JP5512405B2

JP5512405B2 - Manufacturing method of car body structure

Info

Publication number: JP5512405B2
Application number: JP2010130690A
Authority: JP
Inventors: 正俊小池; 雄二郎三井; 純清水; 哲郎川田
Original assignee: Fuji Jukogyo KK
Current assignee: Subaru Corp
Priority date: 2010-06-08
Filing date: 2010-06-08
Publication date: 2014-06-04
Anticipated expiration: 2030-06-08
Also published as: JP2011255745A

Description

本発明は、車体構造の製造方法に関し、特に中空閉断面構造内に粒状の中空金属球及び発泡樹脂材からなる充填部材を充填して補剛する車体構造の製造方法に関する。 The present invention relates to a method for manufacturing a vehicle body structure, and more particularly to a method for manufacturing a vehicle body structure in which a hollow hollow cross-sectional structure is filled with a filling member made of a granular hollow metal sphere and a foamed resin material and stiffened.

自動車等の中空閉断面構造を有するフロントピラー、センタピラー、サイドシル、サイドレール、フロントサイドフレーム等の車体構造は一般に骨格部材としての機能を果たしているが、更に剛性を高める補剛や遮音効果が要求される。このような骨格部材となる中空閉断面構造を補剛及び遮音する手段として従来から発泡樹脂材が広く使用されている。 Body structures such as front pillars, center pillars, side sills, side rails, and front side frames that have a hollow closed cross-section structure such as automobiles generally function as skeletal members, but require stiffening and sound insulation effects that further increase rigidity. Is done. Conventionally, a foamed resin material has been widely used as a means for stiffening and sound-insulating a hollow closed cross-sectional structure serving as such a skeleton member.

例えば、特許文献１には、図１４に示すように中空閉断面形状のフロントサイドフレーム１０１内を一対の移動防止部材１０２で仕切り、移動防止部材１０２で仕切られた空間に、発泡原液を収容した袋を装填し、しかる後に発泡膨張させることで移動部材１０２間を発泡樹脂材１０３で充填する補剛構造が開示されている。 For example, in Patent Document 1, as shown in FIG. 14, the front side frame 101 having a hollow closed cross-sectional shape is partitioned by a pair of movement preventing members 102, and the foaming stock solution is accommodated in a space partitioned by the movement preventing members 102. A stiffening structure is disclosed in which a bag is filled and then expanded by foaming to fill a space between moving members 102 with a foamed resin material 103.

また、図１５に示すように、閉断面形状のフロントサイドフレーム１０１内を一対の移動防止部材１０２で仕切り、移動防止部材１０２で仕切られた空間に、硬化した発泡樹脂材１０５を収容した袋体１０６を装填して袋体１０６の一部をフロントサイドフレーム１０１の内面に粘着材層１０７によって接着固定するものがある。 Further, as shown in FIG. 15, a bag body in which the front side frame 101 having a closed cross-sectional shape is partitioned by a pair of movement preventing members 102 and the cured foamed resin material 105 is accommodated in a space partitioned by the movement preventing members 102. Some of the bags 106 are loaded and adhered and fixed to the inner surface of the front side frame 101 by an adhesive material layer 107.

更に、特許文献２には、サイドシル内に設けられたリンホースに取付孔を形成する一方、遮蔽板及び遮蔽板に装着された未発泡の発泡樹脂材からなる仕切板をリンホースの取付孔にクリップにより取り付け、しかる後、発泡樹脂材を発泡させてサイドシル内を遮蔽するものがある。 Further, in Patent Document 2, a mounting hole is formed in a phosphorus hose provided in a side sill, and a partition plate made of an unfoamed foamed resin material attached to the shielding plate is clipped to the mounting hole of the phosphorus hose. There is one that attaches and then foams a foamed resin material to shield the inside of the side sill.

特開２００１−３１５６６２号公報JP 2001-315562 A 特開２００４−３３８５１９号公報JP 2004-338519 A

上記のように中空閉断面構造内に発泡樹脂材等を配置することで車体構造の剛性及び遮音効果が得られる。しかし、特許文献１においては中空閉断面構造内に充填された発泡樹脂材を保持する移動防止部材を設けることから、その構造が複雑になると共に、構成部品が増加して製造コストの増大が懸念される。また、移動防止部材の設置により局部的に剛性が増大することが懸念される。更に、中空閉断面構造内における移動防止部材を配置することが可能な範囲が制限され、発泡樹脂材の設置箇所が制限される。 By arranging the foamed resin material or the like in the hollow closed cross-section structure as described above, the rigidity and sound insulation effect of the vehicle body structure can be obtained. However, in Patent Document 1, since the movement preventing member for holding the foamed resin material filled in the hollow closed cross-sectional structure is provided, the structure becomes complicated and there is a concern that the number of components increases and the manufacturing cost increases. Is done. Moreover, there is a concern that the rigidity is locally increased by the installation of the movement preventing member. Furthermore, the range in which the movement preventing member can be disposed in the hollow closed cross-section structure is limited, and the installation location of the foamed resin material is limited.

一方、特許文献２においては、クリップにより仕切板を取り付けることから、リンホース等に取付孔の穿孔加工が必要であり、かつ作業者が仕切板の取り付け作業に要する作業孔が必要であり、これらの取付孔及び作業孔により部材の剛性が局部的に低下することが懸念される。また、クリップを要すると共に、取付孔及び作業孔の形成や、仕切板の取付作業に伴う製造コストの増大が懸念される。 On the other hand, in Patent Document 2, since the partition plate is attached by a clip, it is necessary to drill a mounting hole in the phosphorus hose and the like, and the operator needs a work hole required for the partition plate mounting operation. There is a concern that the rigidity of the member is locally reduced by the mounting hole and the work hole. In addition to the need for clips, there is a concern about the increase in manufacturing costs associated with the formation of attachment holes and work holes, and the work of attaching partition plates.

これら特許文献１及び２にあっては、発泡樹脂材が遮音タイプ或いは高剛性タイプの一方に制限され、剛性向上と遮音効果の両立が困難である。 In these Patent Documents 1 and 2, the foamed resin material is limited to one of a sound insulation type and a high rigidity type, and it is difficult to achieve both rigidity improvement and a sound insulation effect.

かかる点に鑑みなされた本発明の目的は、中空閉断面構造の構成部品、製造コストの増加を招くことなく、効率的な剛性及び遮音効果が得られる車体構造の製造方法を提供することにある。 An object of the present invention made in view of such points is to provide a component of a hollow closed cross-section structure, and a method of manufacturing a vehicle body structure that can obtain efficient rigidity and a sound insulation effect without causing an increase in manufacturing cost. .

上記目的を達成する請求項１の車体構造の製造方法の発明は、中空閉断面構造の補剛範囲を発泡樹脂素材が発泡膨張した発泡樹脂材及び中空金属球の充填によって補剛する車体構造の製造方法であって、未発泡状態の発泡樹脂素材を収容すると共に粒状の中空金属球を充填した袋体を前記中空閉断面構造の補剛範囲内に配置し、該袋体内の前記発泡樹脂素材を発泡膨張させて前記補剛範囲内に充填する中空金属球と該中空金属球間の隙間を含む補剛範囲内に充填する発泡樹脂材とからなる充填部材で前記補剛範囲内を充填することを特徴とする。 The invention of the manufacturing method of a vehicle body structure according to claim 1 that achieves the above object is a vehicle body structure in which a stiffening range of a hollow closed cross-section structure is stiffened by filling a foamed resin material in which a foamed resin material is expanded and hollow metal balls. A method of manufacturing, wherein a bag body containing an unfoamed foamed resin material and filled with granular hollow metal spheres is disposed within a stiffening range of the hollow closed cross-sectional structure, and the foamed resin material in the bag body The inside of the stiffening range is filled with a filling member comprising a hollow metal sphere that is expanded and expanded to fill the stiffening range and a foamed resin material that fills the stiffening range including the gap between the hollow metal spheres. It is characterized by that.

