JP4251542B2

JP4251542B2 - Skeletal structure member for transport machinery

Info

Publication number: JP4251542B2
Application number: JP2003189808A
Authority: JP
Inventors: 省二山崎
Original assignee: Honda Motor Co Ltd
Current assignee: Honda Motor Co Ltd
Priority date: 2003-07-01
Filing date: 2003-07-01
Publication date: 2009-04-08
Anticipated expiration: 2023-07-01
Also published as: JP2005022511A

Description

【０００１】
【発明の属する技術分野】
本発明は、鉄道車両、産業車両、船舶、航空機、自動車、自動二輪車等の輸送機械用骨格構造部材に関する。
【０００２】
【従来の技術】
骨格構造部材として、骨格部材に粉粒体を充填したものが知られている。（例えば、特許文献１、特許文献２及び特許文献３参照。）。
【０００３】
【特許文献１】
特開２００２−１９３６４９公報（第９−１０頁、図１−図４）
【特許文献２】
米国特許第４６１０８３６号公報（第３−５欄、図１、図２）
【特許文献３】
米国特許第４６９５３４３号公報（第３−５欄、図１、図２）
【０００４】
特許文献１を図１５で説明し、特許文献２を図１６で説明する。
図１５は従来の骨格構造部材を構成する固形化粉粒体を示す第１拡大断面図であり、固形化粉粒体（即ち、複数の粉粒体を結合して固めたもの）２００は、粉粒体２０１…（…は複数個を示す。以下同じ。）と、これらの粉粒体２０１…を固形にするために粉粒体２０１…のそれぞれの間に満たした樹脂、接着剤等のバインダ２０２とからなり、粉粒体２０１を構造的に密に型に投入した後、バインダ２０２を流し込んで形成する。この固形化粉粒体２００は、車体等の骨格部材内に挿入することで骨格構造部材を形成するものであり、車体の強度、剛性の向上を図る。
【０００５】
図１６は従来の骨格構造部材を構成する固形化粉粒体を示す第２拡大断面図であり、固形化粉粒体２１０は、接着剤２１１をコーティングした粉粒体としてのガラス製の小球体２１２…からなり、これらの小球体２１２…をガラス繊維製のクロスで包み、骨格部材内に満たすことで骨格構造部材を形成する。特許文献３にも同様の構造が記載されている。
【０００６】
図１７は従来の骨格構造部材を構成する固形化粉粒体を示す第３拡大断面図であり、固形化粉粒体２１４は、外部からの加熱、例えば、ヒータ、マイクロウェーブ等によって粉粒体２１５…の表面を融解させることで粉粒体２１５同士を結合したものである。なお、２１６…は粉粒体２１５の表面が融解後に固化した固化部である。
【０００７】
【発明が解決しようとする課題】
図１５に示した固形化粉粒体２００では粉粒体２０１のみの場合に比べてバインダ２０２の分だけ重量が増し、図１６に示した固形化粉粒体２１０でも同様に、小球体２１２のみの場合よりも接着剤２１１の分だけの重量が増すため、これらの固形化粉粒体２００，２１０を用いた骨格構造部材の重量増が大きくなる。
【０００８】
また、粉粒体２０１又は小球体２１２を密に充填すれば、固形化粉粒体２００，２１０の剛性が高められるが、閉空間に粉粒体２０１又は小球体２１２を満たすには、外部から加圧する等の手段を講じなければならなず、容易ではない。
【０００９】
図１８は従来の骨格構造部材の表面融解を示す作用図であり、図１７に示した粉粒体２１５の表面融解により出来た固化部２１６を拡大した拡大図である。
このように、固化部２１６によって粉粒体２１５同士の結合範囲が広くなり、結合は非常に強固となる。
【００１０】
次に、上記の固形化粉粒体２００，２１０を用いた骨格構造部材を曲げ試験で強制的に曲げ変形させて、骨格構造部材の吸収エネルギー量を求める。
図１９は骨格構造部材の曲げ試験の方法を示す説明図であり、曲げ試験は、骨格構造部材２２０を２つの支点２２１，２２１で支え、これらの支点２２１，２２１の間隔の中央位置に対応する骨格構造部材２２０の上面に曲げ試験機の押圧片２２２を介して下向きの荷重Ｆを加えて行う。なお、δは押圧片２２２のストローク量、即ち下方への変位量、２２３（骨格構造部材２２０中に描いた破線）は、骨格構造部材２２０内に挿入した固形化粉粒体を示す。
【００１１】
図２０は骨格構造部材の曲げ試験の結果として得られる荷重と変位量との関係を略式に示すグラフであり、縦軸は荷重Ｆ、横軸は変位量δを表す。
このグラフでは、変位量δが小さいうちは、荷重Ｆは直線的に急激に立ち上がり、そして、荷重Ｆの増加は次第に小さくなって最大の荷重ｆ１が発生し、この後は、変形量δが大きくなるにつれて、荷重Ｆは次第に減少し、やがてほぼ一定になる。
【００１２】
立ち上がりの直線部の上端の荷重をＬ、直線の角度をαとすると、角度αが大きいほど、また、荷重Ｌが大きい（即ち、直線部が長い）ほど骨格構造部材の剛性は大きい。更に、荷重ｆ１が大きいほど、骨格構造部材の強度は大きい。
【００１３】
このグラフ上の線と横軸とで挟まれた部分の面積は、仕事量、即ち骨格構造部材の変形による吸収エネルギー量であり、例えば、車両の骨格構造における衝突時の吸収エネルギー量を求める場合に使用するものである。
【００１４】
図２１（ａ）〜（ｄ）は骨格構造部材の曲げ試験の結果として得られる荷重と変位量との関係及び吸収エネルギー量を示す説明図である。
（ａ）は荷重Ｆと変位量δとの関係を示すグラフであり、縦軸は荷重Ｆ、横軸は変位量δを表す。
グラフ中の試料１は、図２０に示したものと同一のもので、例えば中空の四角形断面とし、内部に固形化粉粒体を挿入していない骨格構造部材の結果である。
【００１５】
試料２は、試料１の最大の荷重ｆ１となる変位量より大きい変位量では、試料１よりも荷重Ｆが大きくなる。
試料３は、試料１の荷重ｆ１となる変位量より大きい変位量では、試料２よりも荷重Ｆが大きくなる。
【００１６】
これらの試料１〜試料３の吸収エネルギー量を示したのが（ｂ）である。
（ｂ）では縦軸が吸収エネルギー量Ｅを表す。試料１〜試料３の各吸収エネルギー量をｅ１〜ｅ３とすると、ｅ１＜ｅ２＜ｅ３となる。
【００１７】
（ｃ）は荷重Ｆと変位量δとの関係を示すグラフであり、縦軸は荷重Ｆ、横軸は変位量δを表す。
試料４は、試料１よりも立ち上がりの角度α（図２０参照）を大きくし、且つ試料１の荷重ｆ１よりも大きな荷重ｆ２を最大値とするものであり、荷重ｆ２のときの変位量よりも大きな変位量δでは、次第に試料１に重なる。
【００１８】
試料５は、試料４よりも立ち上がりの角度α（図２０参照）を大きくし、且つ試料４の荷重ｆ２よりも大きな荷重ｆ３を最大値とするものであり、荷重ｆ３のときの変位量よりも大きな変位量δでは、次第に試料１に重なる。
【００１９】
これらの試料１、試料４及び試料５の吸収エネルギー量を示したのが（ｄ）である。
（ｄ）では縦軸が吸収エネルギー量Ｅを表す。試料４、試料５の各吸収エネルギー量をｅ４、ｅ５とすると、ｅ１＜ｅ４＜ｅ５となる。
【００２０】
以上の（ａ）〜（ｄ）より、荷重Ｆの最大値が大きくなっただけでは吸収エネルギー量の増加は小さいが、荷重Ｆの最大値を大きくするとともに、最大荷重発生後の荷重を高く維持すれば、吸収エネルギー量の増加を大きくすることができる。
【００２１】
図２２は従来の骨格構造部材の曲げ試験結果としての変形状態を示す説明図である。
例えば、固形化粉粒体２００（図１５も参照）を挿入した骨格構造部材２０５を曲げ試験で変形させた場合、固形化粉粒体２００を挿入した部分はほとんど変形せず、固形化粉粒体２００の端部側が大きく変形した。２０６は大きく変形して屈曲した骨格部材２０７の屈曲部である。
【００２２】
これは、粉粒体の高い充填率とバインダによる強い結合のために、固形化粉粒体２００を挿入した部分の強度が非常に高まり、固形化粉粒体２００以外の部分に歪みが集中したと考えられる。
【００２３】
