる。 Further, as shown in FIG. 4A, when the fiber reinforced resin 58 is disposed so as to cover the rib forming recess 66 above the rib forming recess 66, it is shown in FIG. 4B. As described above, the fiber reinforced resin 58 is pressed in a direction substantially orthogonal to the flow direction (orientation direction) of the fiber reinforced resin 58 and the reinforced fiber 56.
しかし、図7(A)に示されるように、リブ形成用凹部66の周辺部に、繊維強化樹脂58の端部が配置されるようにシート状の繊維強化樹脂58が配置された場合、図7(B)に示されるように、当該繊維強化樹脂58の端部はリブ形成用凹部66の内壁に沿って案内されるため、繊維強化樹脂58及び強化繊維56の配向がリブ形成用凹部66の形状に沿って形成されることとなる。このため、リブ形成用凹部66内へ繊維強化樹脂58をさらに充填させ易くすることができる。 However, as shown in FIG. 7A, when the sheet-like fiber reinforced resin 58 is arranged so that the end portion of the fiber reinforced resin 58 is arranged around the rib forming recess 66, As shown in FIG. 7B, since the end portion of the fiber reinforced resin 58 is guided along the inner wall of the rib forming recess 66, the orientation of the fiber reinforced resin 58 and the reinforcing fiber 56 is the rib forming recess 66. It will be formed along the shape. For this reason, the fiber-reinforced resin 58 can be further easily filled into the rib forming recess 66.
さらに、繊維強化樹脂58は金型60の空間70で流動するため、図8(A)、(B)に示されるように、リブ形成用凹部66の周辺部から多少離れた位置に繊維強化樹脂58の端部が配置されるように当該繊維強化樹脂58を配置しても良い。これによっても、図7(A)、(B)で示されるように、リブ形成用凹部66の周辺部に、繊維強化樹脂58の端部が配置されるように当該繊維強化樹脂58を配置した場合と略同様の効果を得ることができる。つまり、シート状の繊維強化樹脂58を下型64に配置する場合、リブ形成用凹部66の周辺部の位置から繊維強化樹脂58の端部が多少ずれたとしても、成形性にさほど影響を与えない。 Furthermore, since the fiber reinforced resin 58 flows in the space 70 of the mold 60, as shown in FIGS. 8A and 8B, the fiber reinforced resin 58 is positioned slightly away from the peripheral portion of the rib forming recess 66. The fiber reinforced resin 58 may be arranged so that the end of 58 is arranged. Also by this, as shown in FIGS. 7A and 7B, the fiber reinforced resin 58 is arranged so that the end of the fiber reinforced resin 58 is arranged around the rib forming recess 66. It is possible to obtain substantially the same effect as the case. That is, when the sheet-like fiber reinforced resin 58 is disposed in the lower mold 64, even if the end of the fiber reinforced resin 58 is slightly deviated from the peripheral position of the rib forming recess 66, the moldability is greatly affected. Absent.
(実施形態の補足)
本実施形態では、図2に示されるように、アッパパネル20側にリブ44及び凹部48を設けたが、ロアパネル22側にリブ及び凹部を設けて良いのは勿論のことである。また、アッパパネル20のフロア上部14Bにリブ44を設けたが、当該アッパパネル20の強度及び剛性を向上させることができれば良いため、当該フロア上部14Bに限るものではない。
(Supplement of embodiment)
In this embodiment, as shown in FIG. 2, the ribs 44 and the recesses 48 are provided on the upper panel 20 side, but it is needless to say that the ribs and recesses may be provided on the lower panel 22 side. Moreover, although the rib 44 was provided in the floor upper part 14B of the upper panel 20, since the intensity | strength and rigidity of the said upper panel 20 should just be improved, it is not restricted to the said floor upper part 14B.
例えば、上フランジ50とダッシュリアパネル16Bとを架け渡すようにしてリブを設けても良い。この場合、上フランジ50及びダッシュリアパネル16Bの何れか一方において、リブが設けられた面と反対側の面であって当該リブと対向する位置に凹部が設けられる。 For example, a rib may be provided so as to bridge the upper flange 50 and the dash rear panel 16B. In this case, in any one of the upper flange 50 and the dash rear panel 16B, a concave portion is provided at a position opposite to the surface on which the rib is provided and facing the rib.