これによると、中空閉断面構造の補剛範囲に、粒状の中空金属球が充填されると共に未発泡状態の発泡樹脂素材を収容した袋体を中空閉断面構造の補剛範囲内に設置し、袋体内の発泡樹脂素材を発泡膨張させる簡単な作業で、補剛範囲内に充填する中空金属球と中空金属球間の隙間を含む補剛範囲内に充填する発泡樹脂材とからなるブロック状の充填部材が補剛範囲内に充填され、充填部材によって中空閉断面構造の補剛範囲の剛性が確保されると共に遮音効果が得られる。 According to this, in the stiffening range of the hollow closed cross-section structure, a bag body filled with granular hollow metal spheres and containing the foamed resin material in an unfoamed state is installed within the stiffening range of the hollow closed cross-section structure, A block-shaped block consisting of a hollow metal sphere that fills the stiffening range and a foamed resin material that fills the stiffening range including the gap between the hollow metal spheres by a simple operation of foaming and expanding the foamed resin material in the bag. The filling member is filled in the stiffening range, and the rigidity of the stiffening range of the hollow closed cross-section structure is secured by the filling member and a sound insulation effect is obtained.

更に、取付孔やクリップ等の取付手段が不要で発泡樹脂素材及び中空金属球を収容した袋体の設置範囲が制限されることなく、中空閉断面構造の適宜範囲を充填部材により容易に補剛することができる。 Furthermore, mounting means such as mounting holes and clips are not required, and the installation range of the bag body containing the foamed resin material and the hollow metal sphere is not limited, and the appropriate range of the hollow closed cross-section structure can be easily stiffened by the filling member. can do.

また、中空閉断面構造の補剛範囲におけるリンホース等の補剛部材等の削減や省略が可能になり、かつ充填部材等を保持するクリップや取付孔等の充填部材を装着する取付手段が不要であり構造構成部品の増加を招くことなく車体構造の簡素化及び形状等の制限が緩和されると共に、中空金属球が軽量かつ安価であり、発泡樹脂材の必要量の低減と相俟って製造コスト及び質量の増加を招くことなく、効率的な剛性及び遮音効果が得られる。また、充填部材における中空金属球の充填によって補剛範囲の剛性が確保できることから、発泡樹脂材の選択が制限されることなくなり、要望に応じた遮音タイプ或いは高剛性タイプ等を選択することで所望の剛性向上と遮音効果の両立が容易に達成できる。 In addition, it is possible to reduce or omit the stiffening member such as phosphorus hose in the stiffening range of the hollow closed cross-section structure, and there is no need for a mounting means for attaching a filling member such as a clip or a mounting hole for holding the filling member. There is no need to increase the number of structural components, and the simplification of the vehicle body structure and restrictions on the shape, etc. are eased, and the hollow metal sphere is lightweight and inexpensive, and is manufactured in combination with the reduction in the required amount of foamed resin material. Efficient rigidity and sound insulation effect can be obtained without increasing the cost and mass. Moreover, since the rigidity of the stiffening range can be secured by filling the hollow metal spheres in the filling member, the selection of the foamed resin material is not limited, and it is desired to select the sound insulation type or the high rigidity type according to the request. It is possible to easily achieve both improvement in rigidity and sound insulation effect.

上記目的を達成する請求項２の車体構造の製造方法の発明は、中空閉断面構造の連続する第１補剛範囲及び第２補剛範囲をそれぞれ発泡樹脂素材が発泡した発泡樹脂材と中空金属球による第１充填部材の充填及び発泡樹脂素材が発泡した発泡樹脂材からなる第２充填部材の充填によって補剛する車体構造の製造方法であって、前記中空金属球の通過を阻止すると共に流動性を有する未硬化状態の発泡樹脂材の通過を許容する中空金属規制部材によって前記第１補剛範囲内に装着可能な中空金属球充填部と第２補剛範囲内に装着可能な発泡樹脂材充填部とに区画した袋体を用い、前記中空金属球充填部に粒状の中空金属球を充填すると共に未発泡状態の発泡樹脂素材を収容した前記袋体を、該中空金属球充填部を前記第１補剛範囲内に発泡樹脂材充填部を第２補剛範囲内に配置して中空閉断面構造に装着し、該袋体内の前記発泡樹脂素材を発泡膨張させて前記第１補剛範囲内に充填する中空金属球と該中空金属球間の隙間を含む第１補剛範囲内に充填する発泡樹脂材とからなる第１充填部材で前記第１補剛範囲内を充填すると共に発泡樹脂材からなる第２充填部材で前記第２補剛範囲内を充填することを特徴とする。 The invention of the method for manufacturing a vehicle body structure according to claim 2, which achieves the above object, comprises a foamed resin material and a hollow metal in which a foamed resin material is foamed in each of the first stiffening range and the second stiffening range in which the hollow closed section structure is continuous. A method of manufacturing a vehicle body structure that stiffens by filling a first filling member with a sphere and filling a second filling member made of a foamed resin material of a foamed resin material, wherein the hollow metal sphere is prevented from passing through and flows. A hollow metal sphere filling portion that can be mounted within the first stiffening range and a foamed resin material that can be mounted within the second stiffening range by a hollow metal regulating member that allows passage of the uncured foamed resin material having a property Using a bag body divided into a filling portion, filling the hollow metal sphere filling portion with a granular hollow metal sphere and containing the foamed resin material in an unfoamed state, the hollow metal sphere filling portion with the hollow metal sphere filling portion Foamed resin within the first stiffening range A hollow metal sphere disposed in a second closed stiffening range and attached to a hollow closed cross-sectional structure, and expanded and expanded with the foamed resin material in the bag body and filled in the first stiffening range and the hollow A first filling member made of a foamed resin material filling a first stiffening range including a gap between metal balls fills the first stiffening range and a second filling member made of a foamed resin material. 2 It is characterized by filling in the stiffening range.

これによると、中空金属規制部材によって第１補剛範囲に装着可能な中空金属球充填部と第２補剛範囲に装着可能な発泡樹脂材充填部に区画された袋体を用い、中空金属球充填部に粒状の中空金属球を充填すると共に未発泡状態の発泡樹脂素材を収容した袋体を、第１補剛範囲及び第２補剛範囲内に配置して、袋体内の前記発泡樹脂素材を発泡膨張させる簡単な作業で、第１補剛範囲内が中空金属球及び発泡樹脂材とからなる第１充填部材で充填されて比較的高剛性が得られると共に第２補剛範囲内が発泡樹脂材からなる第２充填部材で充填され遮音効果が得られる。更に、取付孔やクリップ等の取付手段が不要で発泡樹脂素材及び中空金属球を収容した袋体の設置範囲が制限されることなく、中空閉断面構造の適宜範囲を充填部材により容易に補剛することができる。 According to this, a hollow metal sphere is formed using a bag body that is divided into a hollow metal sphere filling portion that can be attached to the first stiffening range by a hollow metal regulating member and a foamed resin material filling portion that can be attached to the second stiffening range. A foam body in which a filling portion is filled with granular hollow metal spheres and an unfoamed foamed resin material is accommodated is disposed in the first stiffening range and the second stiffening range, and the foamed resin material in the bag body The first stiffening range is filled with a first filling member made of a hollow metal sphere and a foamed resin material to obtain relatively high rigidity, and the second stiffening range is foamed. Filled with a second filling member made of a resin material, a sound insulation effect is obtained. Furthermore, mounting means such as mounting holes and clips are not required, and the installation range of the bag body containing the foamed resin material and the hollow metal sphere is not limited, and the appropriate range of the hollow closed cross-section structure can be easily stiffened by the filling member. can do.

中空閉断面構造の補剛範囲におけるリンホース等の補剛部材等の削減や省略が可能になり、かつ充填材等を保持するクリップや取付孔等の充填材を装着する取付手段が不要である構造構成部品の増加を招くことなく車体構造の簡素化及び形状等の制限が緩和されると共に、中空金属球が軽量かつ安価であり、発泡樹脂材の必要量の低減と相俟って製造コスト及び質量の増加を招くことなく車体構造の効率的な剛性及び遮音効果が得られる。 A structure that allows reduction or omission of stiffening members such as phosphorus hoses in the stiffening range of the hollow closed cross-section structure, and eliminates the need for mounting means for mounting fillers such as clips and mounting holes for holding fillers, etc. The simplification of the vehicle body structure and the restriction on the shape and the like are eased without increasing the number of components, and the hollow metal sphere is light and inexpensive, coupled with the reduction in the required amount of foamed resin material, Efficient rigidity and sound insulation effect of the vehicle body structure can be obtained without causing an increase in mass.

更に、第１充填部材における中空金属球の充填によって第１補剛範囲の剛性が確保できることから、発泡樹脂材の選択が制限されることなくなり、要望に応じた遮音タイプ或いは高剛性タイプ等を選択することで所望の剛性向上と遮音効果の両立が容易に達成できる。 Furthermore, since the rigidity of the first stiffening range can be secured by filling the hollow metal sphere in the first filling member, the selection of the foamed resin material is not restricted, and the sound insulation type or high rigidity type according to the request is selected. By doing so, it is possible to easily achieve both a desired rigidity improvement and a sound insulation effect.