図２３は従来の骨格構造部材の曲げ試験により得られた荷重と変位量との関係を示すグラフであり、縦軸は荷重Ｆ、横軸は変位量δを表す。各データの最大の変位量δは、変位量δを次第に増していって、急激に荷重Ｆが低下する直前の値である（以下同じ）。
【００２４】
図中に短い破線で示した比較例１は、中空の四角形断面を有する骨格構造部材で固形化粉粒体を挿入していないもののデータであり、最大の変位量ｄ５は大きいが、最大の荷重ｆ５は小さい。
【００２５】
一点鎖線で示した比較例２は、図１５及び図２２に示した骨格構造部材、即ち中実の粉粒体をバインダで結合した固形化粉粒体を備えたもののデータであり、粉粒体の結合が強固であるために最大の荷重ｆ６は大きくなるが、曲げ試験の早期に固形化粉粒体以外の部分が局部的に大きく変形することにより最大の変位量ｄ６は小さくなる。
【００２６】
二点鎖線で示した比較例３は、図１６に示した骨格構造部材、即ち中実の粉粒体に接着剤をコーティングして結合した固形化粉粒体を備えたもののデータであり、粉粒体の結合が強固なために最大の荷重ｆ７は比較例２よりも大きくなるが、比較例２と同様に局部的な変形が大きいため、最大の変位量ｄ７は小さい。
【００２７】
長い破線で示した比較例４は、中実の粉粒体を表面融解させて結合した固形化粉粒体を備えたもののデータであり、表面融解によって粉粒体の結合が強固なために最大の荷重ｆ８は比較例２とほぼ同等であるが、荷重ｆ８の発生した変位量δよりも変位量が大きくなると、荷重Ｆは急激に低下し、その変位量ｄ８は大きくならない。このような荷重Ｆの低下を抑えることができれば、大きな荷重を大きな変位量まで維持でき、骨格構造部材の吸収エネルギー量が増大できる。
【００２８】
そこで、本発明の目的は、輸送機械用骨格構造部材を改良することで、粉粒体の固形化に伴う重量増を抑え、しかも、骨格構造部材の吸収エネルギー量を増大させることにある。
【００２９】
【課題を解決するための手段】
上記目的を達成するために請求項１は、輸送機械の骨格部材内及び／又は骨格部材とその周囲のパネル部材とで囲まれる空間に、複数の粉粒体を結合して固めた固形化粉粒体を配置した骨格構造部材であって、粉粒体を、その表面に部分的に無機材料層を形成することで無機材料層の間から外部に粉粒体の表面である露出部を露出させ、この露出部を加熱したときに表面融解させて粉粒体が互いに部分的に結合するようにしたことを特徴とする。
【００３０】
例えば、粉粒体の表面全体を融解させることにより粉粒体同士を結合する場合にはその結合が非常に強固になり、固形化粉粒体に外部から荷重が作用した場合に、結合部が割れて破片となり、破片が移動しないために歪みが集中する。従って、骨格構造部材に局部的に変形が進行し、大きな荷重を支えることができなくなる。
【００３１】
これに対して、本発明では、粉粒体を、互いに部分的に表面融解させることにより結合することで、固形化粉粒体に外部から荷重が作用した場合に、固形化粉粒体は、部分的に表面融解し固化した固化部が剥がれて粉粒体単体となって流動性を備えるようになり、外部からの荷重により発生する歪みを拡散して歪みの集中を防ぐことができる。
【００３２】
この結果、骨格構造部材をほぼ均等に且つ大きな変形量まで変形させることができる。このとき、バインダによる粉粒体の結合ほど強固ではないが、粉粒体の大きな結合によって、大きな変位量まで大きな荷重を支えることができ、従来に比較して、骨格構造部材の吸収エネルギー量を増大させることができる。
【００３３】
また、粉粒体同士が表面融解により結合するため、粉粒体同士の結合に接着剤や樹脂等のバインダを用いるのに比べて、固形化に伴う重量増を抑えることができる。
【００３４】
更に、粉粒体に部分的に無機材料層を形成することで、粉粒体を容易に部分的に結合させることができる。
【００３５】
【発明の実施の形態】
本発明の実施の形態を添付図に基づいて以下に説明する。なお、図面は符号の向きに見るものとする。
図１は本発明に係る輸送機械用骨格構造部材の斜視図であり、中空とした骨格部材１１内に固形化粉粒体を充填した輸送機械用骨格構造部材１２（以下、単に「骨格構造部材１２」と記す。）を示す。なお、１３，１３は骨格部材１１の両端を塞ぐ端部閉塞部材である。
【００３６】
図２は図１の２−２線断面図であり、骨格構造部材１２は、骨格部材１１内に隔壁部材１５，１５を取付け、これらの隔壁部材１５，１５の間の空間に固形化粉粒体１６を充填したことを示す。ここでは、固形化粉粒体１６を骨格構造部材１２の長手方向の中央に配置した。図中の１８…は粉粒体であり、実際には外径が１０μｍ〜５．０ｍｍであるが、説明の都合上、大きく描いた（以下同じ）。
【００３７】
図３は図１の３−３線断面図であり、中空の四角形断面とした骨格部材１１内に、粉粒体１８…をそれぞれ結合させて固形にした固形化粉粒体１６を充填したことを示す。
【００３８】
図４は本発明に係る固形化粉粒体の結合状態を示す拡大断面図であり、加熱による表面融解の後に部分的に結合した粉粒体１８…を示す。
粉粒体１８は、熱可塑性樹脂製の粉粒体１８Ａと、この粉粒体１８Ａの表面に部分的に形成した無機材料層２３…とからなる。なお、２４…は無機材料層２３…の間から外部に露出した粉粒体１８Ａの表面である露出部である。
【００３９】
粉粒体１８同士は、加熱により露出部２４…が融解した後に冷却によって固化した固化部２２…で結合する。
無機材料層２３を形成する無機材料としては、炭酸カルシウム、酸化チタンが好適である。
【００４０】
図５は本発明に係る骨格構造部材の製造方法を示す作用図である。
まず、無機材料を粉粒体１８Ａの表面に部分的に付着、あるいは部分的にコーティングすることで無機材料層２３…を形成した粉粒体１８…を造る。
次に、粉粒体１８…を骨格部材１１内に所定量投入する。
そして、骨格部材１１及び粉粒体１８…を加熱する。
【００４１】
これにより、各粉粒体１８が部分的に表面融解を起こし、詳しくは、各粉粒体１８の露出部２４…（図４参照）のみが融解し、各粉粒体１８の融解部分同士が一体になり、冷却した後に、粉粒体１８同士が部分的に結合して、即ち粉粒体１８同士が固化部２２…を介して結合して固形化粉粒体１６を形成し、骨格構造部材１２が出来る。
【００４２】
例えば、車両では、車両骨格部材内に粉粒体１８を投入しておき、車両の塗装を乾燥させるために製造ラインに設けた塗装乾燥路で１３０〜２００℃に加熱すれば、塗装乾燥の完了とほぼ同時に骨格構造部材が出来る。従って、別に加熱装置を必要とせず、しかも粉粒体１８のための加熱時間も別に必要がないから、コストアップ及び製造工数の増加を抑えることができる。
また、粉粒体１８Ａを熱可塑性樹脂製とすることで低い温度で融解させることができるため、高温を発生させるような特別な加熱装置を必要としない。
【００４３】
図６（ａ）〜（ｄ）は骨格構造部材の曲げ試験の結果を示す説明図であり、（ａ）及び（ｂ）は実施例（本実施の形態）、（ｃ）及び（ｄ）は比較例を示す。
（ａ）は骨格構造部材１２（図２も参照）の曲げ試験を実施した後の状態を示す拡大正面図であり、骨格構造部材１２の固形化粉粒体１６（図中の破線部）を充填した部分がほぼ円弧状に変形したことを示す。
【００４４】
（ｂ）は骨格構造部材１２の曲げ試験時に発生する歪みを説明する図であり、模式的に描いた骨格構造部材１２を２つの支点３１，３１で支え、これらの支点３１，３１の間隔の中央位置に対応する骨格構造部材１２の上面に下向きの荷重Ｆを加えたときに、骨格構造部材１２の支点３１，３１間に発生する歪みをグラフとして表したものである。縦軸は歪み、横軸は骨格構造部材１２の長手方向の位置を表す。
【００４５】
支点３１，３１の位置では歪みはゼロであり、この位置から次第に固形化粉粒体１６（図中のハッチングを施した部分）に近づくにつれて歪みは徐々に増加し、固形化粉粒体１６の位置では歪みは一定になる。このときの歪みをε１とする。
【００４６】
（ｃ）は無機材料層を有していない中実の粉粒体を表面融解させて形成した固形化粉粒体を挿入した骨格構造部材２３０の曲げ試験を実施した後の状態を示す拡大正面図であり、骨格構造部材２３０の固形化粉粒体２３１（図中の破線部）を充填した部分はほとんど変形せず、固形化粉粒体２３１の外側の骨格部材２３２が大きく変形したことを示す。
【００４７】