また、これ以外にも、ロアパネル22において、ダッシュフロントパネル16Aとフロア下部14Aとを架け渡すようにしてリブを設けても良い。この場合も上記と同様、ダッシュフロントパネル16A及びはフロア下部14Aにおいて、リブが設けられた面と反対側の面であって当該リブと対向する位置に凹部が設けられる。 In addition, ribs may be provided on the lower panel 22 so as to bridge the dash front panel 16A and the floor lower portion 14A. In this case as well, in the dash front panel 16A and the floor lower portion 14A, a concave portion is provided at a position opposite to the surface on which the rib is provided and facing the rib.
また、ここでは、板状のリブ44が車両幅方向の略全域に亘って形成されているが、これに限るものではない。例えば、車両幅方向に沿って所定の間隔で複数のリブが設けられるようにしても良いし、当該リブが車両前後方向に沿って形成されても良い。さらに、当該リブが格子状を成すように形成されても良い。また、凸部として、リブの代わりにボスを設けても良い。 Here, the plate-like ribs 44 are formed over substantially the entire region in the vehicle width direction, but the present invention is not limited to this. For example, a plurality of ribs may be provided at predetermined intervals along the vehicle width direction, or the ribs may be formed along the vehicle front-rear direction. Further, the ribs may be formed in a lattice shape. Moreover, you may provide a boss instead of a rib as a convex part.
また、ここでは、図3に示されるように、凹部48の縁部間の幅(W1)が、リブ44の根元部の幅(W2)よりも狭くなるように設定されるようにしたが、これに限るものではない。例えば、凹部48の縁部間の幅(W1)が、リブ44の根元部の幅(W2)以上の大きさとなるように設定されても良い。また、凹部48は断面形状が半円状を成す形状としたが、これに限るものではない。例えば、図9に示されるように、凹部72の断面形状がV字状を成すように形成されても良い。 Further, here, as shown in FIG. 3, the width (W1) between the edges of the recess 48 is set to be narrower than the width (W2) of the root portion of the rib 44. This is not a limitation. For example, the width (W 1) between the edges of the recess 48 may be set to be larger than the width (W 2) of the root portion of the rib 44. Moreover, although the recessed part 48 was made into the shape where cross-sectional shape comprises a semicircle shape, it does not restrict to this. For example, as shown in FIG. 9, the recess 72 may be formed to have a V-shaped cross section.
また、ここでは車両フロアに適用させた実施形態について説明したが、繊維強化樹脂で形成された基部材を備えた車両構造部材であれば良いため、車両フロアに限るものではない。また、繊維強化樹脂58としては、熱可塑性繊維強化樹脂に限るものではなく、本発明は、長繊維強化材料を成形型内で流動させて成形する場合に有効である。 Moreover, although embodiment applied to the vehicle floor was demonstrated here, since it should just be a vehicle structural member provided with the base member formed with the fiber reinforced resin, it is not restricted to a vehicle floor. Further, the fiber reinforced resin 58 is not limited to the thermoplastic fiber reinforced resin, and the present invention is effective when the long fiber reinforced material is molded by flowing in a mold.
以上、本発明を実施するための一形態として一実施例を用いて説明したが、本発明はこうした一実施例に何ら限定されるものではなく、本発明の要旨を逸脱しない範囲内において、上述した一実施例に種々の変形及び置換を加えることができる。 As described above, the present invention has been described with reference to one embodiment. However, the present invention is not limited to the embodiment, and the above-described embodiments are within the scope of the present invention. Various modifications and substitutions can be made to the embodiment.
12 アンダーボディ(車両フロア)
20 アッパパネル(基部材、車両構造部材)
22 ロアパネル(車両構造部材)
36A 上壁(基部材)
38A 上壁(基部材)
40 架設壁(基部材)
44 リブ(凸部)
48 凹部
55 基部材
58 繊維強化樹脂
12 Underbody (vehicle floor)
20 Upper panel (base member, vehicle structural member)
22 Lower panel (vehicle structural member)
36A Upper wall (base member)
38A Upper wall (base member)
40 Construction wall (base member)
44 Ribs (convex parts)
48 recess 55 base member 58 fiber reinforced resin
Claims (3)
前記基部材の一方の面から突出する凸部と、
前記基部材の他方の面に設けられ、前記凸部と対向する位置に形成された凹部と、
を有する車両構造部材。 A base member formed into a plate shape by a fiber reinforced resin;
A protrusion protruding from one surface of the base member;
A concave portion provided on the other surface of the base member and formed at a position facing the convex portion;
A vehicle structural member.
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CN113998005A (en) * | 2020-07-28 | 2022-02-01 | 丰田自动车株式会社 | Reinforcing structure for frame member in vehicle |
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