請求項３に記載の発明は、請求項１または２に記載の車体構造の製造方法において、前記発泡樹脂素材は、加熱発泡型であって、塗装乾燥工程における熱源により加熱発泡させることを特徴とする。 The invention according to claim 3 is the method for manufacturing a vehicle body structure according to claim 1 or 2, wherein the foamed resin material is a heat-foaming type, and is heat-foamed by a heat source in a paint drying process. To do.

これによると、塗装乾燥工程における熱源により発泡樹脂素材を加熱発泡させることで、発泡樹脂素材の加熱発泡のための専用の加熱手段が不要になり設備及び製造コストの抑制が得られる。 According to this, by heating and foaming the foamed resin material with the heat source in the paint drying process, a dedicated heating means for heating and foaming the foamed resin material becomes unnecessary, and the equipment and the manufacturing cost can be suppressed.

請求項４に記載の発明は、請求項１〜３のいずれか１項に記載の車体構造の製造方法において、前記袋体は、前記発泡樹脂素材の発泡膨張に必要な温度では溶解することのない弾性変形可能な材料製であることを特徴とする。 According to a fourth aspect of the present invention, in the method for manufacturing a vehicle body structure according to any one of the first to third aspects, the bag body is melted at a temperature required for foaming expansion of the foamed resin material. It is made of a material that is not elastically deformable.

これによると、発泡樹脂素材の発泡膨張に必要な温度では袋体が溶解することなく、発泡過程において発泡樹脂樹材の形状が袋体によって保持されて所期の補剛範囲の形状に倣った形状の充填部材が確保でき、充填部材による所期の効果が確保できる。 According to this, the bag body does not melt at the temperature required for foaming expansion of the foamed resin material, and the shape of the foamed resin tree material is retained by the bag body in the foaming process, following the shape of the desired stiffening range The shape-shaped filling member can be secured, and the expected effect of the filling member can be secured.

本発明によると、中空閉断面構造の補剛範囲に、粒状の中空金属球が充填されると共に未発泡状態の発泡樹脂素材を収容した袋体を中空閉断面構造の補剛範囲内に設置し、袋体内の発泡樹脂素材を発泡膨張させる簡単な工程で、補剛範囲内に充填する中空金属球と中空金属球間の隙間を含む補剛範囲内に充填する発泡樹脂材とからなるブロック状の充填部材が補剛範囲内に充填され、充填部材によって中空閉断面構造の補剛範囲の剛性が確保されると共に遮音効果が得られる。 According to the present invention, a bag body filled with granular hollow metal spheres and containing an unfoamed foamed resin material is installed in the stiffening range of the hollow closed cross-section structure within the stiffening range of the hollow closed cross-section structure. The block shape is made of a hollow metal sphere filled in the stiffening range and a foamed resin material filled in the stiffening range including the gap between the hollow metal spheres in a simple process of foaming and expanding the foamed resin material in the bag. The filling member is filled in the stiffening range, and the rigidity of the stiffening range of the hollow closed cross-sectional structure is ensured by the filling member and a sound insulation effect is obtained.

また、中空閉断面構造の補剛範囲におけるリンホース等の補剛部材等の削減や省略が可能になり、かつ充填材等を保持するクリップや取付孔等の充填材を装着する取付手段が不要である構造構成部品の増加を招くことなく車体構造の簡素化及び形状等の制限が緩和されると共に、中空金属球が軽量かつ安価であり、発泡樹脂材の必要量の低減と相俟って製造コスト及び質量の増加を招くことなく、効率的な剛性及び遮音効果が得られる。 In addition, it is possible to reduce or omit stiffening members such as phosphorus hoses in the stiffening range of the hollow closed cross-sectional structure, and there is no need for attachment means for attaching fillers such as clips and attachment holes for holding fillers etc. The simplification of the body structure and the restriction on the shape, etc. are eased without increasing the number of structural components, and the hollow metal sphere is lightweight and inexpensive, and is manufactured in combination with the reduction in the required amount of foamed resin material. Efficient rigidity and sound insulation effect can be obtained without increasing the cost and mass.

本発明の第１実施の形態に係る車体の要部斜視図である。It is a principal part perspective view of the vehicle body which concerns on 1st Embodiment of this invention. 図１におけるＩＩ部断面図である。It is II section sectional drawing in FIG. 図２のＩＩＩ−ＩＩＩ線断面図である。It is the III-III sectional view taken on the line of FIG. 図３のＩＶ部拡大図である。It is the IV section enlarged view of FIG. 中空金属球の断面図である。It is sectional drawing of a hollow metal sphere. 袋体の概要を示す一部破断説明図である。It is a partially broken explanatory drawing which shows the outline | summary of a bag. 袋体内に中空金属球及び発泡樹脂素材を供給する作業状態を示す図である。It is a figure which shows the operation state which supplies a hollow metal ball | bowl and a foamed resin raw material in a bag body. 袋体を連結部に設置する作業状態を示す図である。It is a figure which shows the operation | work state which installs a bag body in a connection part. 本発明の第２実施の形態に係るフロントピラーとサイドレールとフロントレールの連結部を模式的に示す図である。It is a figure which shows typically the connection part of the front pillar which concerns on 2nd Embodiment of this invention, a side rail, and a front rail. 図９の要部破断説明図である。It is principal part fracture | rupture explanatory drawing of FIG. 袋体の概要を示す一部破断説明図である。It is a partially broken explanatory drawing which shows the outline | summary of a bag. 袋体内に中空金属球及び発泡樹脂素材を供給する作業状態を示す図である。It is a figure which shows the operation state which supplies a hollow metal ball | bowl and a foamed resin raw material in a bag body. 袋体を設置する作業状態を示す図である。It is a figure which shows the operation state which installs a bag body. 従来の補剛及び遮音構造の説明図である。It is explanatory drawing of the conventional stiffening and sound insulation structure. 従来の補剛及び遮音構造の説明図である。It is explanatory drawing of the conventional stiffening and sound insulation structure.

本発明による車体構造の製造方法の実施の形態を図を参照して説明する。 An embodiment of a method for manufacturing a vehicle body structure according to the present invention will be described with reference to the drawings.

（第１実施の形態）
本発明の第１実施の形態を図１乃至図８を参照して説明する。図１は、車体１の要部斜視図であり、図２は図１のＩＩ部断面図、図３は図２のＩＩＩ−ＩＩＩ線断面図、図４は図３のＩＶ部拡大図である。 (First embodiment)
A first embodiment of the present invention will be described with reference to FIGS. 1 is a perspective view of the main part of the vehicle body 1. FIG. 2 is a sectional view taken along the line II in FIG. 1, FIG. 3 is a sectional view taken along the line III-III in FIG. .

車体１の側部にフロントドア開口部２及びリヤドア開口部３が形成される。フロントドア開口部２及びリヤドア開口部３の下部に車体前後方向に沿ってサイドシル１０が延在し、フロントドア開口部２とリヤドア開口部３との間に上下方向に延在するセンタピラー１５が配置され、フロントドア開口部２の前縁に沿ってフロントピラー２０が配置され、センタピラー１５の下端がサイドシル１０の車体前後方向の中間部に結合し、フロントピラー２０の下端がサイドシル１０の前端に結合される。 A front door opening 2 and a rear door opening 3 are formed on the side of the vehicle body 1. A side sill 10 extends along the longitudinal direction of the vehicle body below the front door opening 2 and the rear door opening 3, and a center pillar 15 extending vertically between the front door opening 2 and the rear door opening 3. The front pillar 20 is disposed along the front edge of the front door opening 2, the lower end of the center pillar 15 is coupled to the middle part of the side sill 10 in the longitudinal direction of the vehicle body, and the lower end of the front pillar 20 is the front end of the side sill 10. Combined with

左右のサイドシル１０は車幅方向に延在するクロスメンバによって連結されると共にフロアパネル５が架け渡され、左右のフロントピラー２０間にフロアパネル５の前端に沿って接合されて車室とエンジンルームとを区画するトーボードが架設される。また、フロントドア開口部２及びリヤドア開口部３の上縁に沿ってサイドレール２５が延在し、センタピラー１５の上部及びフロントピラー２０の上部がサイドレール２５に接合され、左右のサイドレール２５の前端間及び後端間にそれぞれフロントレール３０及びリヤレール３５が架設され、左右のサイドレール２５の間にルーフパネル７が架設される。 The left and right side sills 10 are connected by a cross member extending in the vehicle width direction, and the floor panel 5 is bridged. The left and right side sills 10 are joined along the front end of the floor panel 5 between the left and right front pillars 20, so A toe board that divides Further, the side rail 25 extends along the upper edges of the front door opening 2 and the rear door opening 3, the upper part of the center pillar 15 and the upper part of the front pillar 20 are joined to the side rail 25, and the left and right side rails 25. The front rail 30 and the rear rail 35 are installed between the front ends and the rear ends, respectively, and the roof panel 7 is installed between the left and right side rails 25.