（ｄ）は骨格構造部材２３０の曲げ試験時に発生する歪みを説明する図であり、模式的に描いた骨格構造部材２３０を２つの支点２２１，２２１で支え、これらの支点２２１，２２１の間隔の中央位置に対応する骨格構造部材２３０の上面に下向きの荷重Ｆを加えたときに、骨格構造部材２３０の支点２２１，２２１間に発生する歪みをグラフとして表したものである。縦軸は歪み、横軸は骨格構造部材２３０の長手方向の位置を表す。
【００４８】
支点２２１，２２１の位置では歪みはゼロであり、この位置から次第に固形化粉粒体２３１に近づくにつれて歪みは急激に増加し、固形化粉粒体２３１の両端部近傍の外方位置で歪みは最大になる。このときの歪みをε２とする。
そして、歪みが最大となる位置から固形化粉粒体２３１の端部までは歪みが減少し、固形化粉粒体２３１の位置では歪みが一定になる。このときの歪みをε３とする。
【００４９】
以上の（ａ）〜（ｄ）において、比較例の骨格構造部材２３０では、固形化粉粒体２３０の剛性が過度に大きいために固形化粉粒体２３１はほとんど変形せず、歪みε３は小さくなるが、骨格部材２３２が局部的に大きく変形し、歪みε２は非常に大きくなる。従って、曲げ試験の早期に荷重Ｆは大きく低下する。即ち、吸収エネルギー量は少ない。
【００５０】
これに対して、実施例の骨格構造部材１２では、固形化粉粒体１６の剛性が比較例の固形化粉粒体２３１に比べて小さく、曲げ試験によって固形化粉粒体１６が徐々に変形しするとともにほぼ均一に変形するため、比較例の最大の歪みε２に対して最大の歪みε１を抑えることができる。即ち、歪みε１は歪みε２よりもｄだけ小さい。従って、実施例の骨格構造部材１２では、曲げ試験において大きな変位量まで高い荷重を維持することができ、比較例に対して吸収エネルギー量をより増大させることができる。
【００５１】
図７（ａ）〜（ｃ）は本発明に係る骨格構造部材の曲げ試験時の変形を示す作用図であり、図１９に示したのと同じ方法で骨格構造部材１２の曲げ試験を実施し、そのときの骨格構造部材１２の変形、詳しくは、固形化粉粒体１６の変化を説明する。
（ａ）において、骨格構造部材１２に荷重Ｆを加える。なお、３２は荷重Ｆを加えた骨格部材１１上の加重点である。
【００５２】
（ｂ）において、骨格構造部材１２が撓み、加重点３２近傍の粉粒体１８では、粉粒体１８の固化部２２…（図４参照）が剥がれて粉粒体１８同士の結合が外れて、粉粒体１８…が矢印で示すように移動し、骨格部材１１の内部圧力が激増するのを抑える。
【００５３】
（ｃ）において、骨格構造部材１２の撓みが更に大きくなると、粉粒体１８…の固化部の剥がれが進行し、固形化粉粒体１６（図（ａ）参照）の大部分は粉粒体１８単体に戻って矢印のように流動し、歪みを拡散させる。
従って、骨格構造部材１２は局部的に変形せず、ほぼ均一に変形するため、大きな荷重を維持しつつ流動によって大きな変位量まで安定して変形することができる。
【００５４】
図８は本発明に係る骨格構造部材の曲げ試験終了後の断面図であり、曲げ試験開始前に、固形化粉粒体に、骨格構造部材１２の長手方向に直角な方向に直線として描いた線３４〜線３８の変化を見ると、曲げ試験終了後では、例えば、線３５の両端の点、即ち骨格部材１１と交わる点を端点４１，４２とし、これらの端点４１，４２を通る直線４３を引いたときに、直線３５は、直線４３よりも骨格構造部材１２の端部側に湾曲していることが分かる。即ち、骨格部材１１の上部が凹状に変形することで、前述した表面融解部が剥がれた粉粒体は、白抜き矢印で示すように、一方の隔壁部材１５側に流動したことが分かる。
【００５５】
図９は本発明に係る骨格構造部材の曲げ試験の結果得られた荷重と変位量との関係を示すグラフであり、縦軸は荷重Ｆ、横軸は変位量δを表す。
実施例（中実粉＋無機材料層）の骨格構造部材１２のデータ（実線で示す。）は、立ち上がりの直線部の長さ、例えば変位量ｄ９における荷重ｆ９は比較例２〜比較例４に対してそれほど大きくないが、大きな変位量まで徐々に荷重Ｆが増加する。従って、本発明の骨格構造部材１２では、比較例１〜比較例４に比べて吸収エネルギー量をより増大させることができる。
【００５６】
図１０（ａ），（ｂ）は本発明に係る骨格構造部材を車両に採用した例を示す斜視図である。
（ａ）において、本発明の骨格構造部材は、車体前部のエンジン両側方下方に配置するフロントサイドフレーム５１，５１、車室の両側方下部に配置するサイドシル５２，５２、左右のサイドシル５２，５２間に渡したフロントフロアクロスメンバ５３、サイドシル５２，５２から立ち上げたセンタピラー５４，５４、サイドシル５２，５２から後方へ延ばしたリヤフレーム５６，５６に採用する。
【００５７】
また、（ｂ）において、本発明の骨格構造部材は、フロントピラー６１，６１、フロントドア（不図示）内及びリヤドア（不図示）内にそれぞれ配置したドアビーム６２，６３、ルーフの両側部に設けたルーフサイドレール６４，６４、左右のルーフサイドレール６４，６４に渡したルーフレール６６，６７に採用する。
【００５８】
図１１（ａ）〜（ｅ）は本発明に係る骨格構造部材をフロントサイドフレームに採用した例の説明図である。なお、骨格構造部材としてのフロントサイドフレーム５１の符号５１を、ここでは便宜上、５１Ａ〜５１Ｅと変更した。フロントサイドフレーム５１Ａ〜５１Ｄでは、粉粒体１８…を、直接に骨格部材内に充填し、フロントサイドフレーム５１Ｅでは、粉粒体１８…を予め別の骨格部材内に充填した状態で骨格部材内に挿入する。
【００５９】
（ａ）に示すフロントサイドフレーム５１Ａは、アウタパネル７１と、このアウタパネル７１よりもエンジン室側に設けたインナパネル７２とから骨格部材７３を形成し、この骨格部材７３内に粉粒体１８…を充填した部材である。なお、フロントサイドフレーム５１Ａに粉粒体１８を充填する場合に、フロントサイドフレーム５１Ａの長手方向全体に充填してもよいし、あるいは、フロントサイドフレーム５１Ａの長手方向に部分的に充填する、即ち、フロントサイドフレーム５１Ａ内に長手方向に所定間隔を開けて２枚の隔壁を設け、これら２枚の隔壁間に粉粒体１８を充填してもよい。以下に述べる部位についても同様である。
【００６０】
（ｂ）に示すフロントサイドフレーム５１Ｂは、斜面７５を設けたアウタパネル７６と、このアウタパネル７６のエンジン室側に設けるとともに斜面７７を形成したインナパネル７８とから骨格部材８１を形成し、この骨格部材８１に粉粒体１８…を充填した部材である。
【００６１】
（ｃ）に示すフロントサイドフレーム５１Ｃは、アウタパネル７１と、インナパネル７２と、これらのアウタパネル７１及びインナパネル７２の内側に取付けた隔壁８３とから骨格部材８４を形成し、アウタパネル７１及びインナパネル７２内の隔壁８３で区画した第１室８５及び第２室８６のうちの第１室８５内に粉粒体１８…を充填した部材である。
【００６２】
（ｄ）に示すフロントサイドフレーム５１Ｄは、（ｃ）に示したフロントサイドフレーム５１Ｃの第２室８６に粉粒体１８…を充填した部材である。
（ｅ）に示すフロントサイドフレーム５１Ｅは、骨格部材８８内に粉粒体１８…を充填し、この骨格部材８８を骨格部材７３の内側に配置した部材である。
【００６３】
図１２（ａ）〜（ｄ）は本発明に係る骨格構造部材をリヤフレームに採用した例の説明図である。なお、骨格構造部材としてのリヤフレーム５６の符号５６を、ここでは便宜上、５６Ａ〜５６Ｄと変更した。
（ａ）に示すリヤフレーム５６Ａは、パネル部材としてのロアパネル９１と、このロアパネル９１の上部に設けたパネル部材としてのリヤフロアパネル９２との間に粉粒体１８を充填した部材である。
【００６４】
（ｂ）に示すリヤフレーム５６Ｂは、ロアパネル９１と、このロアパネル９１の上部に取付けたサブロアパネル９３との間に粉粒体１８…を充填した部材である。
【００６５】
（ｃ）に示すリヤフレーム５６Ｃは、ロアパネル９１の上部に取付けたサブロアパネル９３と、このサブロアパネル９３の上部に設けたリヤフロアパネル９２との間に粉粒体１８を充填した部材である。
【００６６】
（ｄ）に示すリヤフレーム５６Ｄは、ロアパネル９１とリヤフロアパネル９２とで囲まれる閉空間内に骨格部材９４を配置し、この骨格部材９４内に粉粒体１８…を充填した部材である。
【００６７】