これら骨格部材となるサイドシル１０、センタピラー１５、フロントピラー２０、サイドレール２５、フロントレール３０、リヤレール３５は中空閉断面構造であって、サイドシル１０はサイドシルアウタパネル１１とサイドシルインナパネル１２によって車体前後方向に延在する中空閉断面状に形成され、センタピラー１５はセンタピラーアウタパネル１６とセンタピラーインナパネル１７によって上下方向に延在する中空閉断面状に形成される。 The side sill 10, the center pillar 15, the front pillar 20, the side rail 25, the front rail 30, and the rear rail 35, which are the skeleton members, have a hollow closed cross-sectional structure, and the side sill 10 is constituted by a side sill outer panel 11 and a side sill inner panel 12. The center pillar 15 is formed by a center pillar outer panel 16 and a center pillar inner panel 17 in a hollow closed cross section extending in the vertical direction.

サイドシル１０とセンタピラー１５との連結部１０Ａは、図３に示すようにサイドシルアウタパネル１１の上縁とセンタピラーアウタパネル１６の下端が接合し、サイドシルインナパネル１２の上縁とセンタピラーインナパネル１７の下端が接合した中空状で連続するＴ字状に形成される。また、センタピラーインナ１７には、連結部１０Ａより上方位置に、例えばシートベルト装置取付用の開口部１８が開口している。 As shown in FIG. 3, the connecting portion 10 A between the side sill 10 and the center pillar 15 joins the upper edge of the side sill outer panel 11 and the lower end of the center pillar outer panel 16, and connects the upper edge of the side sill inner panel 12 and the center pillar inner panel 17. It is formed in a hollow and continuous T shape with the lower ends joined. Further, the center pillar inner 17 has an opening 18 for attaching a seat belt device, for example, at a position above the connecting portion 10A.

ここで、サイドシル１０とセンタピラー１５との連結部１０Ａは、サイドシル１０、センタピラー１５及びフロアパネル５を強固に結合して車体剛性を確保し、更に衝突時等の荷重入力に対処すべく比較的大きな剛性が要求されると共に、制振及び遮音機能が要求される。 Here, the connecting portion 10A between the side sill 10 and the center pillar 15 is firmly connected to the side sill 10, the center pillar 15 and the floor panel 5 to ensure the rigidity of the vehicle body, and further compared to cope with load input at the time of a collision or the like. A large rigidity is required, and vibration damping and sound insulation functions are required.

この比較的大きな剛性が要求されると共に制振及び遮音機能が要求される補剛範囲となる連結部１０Ａ内に、比較的軽量で剛性を有する粒状の中空金属球５１及び制振及び遮音機能に優れた発泡樹脂材５２からなる充填部材５０が充填される。この充填部材５０は、粒状の中空金属球５１と未発泡状態の発泡樹脂素材５３が収容された袋体５５を連結部１０Ａ内に装着し、しかる後、塗装乾燥工程における熱源により発泡樹脂素材５３を加熱発泡させることで形成される。 A relatively lightweight and rigid granular hollow metal sphere 51 and a damping and sound insulating function are provided in the connecting portion 10A that is a stiffening range where a relatively large rigidity is required and a damping and sound insulating function is required. A filling member 50 made of an excellent foamed resin material 52 is filled. In this filling member 50, a bag body 55 in which granular hollow metal spheres 51 and an unfoamed foamed resin material 53 are accommodated is mounted in the connecting portion 10A, and then the foamed resin material 53 is applied by a heat source in a paint drying process. It is formed by heating and foaming.

次に、この充填部材５０を中空閉断面構造の補剛範囲となる連結部１０Ａ内に充填する作業工程を説明する。 Next, an operation process for filling the filling member 50 into the connecting portion 10A that is a stiffening range of the hollow closed cross-sectional structure will be described.

充填材５０を構成する粒状の中空金属球５１は、中空球状にして比重を軽減したものであって、図５にその断面を示すように、例えば直径ｄが１〜５ｍｍで、肉厚ｔが７０〜１００μｍで見かけの密度が０．８〜０．９ｇ／ｃｍ^３の軽量な中空鉄球によって構成される。この中空鉄球は、例えば特開２００９−１２１５９９号公報に開示されるように、発泡樹脂球の表面に、酸化鉄を含むスラリを噴霧して皮膜を付け、得られた皮膜付発泡樹脂材を焼結することで得られる。 The granular hollow metal sphere 51 constituting the filler 50 is a hollow sphere having a reduced specific gravity. As shown in the cross section of FIG. 5, for example, the diameter d is 1 to 5 mm and the thickness t is It is composed of a lightweight hollow iron sphere having an apparent density of 70 to 100 μm and an apparent density of 0.8 to 0.9 g / cm ³ . For example, as disclosed in Japanese Patent Application Laid-Open No. 2009-121599, the hollow iron sphere is formed by spraying a slurry containing iron oxide on the surface of the foamed resin sphere to form a film, and coating the obtained foamed resin material with a film. Obtained by sintering.

発泡樹脂素材は、一般に液状或いはビーズ状であり、本実施の形態における発泡樹脂素材５３は液状で、加熱により発泡膨張する加熱発泡型である。また、発泡後の発泡樹脂材５２において主に遮音機能を目的とする遮音タイプである。 The foamed resin material is generally liquid or bead-shaped, and the foamed resin material 53 in the present embodiment is a liquid and is a heat-foaming type that foams and expands when heated. The foamed resin material 52 after foaming is a sound insulation type mainly for the purpose of a sound insulation function.

袋体５５は、発泡樹脂素材５３の発泡膨張に必要な温度（例えば１４０℃〜１７０℃）では溶解することがないゴム等の弾性変形可能な材料製であって、図６に一部破断斜視図に示すように、補剛範囲となる連結部１０Ａにおけるサイドシル１０内に嵌装してサイドシル１０の延在方向に延在するサイドシル対応部分５６及びサイドシル対応部分５６から分岐してセンタピラー１５の下部内に嵌装可能なセンタピラー対応部分５７が一体形成さたれＴ字状の中空形状で、ほぼ連結部１０Ａの内面形状に倣った形状で、連結部１０Ａの内部空間内に嵌装可能に形成される。この袋体５５の適宜箇所、例えばセンタピラー対応部分５７の頂端部に中空金属球５１及び発泡樹脂素材５３を投入するための材料供給口５５ａが形成される。 The bag body 55 is made of an elastically deformable material such as rubber that does not melt at a temperature (for example, 140 ° C. to 170 ° C.) necessary for the foaming expansion of the foamed resin material 53, and is partially broken perspective in FIG. As shown in the figure, a side sill corresponding portion 56 that extends in the extending direction of the side sill 10 and is branched into the side sill 10 in the connecting portion 10 A that becomes a stiffening range and branches from the side sill corresponding portion 56. Center-pillar-corresponding portion 57 that can be fitted in the lower part is integrally formed with a T-shaped hollow shape, and is shaped substantially like the inner surface shape of coupling portion 10A, so that it can be fitted in the internal space of coupling portion 10A. It is formed. A material supply port 55 a for introducing the hollow metal sphere 51 and the foamed resin material 53 is formed at an appropriate location of the bag body 55, for example, at the top end portion of the center pillar corresponding portion 57.

そして、図７に作業状態を示すように、充填部材５０を充填すべき連結部１０Ａの内部空間容積とほぼ同様の量の中空金属球５１を、材料供給口５５ａから袋体５５に投入する。更に袋体５５に、予め設定された量の発泡樹脂素材５３、例えば発泡膨張した際に袋体５５内の中空金属球５１間に侵入し、かつ中空金属球５１と共に連結部１０Ａの内部空間を充填する発泡樹脂材５２となるに十分な未発泡の発泡樹脂素材５３を供給して準備する。これら袋体５５に投入する中空金属球５１の量及び発泡樹脂素材５３の量は実験やシミュレーション等により設定することが好ましい。 Then, as shown in FIG. 7, the hollow metal sphere 51 having an amount substantially the same as the internal space volume of the connecting portion 10A to be filled with the filling member 50 is introduced into the bag body 55 from the material supply port 55a. Further, a predetermined amount of foamed resin material 53, for example, when the foam expands, enters the bag body 55 between the hollow metal spheres 51 in the bag body 55, and together with the hollow metal sphere 51, the internal space of the connecting portion 10A. An unfoamed foamed resin material 53 sufficient to become the foamed resin material 52 to be filled is supplied and prepared. It is preferable to set the amount of the hollow metal sphere 51 and the amount of the foamed resin material 53 to be introduced into the bag body 55 by experiments, simulations, or the like.

この粒状の中空金属球５１及び発泡樹脂素材５３を収容した袋体５５を、図８に作業状態を示すように、センタピラーインナ１７に開口する開口部１８や他の開口部等から連結部１０Ａ内に挿入して連結部１０Ａの内部空間内に位置決めして設置する。即ち連結部１０Ａにおけるサイドシルアウタパネル１１とサイドシルインナパネル１２との間にサイドシル対応部分５６が嵌合保持され、センタピラーアウタ１６とセンタピラーインナ１７によってセンタピラー対応部分５７が嵌合保持された状態で袋体５５が連結部１０Ａ内に安定した状態で保持される。これにより袋体５５を介在して連結部１０Ａの内部空間が粒状の中空金属球５１で充填され、袋体５５の底部に発泡樹脂材料５３が貯留される。 The bag 55 containing the granular hollow metal sphere 51 and the foamed resin material 53 is connected to the connecting portion 10A from the opening 18 opened to the center pillar inner 17 or other opening as shown in FIG. It inserts in and positions and installs in the internal space of 10 A of connection parts. That is, the side sill corresponding portion 56 is fitted and held between the side sill outer panel 11 and the side sill inner panel 12 in the connecting portion 10A, and the center pillar corresponding portion 57 is fitted and held by the center pillar outer 16 and the center pillar inner 17. The bag body 55 is held in a stable state in the connecting portion 10A. Accordingly, the internal space of the connecting portion 10 A is filled with the granular hollow metal sphere 51 through the bag body 55, and the foamed resin material 53 is stored at the bottom of the bag body 55.

しかる後、組み立てられた車体は塗装工程に搬送される。車体の組み立てや搬送過程において、中空金属球５１及び発泡樹脂素材５３を収容した袋体５５はサイドシル１１とセンタピラー１５の連結部１０Ａの内部空間内に嵌合保持され、連結部１０Ａ内に設置された状態が維持される。 Thereafter, the assembled vehicle body is conveyed to the painting process. In the process of assembling and transporting the vehicle body, the bag body 55 containing the hollow metal sphere 51 and the foamed resin material 53 is fitted and held in the internal space of the connecting portion 10A of the side sill 11 and the center pillar 15, and installed in the connecting portion 10A. The maintained state is maintained.

塗装工程に搬送された車体が塗装され、塗装乾燥工程において加熱乾燥される。この塗装乾燥工程における熱源により連結部１０Ａの内部空間に装着された袋体５５内の発泡樹脂素材５３を加熱発泡させる。このように塗装乾燥工程における熱源によって連結部１０Ａ内に袋体５５を介在して保持された発泡樹脂素材５３を加熱発泡させることで、加熱発泡のための専用の加熱手段が不要になり設備及び製造コストの抑制が得られる。 The vehicle body transported to the painting process is painted and dried by heating in the painting drying process. The foamed resin material 53 in the bag body 55 mounted in the internal space of the connecting portion 10A is heated and foamed by a heat source in the paint drying process. Thus, by heating and foaming the foamed resin material 53 held through the bag body 55 in the connecting portion 10A by the heat source in the paint drying process, a dedicated heating means for heating and foaming becomes unnecessary, and the equipment and Reduction of manufacturing cost can be obtained.

この発泡樹脂素材５３の発泡膨張に伴って、連結部１０Ａのサイドシル１０及びセンタピラー１５によって保持された袋体５５のサイドシル対応部分５６及びセンタピラー対応部分５７が発泡した未硬化状態の発泡樹脂材５２で満たされ、袋体５５内に充填された各中空金属球５１間及び中空金属球５１と袋体５５の内面との間の隙間に侵入して袋体５５内が粒状の中空金属球５１と発泡樹脂材５２によって充填される。更に袋体５５のサイドシル対応部分５６がサイドシルアウタパネル１１及びサイドシルインナパネル１２の内面に倣って押圧されて密着すると共にセンタピラー対応部分５７がセンタピラーアウタパネル２１及びセンタピラーインナパネル２２の内面形状に倣って押圧されて密接して袋体５５が溶解し、連結部１０Ａの内部空間が多数の中空金属球５１及び発泡樹脂材５２からなるブロック状の充填部材５０によって充填され、しかる後発泡樹脂材５２が硬化する。ここで、発泡樹脂素材５３の発泡膨張に必要な温度では袋体５５が溶解することなく、発泡過程において発泡する発泡樹脂樹材料５２の形状が袋体５５によって保持されて連結部１０Ａ内の複雑な形状に倣った形状の充填部材５０が確保できる。 With the expansion of the foamed resin material 53, the uncured foamed resin material in which the side sill-corresponding portion 56 and the center pillar-corresponding portion 57 of the bag 55 held by the side sill 10 and the center pillar 15 of the connecting portion 10A are foamed. The hollow metal spheres 51 that are filled with 52 and enter the gaps between the hollow metal spheres 51 filled in the bag body 55 and between the hollow metal spheres 51 and the inner surface of the bag body 55 and the inside of the bag body 55 is granular. And the foamed resin material 52. Further, the side sill corresponding portion 56 of the bag body 55 is pressed and closely adhered to the inner surfaces of the side sill outer panel 11 and the side sill inner panel 12, and the center pillar corresponding portion 57 follows the inner shape of the center pillar outer panel 21 and the center pillar inner panel 22. The bag body 55 is melted by being pressed in close contact with each other, and the internal space of the connecting portion 10A is filled with a block-shaped filling member 50 composed of a number of hollow metal spheres 51 and a foamed resin material 52, and then the foamed resin material 52 is filled. Is cured. Here, at the temperature required for the foaming expansion of the foamed resin material 53, the shape of the foamed resin tree material 52 that is foamed in the foaming process is held by the bag body 55 without dissolving the bag body 55, and the inside of the connecting portion 10A is complicated. Thus, the filling member 50 having a shape that follows the desired shape can be secured.

この発泡充填に伴う充填部材５０内に残留する空気及び発泡ガスは、サイドシル１０及びセンタピラー１５を介して放出され、充填部材５０内に残留ガスが滞留することが回避されて、ボイドの発生が抑制されて円滑な発泡充填が確保できる。 Air and foam gas remaining in the filling member 50 due to the foam filling are discharged through the side sill 10 and the center pillar 15, and the residual gas is prevented from staying in the filling member 50, thereby generating voids. Suppressed and smooth foam filling can be secured.

このようにサイドシル１０とセンタピラー１５との連結部１０Ａにおいて中空Ｔ字状に区画された連結部１０Ａ内に充填された中空金属球５１及び発泡樹脂材５２からなる充填部材５０を備えることで、連結部１０Ａ内が比較的剛性の高い中空金属球５１が充填され比較的大きな剛性が確保されると共に、遮音及び制振機能に優れた発泡樹脂材５２により該部範囲における遮音及び振動抑制が得られる。 Thus, by providing the filling member 50 composed of the hollow metal sphere 51 and the foamed resin material 52 filled in the connecting portion 10A partitioned in the hollow T shape at the connecting portion 10A of the side sill 10 and the center pillar 15, The inside of the connecting portion 10A is filled with a relatively high rigidity hollow metal sphere 51 to ensure a relatively large rigidity, and the foamed resin material 52 having an excellent sound insulation and vibration control function can suppress sound insulation and vibration in the region. It is done.