また、骨格部材９４内には粉粒体１８…を充填せず、骨格部材９４とその周囲のパネル部材としてのロアパネル９１、リヤフロアパネル９２とで囲まれる空間９５に粉粒体１８…を充填してもよく、更には、骨格部材９４内及び空間９５内の両方に粉粒体１８…を充填してもよい。
【００６８】
図１３（ａ）〜（ｃ）は本発明に係る骨格構造部材をセンタピラーに採用した例の説明図である。なお、骨格構造部材としてのセンタピラー５４の符号５４を、ここでは便宜上、５４Ａ〜５４Ｃと変更した。
（ａ）に示したセンタピラー５４Ａは、アウタパネル９６と、このアウタパネル９６の車室側に配置したインナパネル９７とで骨格部材９８を形成し、この骨格部材９８に粉粒体１８…を充填した部材である。
【００６９】
（ｂ）に示したセンタピラー５４Ｂは、アウタパネル９６とインナパネル９７との間に補強部材１０１を取付けることで骨格部材１０２を形成し、補強部材１０１とアウタパネル９６との間に粉粒体１８…を充填した部材である。
【００７０】
（ｃ）に示したセンタピラー５４Ｃは、アウタパネル９６とインナパネル９７との間に補強部材１０１を取付け、この補強材１０１とインナパネル９７との間に粉粒体１８…を充填した部材である。
【００７１】
図１４（ａ）〜（ｃ）は本発明に係る骨格構造部材をルーフサイドレールに採用した例の説明図である。なお、骨格構造部材としてのルーフサイドレール６４の符号を、ここでは便宜上、６４Ａ〜６４Ｃと変更した。
【００７２】
（ａ）に示したルーフサイドレール６４Ａは、アウタパネル１０４と、このアウタパネル１０４の車室側に配置したインナパネル１０５とで骨格部材１０６を形成し、この骨格部材１０６に粉粒体１８…を充填した部材である。
【００７３】
（ｂ）に示したルーフサイドレール６４Ｂは、アウタパネル１０４とインナパネル１０５との間に補強部材１０７を取付けることで骨格部材１０８を形成し、補強部材１０７とアウタパネル１０４との間に粉粒体１８…を充填した部材である。
【００７４】
（ｃ）に示したルーフサイドレール６４Ｃは、アウタパネル１０４とインナパネル１０５との間に補強部材１０７を取付けることで骨格部材１０８を形成し、補強部材１０７とインナパネル１０５との間に粉粒体１８…を充填した部材である。
【００７５】
以上の図５で説明したように、本発明第１には、輸送機械の骨格部材１１内及び／又は骨格部材１１とその周囲のパネル部材（例えば、図１２に示したロアパネル９１、リヤフロアパネル９２）とで囲まれる空間（例えば、図１２に示した空間９５）に、複数の粉粒体１８を結合して固めた固形化粉粒体１６を配置した骨格構造部材１２であって、粉粒体１８を、互いに部分的に表面融解させることにより結合するようにしたことを特徴とする。
【００７６】
例えば、粉粒体の表面全体を融解させることにより粉粒体同士を結合する場合にはその結合が非常に強固になり、固形化粉粒体に外部から荷重が作用した場合に、結合部が割れて破片となり、破片が移動しないために歪みが集中する。従って、骨格構造部材に局部的に変形が進行し、大きな荷重を支えることができなくなる。
【００７７】
これに対して、本発明では、粉粒体１８を、互いに部分的に表面融解させることにより結合することで、固形化粉粒体１６に外部から荷重が作用した場合に、固形化粉粒体１６は、部分的に表面融解し固化した固化部２２…が剥がれて粉粒体１８の単体となって流動性を備えるようになり、外部からの荷重により発生する歪みを拡散して歪みの集中を防ぐことができる。
【００７８】
この結果、骨格構造部材１２をほぼ均等に且つ大きな変形量まで変形させることができる。このとき、バインダによる粉粒体の結合ほど強固ではないが、粉粒体１８の大きな結合によって、大きな変位量まで大きな荷重を支えることができ、従来に比較して、骨格構造部材１２の吸収エネルギー量を増大させることができる。
【００７９】
また、粉粒体１８同士が表面融解により結合するため、粉粒体１８同士の結合に接着剤や樹脂等のバインダを用いるのに比べて、固形化に伴う重量増を抑えることができる。
【００８０】
本発明は第２に、粉粒体１８Ａを、その表面に部分的に無機材料層２３…を形成することで加熱したときに部分的に表面融解させるようにしたことを特徴とする。
粉粒体１８に部分的に無機材料層２３…を形成することで、粉粒体１８を容易に部分的に結合させることができる。
【００８１】
尚、本発明の実施の形態では、骨格部材内に粉粒体をそのまま投入したが、これに限らず、袋（ゴム製、ポリエチレン等の樹脂製、紙製のもの）や容器に予め詰めた状態で骨格部材内に投入してもよい。
【００８２】
【発明の効果】
本発明は上記構成により次の効果を発揮する。
請求項１の輸送機械用骨格構造部材は、粉粒体を、その表面に部分的に無機材料層を形成することで無機材料層の間から外部に粉粒体の表面である露出部を露出させ、この露出部を加熱したときに表面融解させて粉粒体が互いに部分的に結合するようにしたので、固形化粉粒体に外部から荷重が作用した場合に、固形化粉粒体は、部分的に表面融解し固化した固化部が剥がれて粉粒体単体となって流動性を備えるようになり、外部からの荷重により発生する歪みを拡散して歪みの集中を防ぐことができる。
【００８３】
この結果、骨格構造部材をほぼ均等に且つ大きな変形量まで変形させることができる。このとき、バインダによる粉粒体の結合ほど強固ではないが、粉粒体の大きな結合によって、大きな変位量まで大きな荷重を支えることができ、従来に比較して、骨格構造部材の吸収エネルギー量を増大させることができる。
【００８４】
また、粉粒体同士が表面融解により結合するため、粉粒体同士の結合に接着剤や樹脂等のバインダを用いるのに比べて、固形化に伴う重量増を抑えることができる。
【００８５】
更に、粉粒体を、その表面に部分的に無機材料層を形成したので、粉粒体に部分的に形成した無機材料層によって、粉粒体を容易に部分的に結合させることができる。
【図面の簡単な説明】
【図１】本発明に係る輸送機械用骨格構造部材の斜視図
【図２】図１の２−２線断面図
【図３】図１の３−３線断面図
【図４】本発明に係る固形化粉粒体の結合状態を示す拡大断面図
【図５】本発明に係る骨格構造部材の製造方法を示す作用図
【図６】骨格構造部材の曲げ試験の結果を示す説明図
【図７】本発明に係る骨格構造部材の曲げ試験時の変形を示す作用図
【図８】本発明に係る骨格構造部材の曲げ試験終了後の断面図
【図９】本発明に係る骨格構造部材の曲げ試験の結果得られた荷重と変位量との関係を示すグラフ
【図１０】本発明に係る骨格構造部材を車両に採用した例を示す斜視図
【図１１】本発明に係る骨格構造部材をフロントサイドフレームに採用した例の説明図
【図１２】本発明に係る骨格構造部材をリヤフレームに採用した例の説明図
【図１３】本発明に係る骨格構造部材をセンタピラーに採用した例の説明図
【図１４】本発明に係る骨格構造部材をルーフサイドレールに採用した例の説明図
【図１５】従来の骨格構造部材を構成する固形化粉粒体を示す第１拡大断面図
【図１６】従来の骨格構造部材を構成する固形化粉粒体を示す第２拡大断面図
【図１７】従来の骨格構造部材を構成する固形化粉粒体を示す第３拡大断面図
【図１８】従来の骨格構造部材の表面融解を示す作用図
【図１９】骨格構造部材の曲げ試験の方法を示す説明図
【図２０】骨格構造部材の曲げ試験の結果として得られる荷重と変位量との関係を略式に示すグラフ
【図２１】骨格構造部材の曲げ試験の結果として得られる荷重と変位量との関係及び吸収エネルギー量を示す説明図
【図２２】従来の骨格構造部材の曲げ試験結果としての変形状態を示す説明図
【図２３】従来の骨格構造部材の曲げ試験により得られた荷重と変位量との関係を示すグラフ
【符号の説明】
１１…骨格部材、１２…輸送機械用骨格構造部材、１６…固形化粉粒体、１８，１８Ａ…粉粒体、２３…無機材料層、２４…露出部、９１，９２…パネル部材（ロアパネル、リヤフロアパネル）、９５…空間。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a framework structure member for a transport machine such as a railway vehicle, an industrial vehicle, a ship, an aircraft, an automobile, and a motorcycle.