更に、サイドシル１０及びセンタピラー１５に外方から荷重が加わる際には、荷重が入力される部分、例えば図４に矢印Ｐで示す荷重がサイドシルアウタパネル１１に入力すると、サイドシルアウタパネル１１が撓み乃至変形し、この撓み乃至変形に伴ってサイドシルアウタパネル１１の撓み乃至変形発生範囲に接する中空金属球５１が隣接する中空金属球５１に圧接して摩擦力による荷重吸収及び荷重が分散し、個々の中空金属球５１が次々に隣接する中空金属球５１に圧接して荷重を吸収分散して連結部１０Ａの広い範囲に荷重分散すると共に、各中空金属球５１間及び中空金属球５１とサイドシル１０及びセンタピラー１５の内面との間の隙間に介在する発泡樹脂材５２の変形によって荷重が吸収され、サイドシル１０及びセンタピラー１５の変形に伴う大きな抗力が確保される。 Further, when a load is applied to the side sill 10 and the center pillar 15 from the outside, when a load is input, for example, a load indicated by an arrow P in FIG. 4 is input to the side sill outer panel 11, the side sill outer panel 11 is bent or deformed. With this bending or deformation, the hollow metal sphere 51 in contact with the bending or deformation occurrence range of the side sill outer panel 11 comes into pressure contact with the adjacent hollow metal sphere 51 and the load absorption and load due to the frictional force are dispersed. The spheres 51 are in pressure contact with the adjacent hollow metal spheres 51 to absorb and disperse the load to disperse the load over a wide range of the connecting portion 10A, and between the hollow metal spheres 51 and between the hollow metal spheres 51, the side sill 10, and the center pillar. The load is absorbed by the deformation of the foamed resin material 52 interposed in the gap between the inner surface 15 and the side sill 10 and the center pillar. Large drag is ensured due to the deformation of the 15.

また、サイドシル１０とセンタピラー１５との連結部１０Ａの内部空間内に中空金属球５１が充填され、かつ各中空金属球５１間及び中空金属球５１とサイドシル１０及びセンタピラー１５の内面との間の隙間に侵入して充填部材５０が形成されることから、連結部１０Ａ内において中空金属球５１の移動が規制され、安定した状態で各中空金属球５１が保持される。 In addition, the hollow metal sphere 51 is filled in the internal space of the connecting portion 10 A between the side sill 10 and the center pillar 15, and between the hollow metal spheres 51 and between the hollow metal sphere 51 and the side sill 10 and the inner surface of the center pillar 15. Since the filling member 50 is formed by entering the gap, the movement of the hollow metal spheres 51 is restricted in the connecting portion 10A, and the hollow metal spheres 51 are held in a stable state.

従って、剛性、制振及び遮音が要求されるサイドシル１０とセンタピラー１５との連結部１０Ａに、粒状の中空金属球５１及び未発泡状態の発泡樹脂素材５３を収容した袋体５５を設置し、塗装乾燥の際の熱源、例えば乾燥熱で発泡樹脂素材５３を発泡膨張させることで、複雑な形状の連結部１０Ａの内部空間が中空金属球５１及び発泡樹脂材５２からなるブロック状の充填部材５０によって充填されることから、簡単な構成及び作業で効率的にサイドシル１０とセンタピラー１５との連結部１０Ａにおける遮音効果が得られ、剛性が確保できる。 Therefore, the bag body 55 containing the granular hollow metal sphere 51 and the unfoamed foamed resin material 53 is installed in the connecting portion 10A between the side sill 10 and the center pillar 15 where rigidity, vibration suppression and sound insulation are required, A block-shaped filling member 50 in which the internal space of the connecting portion 10 A having a complicated shape is composed of the hollow metal sphere 51 and the foamed resin material 52 by foaming and expanding the foamed resin material 53 with a heat source during coating drying, for example, drying heat. Therefore, the sound insulation effect at the connecting portion 10A between the side sill 10 and the center pillar 15 can be efficiently obtained with a simple configuration and operation, and rigidity can be ensured.

また、サイドシル１０とセンタピラー１５との連結部１０Ａにおけるリンホース等の補剛部材等の削減や省略が可能になり、かつ充填材等を保持するクリップや取付孔等の充填材を装着する取付手段が不要であり構造構成部品の増加を招くことなく車体構造の簡素化及び形状等の制限が緩和される。更に、中空金属球５１が軽量かつ安価であり、発泡樹脂材の必要量の低減と相俟って製造コスト及び質量の増加を招くことなく、車体構造の効率的な剛性及び遮音効果が得られる。 Further, it is possible to reduce or omit a stiffening member such as a phosphorus hose in the connecting portion 10A between the side sill 10 and the center pillar 15, and a mounting means for mounting a filler such as a clip or a mounting hole for holding the filler. Is not required, and the restriction on the simplification and the shape of the vehicle body structure is alleviated without increasing the number of structural components. Further, the hollow metal sphere 51 is light and inexpensive, and the rigidity and sound insulation effect of the vehicle body structure can be obtained without causing an increase in manufacturing cost and mass in combination with a reduction in the required amount of foamed resin material. .

なお、連結部１０Ａの剛性及び遮音機能の要求に応じて剛性の異なる種々の中空金属球５１に変更することも可能であり、また、充填部材５０における中空金属球５１の充填によって連結部１０Ａの剛性が確保されることから、発泡樹脂材５２の選択範囲が緩和され、要望に応じた剛性機能を目的とした高剛性タイプ及び遮音性を目的とした遮音タイプ等種々の発泡樹脂素材５３を適宜選択的に用いることが可能になり所望の剛性向上と遮音効果の両立が容易に達成できる。 It is also possible to change to various hollow metal spheres 51 having different rigidity according to the requirements of the rigidity of the connecting portion 10A and the sound insulation function, and by filling the hollow metal spheres 51 in the filling member 50, the connecting portion 10A Since the rigidity is ensured, the selection range of the foamed resin material 52 is relaxed, and various foamed resin materials 53 such as a high-rigidity type for the purpose of a rigid function and a sound insulation type for the purpose of sound insulation are appropriately used. It can be selectively used, and desired rigidity improvement and sound insulation effect can be easily achieved.

なお、上記実施の形態では袋体５５を塗装乾燥工程における熱源で溶解する材質により構成したが、溶解することのない弾性変形可能な材質によって形成することもできる。この場合、充填部材５０が袋体５５を介在して連結部１０Ａ内に嵌装される。 In the above embodiment, the bag body 55 is made of a material that is melted by a heat source in the paint drying process. However, the bag body 55 can be made of an elastically deformable material that does not melt. In this case, the filling member 50 is fitted into the connecting portion 10 A via the bag body 55.

上記実施の形態では、サイドシル１０とセンタピラー１５の連結部１０Ａを対象に説明したが、充填部材を保持するクリップや取付孔等の充填部材を取り付けるための取付手段が不要であり、発泡樹脂素材５３及び中空金属球５１を充填した袋体５５の設配が制限されることなく、サイドレール６や車体フレーム等の他の中空断面構造の適宜範囲を充填部材５０によって容易に補剛することができる。更に、中空金属球５１は、中空にして比重を軽減したものであって球形に限定されるものではなく、立方体等の球形に類似した形状でよく、素材は鉄、炭素鋼、ステンレス鋼等の鉄系金属や他の金属によって構成することができる。 In the above embodiment, the connecting portion 10A between the side sill 10 and the center pillar 15 has been described. However, there is no need for an attachment means for attaching a filling member such as a clip or an attachment hole for holding the filling member, and a foamed resin material. 53 and the appropriate range of other hollow cross-sectional structures such as the side rail 6 and the vehicle body frame can be easily stiffened by the filling member 50 without restricting the arrangement of the bag body 55 filled with the 53 and the hollow metal sphere 51. it can. Further, the hollow metal sphere 51 is hollow and has a reduced specific gravity, and is not limited to a sphere, and may have a shape similar to a sphere such as a cube, and the material may be iron, carbon steel, stainless steel, or the like. It can be comprised with an iron-type metal and another metal.

（第２実施の形態）
本発明の第２実施の形態を図９乃至図１２を参照して説明する。図９は、車体における中空閉断面構造となるフロントピラー２０とサイドレール２５とフロントレール３０の連結部２０Ａを模式的に示す図、図１０は図９の要部破断説明図である。 (Second Embodiment)
A second embodiment of the present invention will be described with reference to FIGS. FIG. 9 is a diagram schematically showing a connecting portion 20A of the front pillar 20, the side rail 25, and the front rail 30 having a hollow closed cross-sectional structure in the vehicle body, and FIG. 10 is a fragmentary explanatory view of FIG.

図９及び図１０に示すように、フロントピラー２０、サイドレール２５、フロントレール３０は中空閉断面構造であって、上下方向に延在するフロントピラー２０の上端に車体前後方向に延在するサイドレール３０の前端が連結され、フロントピラー２０とサイドレール２５の連結部に車幅方向に延在するフロントレール３０の端部が連結され、フロントピラー２０とサイドレール２５とフロントレール３０との連結部２０Ａはフロントピラー２０の上端、サイドレール２５の前端、及びフロントレール３０の端部によって中空状で連続する複雑な形状の三又構造に形成される。 As shown in FIGS. 9 and 10, the front pillar 20, the side rail 25, and the front rail 30 have a hollow closed cross-sectional structure, and the side that extends in the longitudinal direction of the vehicle body at the upper end of the front pillar 20 that extends in the vertical direction. The front end of the rail 30 is connected, the end of the front rail 30 extending in the vehicle width direction is connected to the connecting portion of the front pillar 20 and the side rail 25, and the front pillar 20, the side rail 25, and the front rail 30 are connected. The portion 20 A is formed into a hollow and continuous three-pronged structure by the upper end of the front pillar 20, the front end of the side rail 25, and the end of the front rail 30.

ここで、フロントピラー２０とサイドレール２５とフロントレール３０との連結部２０Ａは、フロントピラー２０、サイドレール２５、フロントレール３０とを強固に結合して車体剛性を確保すべく比較的大きな剛性が要求され、この連結部２０Ａが第１補剛範囲である。一方、連結部２０Ａに連続するフロントピラー２０の上部範囲２０ａ、サイドレール２５の前部範囲２５ａ、フロントレール３０の側端範囲３０ａには剛性が要求されるとともに制振及び遮音機能が要求され、これらフロントピラー２０の上部範囲２０ａ、サイドレール２５の前部範囲２５ａ、フロントレール３０の側端範囲３０ａが第２補剛範囲となる。 Here, the connecting portion 20A between the front pillar 20, the side rail 25, and the front rail 30 has a relatively large rigidity so as to secure the vehicle body rigidity by firmly connecting the front pillar 20, the side rail 25, and the front rail 30. This connecting portion 20A is in the first stiffening range. On the other hand, the upper range 20a of the front pillar 20 continuous to the connecting portion 20A, the front range 25a of the side rail 25, and the side end range 30a of the front rail 30 are required to have rigidity and vibration suppression and sound insulation functions, The upper range 20a of the front pillar 20, the front range 25a of the side rail 25, and the side end range 30a of the front rail 30 are the second stiffening range.

図１０に示すように比較的大きな剛性が要求されると共に制振及び遮音機能が要求されるフロントピラー２０とサイドレール２５とフロントレール３０との連結部２０Ａ内、即ち第１補剛範囲に比較的軽量で剛性を有する粒状で中空金属球５１及び制振及び遮音機能に優れた発泡樹脂材５２からなる第１充填部材６１が充填して装着される。特に制振及び遮音機能が要求されるフロントピラー２０の上部範囲２０ａ、サイドレール２５の前部範囲２５ａ、フロントレール３０の側端範囲３０ａ、即ち各第２補剛範囲には制振及び遮音機能に優れた発泡樹脂材５２からなる第２充填部材６２、６３、６４が充填して装着される。これら第１充填部材６１、第２充填部材６２、６３、６４は一体形成された充填部材６０となる。 Compared to the first stiffening range in the connecting portion 20A of the front pillar 20, the side rail 25, and the front rail 30, which require a relatively large rigidity and a vibration suppression and sound insulation function as shown in FIG. The first filling member 61 made of a hollow metal sphere 51 and a foamed resin material 52 excellent in vibration damping and sound insulation functions is filled and mounted. In particular, the upper range 20a of the front pillar 20, the front range 25a of the side rail 25, the side end range 30a of the front rail 30, that is, the second stiffening range, in which the vibration suppression and sound insulation functions are required, are provided with the vibration suppression and sound insulation functions. The second filling members 62, 63 and 64 made of the foamed resin material 52 excellent in the above are filled and attached. The first filling member 61 and the second filling members 62, 63, 64 become an integrally formed filling member 60.

この連結部２０Ａ内の第１充填部材６１及びフロントピラー２０の上部範囲２０ａ、サイドレール２５の前部範囲２５ａ、フロントレール３０の側端範囲３０ａの第２充填材６２、６３、６４は、粒状の中空金属球５１と未発泡状態の発泡樹脂素材５３が収容された袋体７０を連結部２０Ａ及びフロントピラー２０の上部範囲２０ａ、サイドレール２５の前部範囲２５ａ、フロントレール３０の側端範囲３０ａ内に亘って装着し、しかる後、塗装乾燥工程における熱源により発泡樹脂素材５３を加熱発泡させることで形成される。 The first filler member 61 and the upper range 20a of the front pillar 20, the front range 25a of the side rail 25, and the second fillers 62, 63, and 64 in the side end range 30a of the front rail 30 in the connecting portion 20A are granular. The hollow metal sphere 51 and the unpacked foamed resin material 53 are accommodated in a bag body 70. An upper range 20a of the connecting portion 20A and the front pillar 20, a front range 25a of the side rail 25, and a side end range of the front rail 30 It is mounted over 30a, and then formed by heating and foaming the foamed resin material 53 with a heat source in the paint drying process.

袋体７０は、発泡樹脂素材５３の発泡膨張に必要な温度では溶解することがないゴム等の弾性変形可能な材料製であって、図１１に一部破断斜視図を示すように、連結部２０Ａ内に嵌装可能な中空金属球充填部となる連結部対応部分７１、この連結部対応部分７１から分岐してそれぞれフロントピラー２０の上部範囲２０ａ内、サイドレール２５の前部範囲２５ａ内、フロントレール３０の側端範囲３０ａ内に嵌装可能な発泡樹脂材充填部となるフロントピラー対応部分７２、サイドレール対応部分７３、フロントレール対応部分７４が突出して一体形成された三又状の中空形状に形成される。 The bag body 70 is made of an elastically deformable material such as rubber that does not melt at a temperature necessary for foaming expansion of the foamed resin material 53, and as shown in a partially broken perspective view in FIG. A connecting portion corresponding portion 71 to be a hollow metal sphere filling portion that can be fitted in 20A, branched from the connecting portion corresponding portion 71, respectively in the upper range 20a of the front pillar 20, in the front range 25a of the side rail 25, A three-pillared hollow in which a front pillar corresponding portion 72, a side rail corresponding portion 73, and a front rail corresponding portion 74 that are foam resin filling portions that can be fitted into the side end range 30a of the front rail 30 are integrally formed by protruding. It is formed into a shape.

連結部対応部分７１とフロントピラー対応部分７２との間が中空金属球５１の通過を阻止する一方、発泡樹脂素材５３及び流動性を有する未硬化状態の発泡樹脂材の通過が可能なメッシュ等の中空金属移動規制部材７５によって区画される。同様に連結部対応部分７１とサイドレール対応部分７３及び連結部対応部分７１とフロントレール対応部分７４が中空金属移動規制部材７６、７７によって区画される。また、連結部対応部分７１に中空金属球５１及び発泡樹脂素材５３を投入するための材料供給口７０ａが形成される。 While the connection portion corresponding portion 71 and the front pillar corresponding portion 72 prevent passage of the hollow metal sphere 51, the foamed resin material 53 and a mesh capable of passing an uncured foamed resin material having fluidity can be used. It is partitioned by the hollow metal movement restricting member 75. Similarly, the connecting portion corresponding portion 71 and the side rail corresponding portion 73 and the connecting portion corresponding portion 71 and the front rail corresponding portion 74 are partitioned by the hollow metal movement restricting members 76 and 77. In addition, a material supply port 70 a for introducing the hollow metal sphere 51 and the foamed resin material 53 into the connecting portion corresponding portion 71 is formed.

そして、図１２に作業状態を示すように、袋体７０内に、その材料供給口７０ａから充填部材６０を充填すべき連結部２０Ａの内部空間容積とほぼ同様の量の中空金属球５１を投入すると共に発泡樹脂素材５３を供給する。材料供給口７０ａから供給された中空金属球５１は中空金属移動規制部材７５、７６、７７によって区画形成された連結部対応部分７１内に保持される。これら袋体７０に投入する中空金属球５１の量及び発泡樹脂素材５３の量は実験やシミュレーション等により設定することが好ましい。 Then, as shown in FIG. 12, the hollow metal sphere 51 having an amount substantially equal to the internal space volume of the connecting portion 20A to be filled with the filling member 60 is introduced into the bag body 70 from the material supply port 70a. In addition, the foamed resin material 53 is supplied. The hollow metal sphere 51 supplied from the material supply port 70 a is held in the connecting portion corresponding portion 71 defined by the hollow metal movement restricting members 75, 76, and 77. It is preferable to set the amount of the hollow metal sphere 51 and the amount of the foamed resin material 53 to be introduced into the bag body 70 through experiments, simulations, or the like.