[0002]
[Prior art]
As a skeleton structure member, a skeleton member filled with powder particles is known. (For example, refer to Patent Document 1, Patent Document 2, and Patent Document 3.)
[0003]
[Patent Document 1]
JP 2002-193649 A (page 9-10, FIGS. 1 to 4)
[Patent Document 2]
US Pat. No. 4,610,836 (columns 3-5, FIGS. 1 and 2)
[Patent Document 3]
US Pat. No. 4,695,343 (column 3-5, FIGS. 1 and 2)
[0004]
Patent Document 1 will be described with reference to FIG. 15, and Patent Document 2 will be described with reference to FIG.
FIG. 15 is a first enlarged cross-sectional view showing a solidified granular material constituting a conventional skeletal structure member. A solidified granular material (that is, a solidified granular material combined 200) is: In order to make these powders 201 ... solid, such as resin, adhesive, etc., in order to make these powders 201 ... solid It consists of a binder 202, and after the granular material 201 is structurally densely put into a mold, the binder 202 is poured into the mold. The solidified granular material 200 forms a skeletal structure member by being inserted into a skeleton member such as a vehicle body, and improves the strength and rigidity of the vehicle body.
[0005]
FIG. 16 is a second enlarged cross-sectional view showing a solidified granular material constituting a conventional skeletal structure member, and the solidified granular material 210 is a glass microsphere as a granular material coated with an adhesive 211. The skeleton structure member is formed by wrapping these small spheres 212 with a glass fiber cloth and filling the skeleton member. Patent Document 3 also describes a similar structure.
[0006]
FIG. 17 is a third enlarged cross-sectional view showing a solidified granular material constituting a conventional skeletal structure member. The solidified granular material 214 is heated by external heating, for example, a heater, microwave, etc. The particles 215 are bonded together by melting the surfaces of 215. In addition, 216... Is a solidified portion where the surface of the granular material 215 is solidified after melting.
[0007]
[Problems to be solved by the invention]
In the solidified granular material 200 shown in FIG. 15, the weight is increased by the amount of the binder 202 compared to the case of only the granular material 201, and in the same way, only the small sphere 212 in the solidified granular material 210 shown in FIG. Since the weight corresponding to the amount of the adhesive 211 is increased as compared with the case of, the increase in the weight of the skeleton structure member using the solidified powder particles 200 and 210 is increased.
[0008]
Further, if the powder particles 201 or the small spheres 212 are densely packed, the rigidity of the solidified powder particles 200 and 210 can be increased. However, in order to fill the powder particles 201 or the small spheres 212 in the closed space, from the outside It is not easy to take pressure.
[0009]
FIG. 18 is an operation diagram showing surface melting of a conventional skeletal structure member, and is an enlarged view in which a solidified portion 216 formed by surface melting of the powder body 215 shown in FIG. 17 is enlarged.
Thus, the solidified part 216 widens the bonding range between the powder bodies 215, and the bonding becomes very strong.
[0010]
Next, the skeleton structure member using the solidified powder particles 200 and 210 is forcibly bent and deformed in a bending test, and the amount of absorbed energy of the skeleton structure member is obtained.
FIG. 19 is an explanatory view showing a bending test method for a skeletal structure member. In the bending test, the skeletal structure member 220 is supported by two fulcrums 221, 221 and corresponds to the center position of the distance between these fulcrums 221, 221. A downward load F is applied to the upper surface of the skeletal structure member 220 via a pressing piece 222 of a bending tester. In addition, δ is the stroke amount of the pressing piece 222, that is, the downward displacement amount, and 223 (broken line drawn in the skeletal structure member 220) indicates the solidified granular material inserted into the skeleton structure member 220.
[0011]
FIG. 20 is a graph schematically showing the relationship between the load and the displacement obtained as a result of the bending test of the skeletal structure member, where the vertical axis represents the load F and the horizontal axis represents the displacement δ.
In this graph, while the displacement amount δ is small, the load F rises linearly and abruptly, and the increase in the load F gradually decreases to generate the maximum load f1, and thereafter, the deformation amount δ increases. As it becomes, the load F gradually decreases and eventually becomes substantially constant.
[0012]
Assuming that the load at the upper end of the rising straight portion is L and the angle of the straight line is α, the rigidity of the skeletal structure member increases as the angle α increases and the load L increases (that is, the straight portion increases). Furthermore, the greater the load f1, the greater the strength of the skeletal structure member.
[0013]
The area of the portion sandwiched between the line on the graph and the horizontal axis is the work amount, that is, the absorbed energy amount due to deformation of the skeletal structure member. For example, when calculating the absorbed energy amount at the time of collision in the skeleton structure of the vehicle It is used for
[0014]
FIGS. 21A to 21D are explanatory views showing the relationship between the load and the displacement obtained as a result of the bending test of the skeletal structure member and the amount of absorbed energy.
(A) is a graph showing the relationship between the load F and the displacement amount δ, where the vertical axis represents the load F and the horizontal axis represents the displacement amount δ.
Sample 1 in the graph is the same as that shown in FIG. 20, and is a result of a skeletal structure member having, for example, a hollow quadrangular cross section and no solidified powder particles inserted therein.
[0015]
In the sample 2, the load F is larger than that in the sample 1 when the displacement amount is larger than the displacement amount that becomes the maximum load f1 of the sample 1.
In the sample 3, the load F is larger than that in the sample 2 when the displacement amount is larger than the displacement amount that becomes the load f1 of the sample 1.
[0016]
(B) shows the amount of absorbed energy of Sample 1 to Sample 3.
In (b), the vertical axis represents the absorbed energy amount E. If the absorbed energy amounts of Sample 1 to Sample 3 are e1 to e3, e1 <e2 <e3.
[0017]
(C) is a graph showing the relationship between the load F and the displacement amount δ, where the vertical axis represents the load F and the horizontal axis represents the displacement amount δ.
The sample 4 has a rising angle α (see FIG. 20) larger than that of the sample 1 and a load f2 larger than the load f1 of the sample 1 is set to the maximum value, and is larger than the displacement amount at the load f2. When the displacement amount δ is large, it gradually overlaps the sample 1.
[0018]
The sample 5 has a rising angle α (see FIG. 20) larger than that of the sample 4 and has a load f3 larger than the load f2 of the sample 4 as a maximum value, which is larger than the displacement amount at the time of the load f3. When the displacement amount δ is large, it gradually overlaps the sample 1.
[0019]
(D) shows the absorbed energy amounts of Sample 1, Sample 4 and Sample 5.
In (d), the vertical axis represents the absorbed energy amount E. When the absorbed energy amounts of the sample 4 and the sample 5 are e4 and e5, e1 <e4 <e5.
[0020]
From the above (a) to (d), the increase in the amount of absorbed energy is small only by increasing the maximum value of the load F, but the maximum value of the load F is increased and the load after the maximum load is generated is kept high. If so, the increase in the amount of absorbed energy can be increased.
[0021]
FIG. 22 is an explanatory view showing a deformation state as a result of a bending test of a conventional skeletal structure member.
For example, when the skeletal structure member 205 into which the solidified granular material 200 (see also FIG. 15) is deformed by a bending test, the portion into which the solidified granular material 200 is inserted hardly deforms, and the solidified granular material The end side of the body 200 was greatly deformed. Reference numeral 206 denotes a bent portion of the skeleton member 207 which is greatly deformed and bent.
[0022]
This is because the strength of the portion where the solidified granular material 200 is inserted is greatly increased due to the high filling rate of the granular material and the strong bonding by the binder, and distortion is concentrated on the portion other than the solidified granular material 200. it is conceivable that.
[0023]
FIG. 23 is a graph showing a relationship between a load and a displacement obtained by a bending test of a conventional skeletal structure member, where the vertical axis represents the load F and the horizontal axis represents the displacement δ. The maximum displacement amount δ of each data is a value immediately before the load F is suddenly decreased by gradually increasing the displacement amount δ (hereinafter the same).
[0024]
Comparative Example 1 indicated by a short broken line in the figure is data of a skeletal structure member having a hollow quadrangular cross section in which no solidified granular material is inserted. The maximum displacement d5 is large, but the maximum load is shown. f5 is small.
[0025]
The comparative example 2 shown with the dashed-dotted line is the data of the skeletal structure member shown in FIG. 15 and FIG. 22, that is, the data including the solidified granular material obtained by binding the solid granular material with a binder. The maximum load f6 is increased because of the strong bonding, but the maximum amount of displacement d6 is reduced by a large local deformation of parts other than the solidified granular material in the early stage of the bending test.
[0026]
Comparative Example 3 indicated by a two-dot chain line is data of the skeletal structure member shown in FIG. 16, that is, the solid structure having a solid powder and bonded to the solid powder by coating with an adhesive. The maximum load f7 is larger than that of Comparative Example 2 due to the strong bonding of the grains, but the maximum displacement d7 is small because of the large local deformation as in Comparative Example 2.
[0027]
Comparative Example 4 shown by a long broken line is data of a solidified granular material obtained by bonding solid powder particles by melting the surface, and the maximum is due to the strong bonding of the granular materials by surface melting. The load f8 is substantially the same as that of the comparative example 2, but when the displacement amount becomes larger than the displacement amount δ generated by the load f8, the load F rapidly decreases and the displacement amount d8 does not increase. If such a decrease in the load F can be suppressed, a large load can be maintained up to a large displacement amount, and the amount of absorbed energy of the skeletal structure member can be increased.
[0028]
Therefore, an object of the present invention is to improve the skeletal structure member for transport machinery, thereby suppressing an increase in weight associated with solidification of the granular material and increasing the amount of absorbed energy of the skeleton structure member.
[0029]
[Means for Solving the Problems]
In order to achieve the above object, the present invention provides a solidified powder obtained by combining and solidifying a plurality of powder particles in a space surrounded by a frame member of a transport machine and / or a frame member and a surrounding panel member. A skeletal structure member in which granules are arranged, By partially forming an inorganic material layer on the surface, the exposed part, which is the surface of the granular material, is exposed from between the inorganic material layers to the outside, and when this exposed part is heated, the surface is melted and the granular material But Part of each other Yui It is characterized by having matched.
[0030]
For example, when the powder particles are bonded together by melting the entire surface of the powder particles, the bond becomes very strong, and when a load is applied to the solidified powder particles from the outside, It breaks into pieces, and the distortion concentrates because the pieces do not move. Accordingly, the skeleton structure member is locally deformed and cannot support a large load.
[0031]
On the other hand, in the present invention, when the powder particles are bonded to each other by partially melting each other, when a load acts on the solidified powder particles from the outside, the solidified powder particles are: The solidified part that is partially melted and solidified on the surface peels off and becomes a single granular material and has fluidity, and strain generated by an external load can be diffused to prevent strain concentration.
[0032]
As a result, the skeletal structure member can be deformed almost uniformly and to a large deformation amount. At this time, although it is not as strong as the bonding of the powder particles by the binder, the large bonding of the powder particles can support a large load up to a large displacement amount, and the amount of absorbed energy of the skeletal structure member is smaller than before. Can be increased.
[0033]
In addition, since the powder particles are bonded to each other by surface melting, an increase in weight due to solidification can be suppressed as compared to using a binder such as an adhesive or a resin for bonding powder particles.
[0034]
More By forming the inorganic material layer partially on the granular material, the granular material can be easily partially bonded.
[0035]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below with reference to the accompanying drawings. The drawings are viewed in the direction of the reference numerals.
FIG. 1 is a perspective view of a skeletal structure member for transport machinery according to the present invention. The skeletal structure member 12 for transport machinery (hereinafter simply referred to as “skeleton structure member”) in which a solid skeleton member is filled in a hollow skeleton member 11. 12 ”). Reference numerals 13 and 13 denote end closing members that close both ends of the skeleton member 11.
[0036]
2 is a cross-sectional view taken along the line 2-2 of FIG. 1, and the skeletal structure member 12 has partition members 15 and 15 mounted in the skeleton member 11, and solidified powder particles in the space between these partition members 15 and 15. The body 16 is filled. Here, the solidified powder particles 16 are arranged in the center of the skeleton structure member 12 in the longitudinal direction. In the figure, 18... Is a granular material, and actually has an outer diameter of 10 .mu.m to 5.0 mm, but is drawn large for convenience of explanation (the same applies hereinafter).
[0037]
FIG. 3 is a cross-sectional view taken along line 3-3 of FIG. 1, and the solidified granular material 16 that is solidified by combining the granular material 18... Indicates.
[0038]
FIG. 4 is an enlarged cross-sectional view showing the bonded state of the solidified powder particles according to the present invention, showing the powder particles 18... Partially bonded after surface melting by heating.
The powder body 18 is composed of a thermoplastic resin powder body 18A and an inorganic material layer 23 partially formed on the surface of the powder body 18A. In addition, 24 ... is an exposed part which is the surface of the granular material 18A exposed to the outside from between the inorganic material layers 23 ....
[0039]
The powder particles 18 are bonded together by solidified portions 22 that are solidified by cooling after the exposed portions 24 are melted by heating.
As the inorganic material forming the inorganic material layer 23, calcium carbonate and titanium oxide are suitable.
[0040]
FIG. 5 is an operation diagram showing a method for manufacturing a skeletal structure member according to the present invention.
First, the granular material 18 with the inorganic material layer 23 formed by partially attaching or partially coating the surface of the granular material 18A with the inorganic material is produced.
Next, a predetermined amount of the granular materials 18 are put into the skeleton member 11.
And the skeleton member 11 and the granular material 18 ... are heated.
[0041]
Thereby, each granular material 18 raise | generates partially surface melting, and specifically, only the exposed part 24 ... (refer FIG. 4) of each granular material 18 melt | dissolves, and the fusion | melting parts of each granular material 18 are mutually. After being united and cooled, the powder particles 18 are partially bonded to each other, that is, the powder particles 18 are bonded to each other through the solidified portion 22 to form the solidified powder particles 16, and the skeleton structure The member 12 is made.
[0042]
For example, in a vehicle, if the granular material 18 is put into a vehicle skeleton member and heated to 130 to 200 ° C. in a coating drying path provided in a production line in order to dry the coating of the vehicle, the drying of the coating is completed. At the same time, a skeletal structure member can be formed. Therefore, a separate heating device is not required, and a separate heating time for the granular material 18 is not necessary, so that an increase in cost and an increase in manufacturing steps can be suppressed.
Moreover, since it can be made to melt | melt at low temperature by making the granular material 18A into a product made from a thermoplastic resin, the special heating apparatus which generate | occur | produces high temperature is not required.
[0043]
6 (a) to 6 (d) are explanatory views showing the results of a bending test of the skeletal structure member. (A) and (b) are examples (this embodiment), and (c) and (d) are A comparative example is shown.
(A) is an enlarged front view which shows the state after implementing the bending test of the frame | skeleton structure member 12 (refer also FIG. 2), and solidified granular material 16 (the broken line part in a figure) of the frame | skeleton structure member 12 is shown. It shows that the filled portion is deformed into a substantially arc shape.
[0044]
(B) is a figure explaining the distortion which generate | occur | produces at the time of the bending test of the frame | skeleton structure member 12, the frame | skeleton structure member 12 drawn typically is supported by the two fulcrum 31,31, and the space | interval of these fulcrum 31,31 is shown. The graph shows the distortion generated between the fulcrums 31, 31 of the skeletal structure member 12 when a downward load F is applied to the upper surface of the skeleton structure member 12 corresponding to the center position. The vertical axis represents strain, and the horizontal axis represents the longitudinal position of the skeletal structure member 12.
[0045]
The strain is zero at the positions of the fulcrums 31, 31, and the strain gradually increases from this position toward the solidified powder 16 (hatched portion in the figure), and the solidified powder 16 The distortion is constant at the position. The distortion at this time is assumed to be ε1.
[0046]
(C) is an enlarged front view showing a state after performing a bending test of a skeletal structure member 230 into which a solidified granular material formed by melting a solid granular material having no inorganic material layer is surface-melted. It is a figure and the part filled with the solidified granular material 231 (broken line part in the figure) of the skeleton structural member 230 is hardly deformed, and the skeleton member 232 outside the solidified granular material 231 is greatly deformed. Show.
[0047]
(D) is a figure explaining the distortion which generate | occur | produces at the time of the bending test of the frame structure member 230, the frame structure member 230 drawn typically is supported by the two fulcrum points 221,221, and the space | interval of these support points 221,221 is shown. The graph shows the distortion generated between the fulcrums 221 and 221 of the skeleton structure member 230 when a downward load F is applied to the upper surface of the skeleton structure member 230 corresponding to the center position. The vertical axis represents strain, and the horizontal axis represents the longitudinal position of the skeletal structure member 230.
[0048]
The strain is zero at the positions of the fulcrums 221, 221. The strain gradually increases from the position toward the solidified powder particles 231, and the strain is increased at the outer positions near both ends of the solidified powder particles 231. Become the maximum. The distortion at this time is assumed to be ε2.
And distortion decreases from the position where distortion becomes the maximum to the edge part of solidification granular material 231, and distortion becomes constant in the position of solidification granular material 231. The distortion at this time is assumed to be ε3.
[0049]
In the above (a) to (d), in the skeleton structure member 230 of the comparative example, since the rigidity of the solidified granular material 230 is excessively large, the solidified granular material 231 hardly deforms and the strain ε3 is small. However, the skeleton member 232 is greatly deformed locally, and the strain ε2 becomes very large. Accordingly, the load F is greatly reduced at an early stage of the bending test. That is, the amount of absorbed energy is small.
[0050]
In contrast, in the skeletal structure member 12 of the example, the rigidity of the solidified powder particles 16 is smaller than that of the solidified powder particles 231 of the comparative example, and the solidified powder particles 16 are gradually deformed by a bending test. However, since it deforms substantially uniformly, the maximum strain ε1 can be suppressed with respect to the maximum strain ε2 of the comparative example. That is, the strain ε1 is smaller than the strain ε2 by d. Therefore, in the skeletal structure member 12 of the example, a high load can be maintained up to a large displacement amount in the bending test, and the amount of absorbed energy can be further increased compared to the comparative example.
[0051]
7 (a) to 7 (c) are operation diagrams showing deformation during the bending test of the skeletal structure member according to the present invention. The bending test of the skeletal structure member 12 was performed in the same manner as shown in FIG. The deformation of the skeletal structure member 12 at that time, specifically, the change of the solidified granular material 16 will be described.
In (a), a load F is applied to the skeletal structure member 12. Reference numeral 32 denotes a weighting point on the skeleton member 11 to which the load F is applied.
[0052]
In (b), the skeletal structure member 12 is bent, and in the granular material 18 in the vicinity of the load point 32, the solidified portion 22 (see FIG. 4) of the granular material 18 is peeled off and the bonding between the granular materials 18 is released. , The granular material 18... Moves as indicated by an arrow, and the internal pressure of the skeleton member 11 is prevented from increasing drastically.
[0053]
In (c), when the flexure of the skeletal structure member 12 is further increased, the solidified part of the granular material 18 is peeled off, and most of the solidified granular material 16 (see FIG. 1A) is a granular material. 18 returns to the simple substance and flows as indicated by an arrow to diffuse the strain.
Therefore, the skeletal structure member 12 does not deform locally but deforms almost uniformly, so that it can be stably deformed to a large displacement amount by flow while maintaining a large load.
[0054]
FIG. 8 is a cross-sectional view of the skeletal structure member according to the present invention after the bending test is completed, and is drawn as a straight line in the direction perpendicular to the longitudinal direction of the skeletal structure member 12 on the solidified powder before starting the bending test. Looking at changes in the lines 34 to 38, after the end of the bending test, for example, the points at both ends of the line 35, that is, the points intersecting the skeleton member 11 are the end points 41 and 42, and a straight line 43 passing through these end points 41 and 42 is obtained. It can be seen that the straight line 35 is curved toward the end of the skeletal structure member 12 with respect to the straight line 43 when. That is, it can be seen that the granular material from which the above-described surface melting portion has peeled off flows into the one partition wall member 15 side as indicated by the white arrow by deforming the upper part of the skeleton member 11 into a concave shape.
[0055]
FIG. 9 is a graph showing the relationship between the load and the displacement obtained as a result of the bending test of the skeletal structure member according to the present invention, where the vertical axis represents the load F and the horizontal axis represents the displacement δ.
The data (indicated by the solid line) of the skeletal structure member 12 of the example (solid powder + inorganic material layer) is the length of the rising straight portion, for example, the load f9 at the displacement d9 is in Comparative Example 2 to Comparative Example 4. On the other hand, although not so large, the load F gradually increases to a large displacement amount. Therefore, in the skeleton structure member 12 of the present invention, the amount of absorbed energy can be further increased as compared with Comparative Examples 1 to 4.
[0056]
10 (a) and 10 (b) are perspective views showing an example in which the skeletal structure member according to the present invention is employed in a vehicle.
In (a), the skeletal structure member of the present invention includes front side frames 51 and 51 disposed below both sides of the engine at the front of the vehicle body, side sills 52 and 52 disposed at the lower portions on both sides of the vehicle compartment, The front floor cross member 53 passed between 52, the center pillars 54 and 54 raised from the side sills 52 and 52, and the rear frames 56 and 56 extending rearward from the side sills 52 and 52 are employed.
[0057]
In (b), the frame structure member of the present invention is provided on the front pillars 61 and 61, door beams 62 and 63 disposed in the front door (not shown) and the rear door (not shown), and both sides of the roof. The roof side rails 64, 64 and the left and right roof side rails 64, 64 are used for the roof rails 66, 67.
[0058]
11 (a) to 11 (e) are explanatory views of an example in which the skeleton structure member according to the present invention is adopted for the front side frame. In addition, the code | symbol 51 of the front side frame 51 as a skeleton structure member was changed with 51A-51E here for convenience. In the front side frames 51A to 51D, the granular material 18 is directly filled in the skeleton member, and in the front side frame 51E, the granular material 18 is filled in the other skeleton member in advance. Insert into.
[0059]
A front side frame 51 A shown in FIG. 5A forms a skeleton member 73 from an outer panel 71 and an inner panel 72 provided closer to the engine chamber than the outer panel 71, and the granular material 18. It is a filled member. In addition, when filling the granular material 18 in the front side frame 51A, it may be filled in the entire longitudinal direction of the front side frame 51A, or may be partially filled in the longitudinal direction of the front side frame 51A. Alternatively, two partition walls may be provided in the front side frame 51A at a predetermined interval in the longitudinal direction, and the powder 18 may be filled between the two partition walls. The same applies to the parts described below.
[0060]
The front side frame 51 B shown in FIG. 5B forms a skeleton member 81 from an outer panel 76 provided with an inclined surface 75 and an inner panel 78 provided on the engine chamber side of the outer panel 76 and formed with an inclined surface 77. 81 is a member in which the granular material 18 is filled.
[0061]
The front side frame 51 C shown in FIG. 5C forms a skeleton member 84 from the outer panel 71, the inner panel 72, and the outer panel 71 and the partition wall 83 attached to the inner side of the inner panel 72, and the outer panel 71 and the inner panel 72. It is a member in which the first and second chambers 85 and 86 partitioned by the inner partition wall 83 are filled with the powder bodies 18.
[0062]
A front side frame 51D shown in (d) is a member in which the second chamber 86 of the front side frame 51C shown in (c) is filled with the granular material 18.
The front side frame 51 E shown in (e) is a member in which the skeleton member 88 is filled with the powder particles 18, and the skeleton member 88 is disposed inside the skeleton member 73.
[0063]
12 (a) to 12 (d) are explanatory views of an example in which the skeleton structure member according to the present invention is employed in the rear frame. In addition, the code | symbol 56 of the rear frame 56 as a skeleton structure member was changed to 56A-56D here for convenience.
A rear frame 56 A shown in FIG. 5A is a member in which the granular material 18 is filled between a lower panel 91 as a panel member and a rear floor panel 92 as a panel member provided on the upper portion of the lower panel 91.
[0064]
The rear frame 56 B shown in FIG. 5B is a member in which powder particles 18 are filled between the lower panel 91 and the sub-lower panel 93 attached to the upper portion of the lower panel 91.
[0065]
A rear frame 56 C shown in FIG. 5C is a member in which the granular material 18 is filled between a sub-lower panel 93 attached to the upper part of the lower panel 91 and a rear floor panel 92 provided on the upper part of the sub-lower panel 93.
[0066]
The rear frame 56 D shown in FIG. 6D is a member in which a skeleton member 94 is disposed in a closed space surrounded by the lower panel 91 and the rear floor panel 92, and the granular material 18 is filled in the skeleton member 94.
[0067]
In addition, the skeleton member 94 is not filled with the powder particles 18, but the space 95 surrounded by the skeleton member 94 and the lower panel 91 and the rear floor panel 92 as the surrounding panel members is filled with the powder particles 18. Alternatively, both the skeleton member 94 and the space 95 may be filled with the powder particles 18.
[0068]
FIGS. 13A to 13C are explanatory views of an example in which the skeleton structure member according to the present invention is adopted as a center pillar. In addition, the code | symbol 54 of the center pillar 54 as a skeleton structure member was changed into 54A-54C here for convenience.
In the center pillar 54A shown in FIG. 5A, a skeleton member 98 is formed by an outer panel 96 and an inner panel 97 arranged on the vehicle compartment side of the outer panel 96, and the skeleton member 98 is filled with powder particles 18. It is a member.
[0069]
The center pillar 54 B shown in FIG. 5B forms the skeleton member 102 by attaching the reinforcing member 101 between the outer panel 96 and the inner panel 97, and the granular material 18 between the reinforcing member 101 and the outer panel 96. Is a member filled with
[0070]
The center pillar 54 C shown in FIG. 5C is a member in which the reinforcing member 101 is attached between the outer panel 96 and the inner panel 97 and the granular material 18 is filled between the reinforcing material 101 and the inner panel 97. .
[0071]
14 (a) to 14 (c) are explanatory views of an example in which the skeletal structure member according to the present invention is adopted for a roof side rail. In addition, the code | symbol of the roof side rail 64 as a skeleton structure member was changed into 64A-64C here for convenience.
[0072]
The roof side rail 64 A shown in (a) forms a skeleton member 106 by the outer panel 104 and the inner panel 105 disposed on the vehicle compartment side of the outer panel 104, and the skeleton member 106 is filled with powder particles 18. It is a member.
[0073]
The roof side rail 64 B shown in FIG. 5B forms a skeleton member 108 by attaching a reinforcing member 107 between the outer panel 104 and the inner panel 105, and the granular material 18 is formed between the reinforcing member 107 and the outer panel 104. Is a member filled with.
[0074]
The roof side rail 64 C shown in (c) forms a skeletal member 108 by attaching a reinforcing member 107 between the outer panel 104 and the inner panel 105, and a granular material between the reinforcing member 107 and the inner panel 105. 18 is a member filled with.
[0075]
As described above with reference to FIG. 5, the first aspect of the present invention includes a panel member (for example, the lower panel 91 and the rear floor panel 92 shown in FIG. 12) in and / or around the skeleton member 11 of the transport machine. ) Is a skeletal structure member 12 in which solidified powder particles 16 in which a plurality of powder particles 18 are combined and hardened are disposed in a space (for example, the space 95 shown in FIG. 12), The bodies 18 are combined with each other by partially melting the surfaces.
[0076]
For example, when the powder particles are bonded together by melting the entire surface of the powder particles, the bond becomes very strong, and when a load is applied to the solidified powder particles from the outside, It breaks into pieces, and the distortion concentrates because the pieces do not move. Accordingly, the skeleton structure member is locally deformed and cannot support a large load.
[0077]
On the other hand, in the present invention, when the powder particles 18 are bonded to each other by partially melting the surfaces thereof, the solidified powder particles are applied when a load acts on the solidified powder particles 16 from the outside. 16, the solidified portion 22 ... which is partially melted and solidified on the surface is peeled off to become a single body of the powder 18 and has fluidity, and the strain generated by an external load is diffused to concentrate the strain. Can be prevented.
[0078]
As a result, the skeletal structure member 12 can be deformed substantially uniformly and to a large deformation amount. At this time, although not as strong as the bonding of the powder particles by the binder, a large load can be supported by a large bond of the powder particles 18, and the absorbed energy of the skeletal structure member 12 compared to the conventional case. The amount can be increased.
[0079]
Moreover, since the powder particles 18 are bonded to each other by surface melting, an increase in weight due to solidification can be suppressed as compared with the case where a binder such as an adhesive or a resin is used for bonding the powder particles 18.
[0080]
Secondly, the present invention is characterized in that the powder 18A is partially melted when heated by partially forming the inorganic material layer 23 on the surface thereof.
By forming the inorganic material layer 23 on the powder body 18 partially, the powder body 18 can be easily partially bonded.
[0081]
In the embodiment of the present invention, the granular material is put into the skeleton member as it is, but not limited to this, and packed in a bag (made of rubber, resin such as polyethylene, paper) or a container in advance. You may throw in in a frame | skeleton member in a state.
[0082]
【The invention's effect】
The present invention exhibits the following effects by the above configuration.
The framework structure member for a transport machine according to claim 1, By partially forming an inorganic material layer on the surface, the exposed part, which is the surface of the granular material, is exposed from between the inorganic material layers to the outside, and when this exposed part is heated, the surface is melted and the granular material But Part of each other Yui As a result, when a load is applied to the solidified powder from outside, the solidified powder is partially melted and solidified, and the solidified part is peeled off to flow as a single powder. Therefore, the strain generated by the external load can be diffused to prevent the concentration of the strain.
[0083]
As a result, the skeletal structure member can be deformed almost uniformly and to a large deformation amount. At this time, although it is not as strong as the bonding of the powder particles by the binder, the large bonding of the powder particles can support a large load up to a large displacement amount, and the amount of absorbed energy of the skeletal structure member is smaller than before. Can be increased.
[0084]
In addition, since the powder particles are bonded to each other by surface melting, an increase in weight due to solidification can be suppressed as compared to using a binder such as an adhesive or a resin for bonding powder particles.
[0085]
More , Partly form an inorganic material layer on its surface Completion Therefore, the granular material can be easily partially bonded by the inorganic material layer partially formed on the granular material.
[Brief description of the drawings]
FIG. 1 is a perspective view of a skeletal structure member for a transport machine according to the present invention.
2 is a sectional view taken along line 2-2 of FIG.
3 is a sectional view taken along line 3-3 in FIG.
FIG. 4 is an enlarged cross-sectional view showing a combined state of the solidified granular material according to the present invention.
FIG. 5 is an operation diagram showing a method for manufacturing a skeletal structure member according to the present invention.
FIG. 6 is an explanatory diagram showing the results of a bending test of a skeletal structure member
FIG. 7 is an operation diagram showing deformation during a bending test of a skeletal structure member according to the present invention.
FIG. 8 is a sectional view of the skeletal structure member according to the present invention after the bending test is completed.
FIG. 9 is a graph showing a relationship between a load and a displacement obtained as a result of a bending test of a skeletal structure member according to the present invention.
FIG. 10 is a perspective view showing an example in which a skeletal structure member according to the present invention is employed in a vehicle.
FIG. 11 is an explanatory diagram of an example in which the skeletal structure member according to the present invention is employed in a front side frame.
FIG. 12 is an explanatory diagram of an example in which the skeletal structure member according to the present invention is employed in a rear frame.
FIG. 13 is an explanatory diagram of an example in which the skeleton structural member according to the present invention is adopted for a center pillar.
FIG. 14 is an explanatory diagram of an example in which the skeletal structure member according to the present invention is adopted for a roof side rail.
FIG. 15 is a first enlarged cross-sectional view showing a solidified powder body constituting a conventional skeletal structure member
FIG. 16 is a second enlarged cross-sectional view showing a solidified powder body constituting a conventional skeletal structure member
FIG. 17 is a third enlarged cross-sectional view showing a solidified granular material constituting a conventional skeletal structure member
FIG. 18 is an action diagram showing surface melting of a conventional skeletal structure member.
FIG. 19 is an explanatory view showing a bending test method for a skeletal structure member.
FIG. 20 is a graph schematically showing a relationship between a load and a displacement obtained as a result of a bending test of a skeleton structural member.
FIG. 21 is an explanatory diagram showing the relationship between the load and the amount of displacement and the amount of absorbed energy obtained as a result of the bending test of the skeletal structure member.
FIG. 22 is an explanatory view showing a deformation state as a result of a bending test of a conventional skeletal structure member.
FIG. 23 is a graph showing a relationship between a load and a displacement obtained by a bending test of a conventional skeletal structure member.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 11 ... Skeletal member, 12 ... Skeletal structure member for transport machinery, 16 ... Solidified powder, 18, 18A ... Powder, 23 ... Inorganic material layer, 24 ... exposed part, 91, 92 ... Panel members (lower panel, rear floor panel), 95 ... space.

Claims

輸送機械の骨格部材内及び／又は骨格部材とその周囲のパネル部材とで囲まれる空間に、複数の粉粒体を結合して固めた固形化粉粒体を配置した骨格構造部材であって、
前記粉粒体は、その表面に部分的に無機材料層を形成することで前記無機材料層の間から外部に粉粒体の表面である露出部が露出し、この露出部が加熱したときに表面融解して粉粒体が互いに部分的に結合することを特徴とする輸送機械用骨格構造部材。A skeletal structure member in which a solidified granular material obtained by combining and solidifying a plurality of powder particles is disposed in a space surrounded by a skeleton member of a transport machine and / or a skeleton member and a surrounding panel member,
When the exposed part which is the surface of a granular material is exposed to the exterior from between the inorganic material layers by forming an inorganic material layer partially on the surface of the granular material, and the exposed part is heated transportation machinery frame structure member, wherein a granular material by surface melting partially binding to each other.