この粒状の中空金属球５１及び発泡樹脂素材５３を収容した袋体７０を、図１３に作業状態を示すように、連結部２０Ａの内部空間に連結部対応部分７１が嵌合すると共に、フロントピラー対応部分７２がフロントピラー２０の上部範囲２０ａ内に嵌装し、サイドレール対応部分７３がサイドレール２５の前部範囲２５ａ内に嵌装し、かつフロントレール対応部分７４がフロントレール３０の側端範囲３０ａ内に嵌装させて設置する。これにより袋体７０を介して連結部２０Ａの内部空間が粒状の中空金属球５１で充填され、フロントピラー対応部分７２内等に発泡樹脂素材５３が貯留される。 The bag 70 containing the granular hollow metal sphere 51 and the foamed resin material 53 is fitted with the connecting portion corresponding portion 71 in the internal space of the connecting portion 20A and the front pillar as shown in FIG. The corresponding portion 72 is fitted in the upper range 20 a of the front pillar 20, the side rail corresponding portion 73 is fitted in the front range 25 a of the side rail 25, and the front rail corresponding portion 74 is a side end of the front rail 30. Installed in the range 30a. As a result, the internal space of the connecting portion 20A is filled with the granular hollow metal sphere 51 via the bag body 70, and the foamed resin material 53 is stored in the front pillar corresponding portion 72 or the like.

しかる後、組み立てられた車体１は塗装工程に搬送される。車体の組み立てや搬送工程において、中空金属球５１及び発泡樹脂素材５３を収容した袋体７０は、連結部２０Ａ及びフロントピラー２０の上部範囲２０ａ、サイドレール２５の前部範囲２５ａ、フロントレール３０の側端範囲３０ａにそれぞれ連結部対応部分７１、フロントピラー対応部分７２、サイドレール対応部分７３、フロントレール対応部分７４が嵌合保持され、所期位置に安定した状態で維持される。 Thereafter, the assembled vehicle body 1 is conveyed to a painting process. In the assembly and transporting process of the vehicle body, the bag body 70 containing the hollow metal sphere 51 and the foamed resin material 53 includes the connecting portion 20A and the upper range 20a of the front pillar 20, the front range 25a of the side rail 25, and the front rail 30. The connecting portion corresponding portion 71, the front pillar corresponding portion 72, the side rail corresponding portion 73, and the front rail corresponding portion 74 are fitted and held in the side end range 30a, respectively, and are maintained in a stable state at the intended positions.

塗装工程に搬送された車体が塗装され、塗装乾燥工程において加熱乾燥される。この塗装乾燥工程における熱源により袋体７０の主にフロントピラー対応部分７２に収容された発泡樹脂素材５３を加熱発泡させる。 The vehicle body transported to the painting process is painted and dried by heating in the painting drying process. The foamed resin material 53 accommodated mainly in the front pillar-corresponding portion 72 of the bag body 70 is heated and foamed by a heat source in the paint drying process.

この発泡樹脂素材５３の発泡膨張により、袋体７０のフロントピラー２０に保持されたフロントピラー対応部７２内が発泡した発泡樹脂材５２で満たされ、更に流動性を有する未硬化状態の発泡樹脂材５２が中空金属移動規制部材７５を通過して、連結部２０Ａ内に保持された連結部対応部分７１内に誘導され、連結部対応部分７１内に充填された各中空金属球５１間及び中空金属球５２と袋体７０の連結部対応部分７１の内面との間の隙間に侵入して袋体７０を介在して連結部２０Ａ内が粒状の中空金属球５１と未硬化状態の発泡樹脂材５２によって充填される。 Due to the foaming expansion of the foamed resin material 53, the inside of the front pillar corresponding portion 72 held by the front pillar 20 of the bag body 70 is filled with the foamed foamed resin material 52, and further, the uncured foamed resin material having fluidity. 52 passes through the hollow metal movement restricting member 75, is guided into the connecting portion corresponding portion 71 held in the connecting portion 20A, and is filled between the hollow metal balls 51 and the hollow metal filled in the connecting portion corresponding portion 71. The hollow metal sphere 51 in which the inside of the connecting portion 20A enters the gap between the sphere 52 and the inner surface of the connecting portion corresponding portion 71 of the bag body 70 and the bag body 70 is interposed, and the foamed resin material 52 in an uncured state. Filled by.

更に、連続する発泡樹脂材５２の発泡膨張に伴って、連結部対応部分７１内の充填に続いて未硬化状態の発泡樹脂材５２が連結部対応部分７１から中空金属移動規制部材７６を通過してサイドレール２５内に保持されたサイドレール対応部分７２内に侵入して袋体７０を介在してサイドレール２５の前部範囲２５ａ内が未硬化状態の発泡樹脂材５２によって充填される。同様に、未硬化状態の発泡樹脂材５２が連結部対応部分７１から中空金属移動規制部材７７を通過してフロントレール３０内に保持されたフロントレール対応部分７４内に侵入して袋体７０を介在してフロントレール３０の側端範囲３０ａ内が未硬化状態の発泡樹脂材５２によって充填される。 Further, as the continuous foamed resin material 52 expands and expands, the uncured foamed resin material 52 passes through the hollow metal movement regulating member 76 from the connecting portion corresponding portion 71 following the filling in the connecting portion corresponding portion 71. Then, it penetrates into the side rail corresponding portion 72 held in the side rail 25 and the inside of the front range 25a of the side rail 25 is filled with the uncured foamed resin material 52 with the bag 70 interposed therebetween. Similarly, the uncured foamed resin material 52 passes through the hollow metal movement restricting member 77 from the connection portion corresponding portion 71 and enters the front rail corresponding portion 74 held in the front rail 30 to thereby remove the bag body 70. The side end range 30a of the front rail 30 is filled with an uncured foamed resin material 52.

この袋体７０内の発泡樹脂材５２の発泡膨張によって、袋体７０の連結部対応部分７１がフロントピラー２０の上端、サイドレール２５の前端、フロントレール３０の側端によって形成された連結部２０Ａの内面に倣って押圧されて密着して連結部対応部分７１が加熱されて溶解し、連結部２０Ａの内部空間が多数の中空金属球５１及び発泡樹脂材５２からなるブロック状の充填部材６１によって充填され、しかる後発泡樹脂材５２が硬化する。 Due to the expansion of the foamed resin material 52 in the bag body 70, the connecting portion corresponding portion 71 of the bag body 70 is formed by the upper end of the front pillar 20, the front end of the side rail 25, and the side end of the front rail 30. The connecting portion corresponding portion 71 is heated and melted by being pressed in close contact with the inner surface of the inner portion of the connecting portion 20A, and the inner space of the connecting portion 20A is formed by a block-shaped filling member 61 composed of a number of hollow metal spheres 51 and a foamed resin material 52. After filling, the foamed resin material 52 is cured.

同様に、フロントピラー対応部分７２がフロントピラー２０の上部範囲２０ａの内面に倣って押圧されて密着してフロントピラー対応部分７２が加熱されて溶解しフロントピラー２０の上部範囲２０ａの内部空間が発泡樹脂材５２からなるブロック状の第２充填部材６２によって充填されて硬化し、サイドレール対応部分７３がサイドレール２５の前部範囲２５ａの内面に倣って押圧されて密着してサイドレール対応部分７３が加熱されて溶解しサイドレール２５の前部範囲２５ａの内部空間が発泡樹脂材５２からなるブロック状の第２充填部材６３によって充填されて硬化し、フロントレール対応部分７４がフロントレール３０の側端範囲３０ａの内面に倣って押圧されて密着してフロントレール対応部分７４が溶解してフロントレール３０の側端部範囲３０ａの内部空間が発泡樹脂材５２からなるブロック状の第２充填部材６４によって充填されて硬化する。これらセンタピラー２０の上部範囲２０ａ内に充填される第２充填部材６２と、サイドレール２５の前部範囲２５ａ内に充填される第２充填部材６３と、フロントレール３０の側端範囲３０ａ内に充填される第２充填部材６４は、連結部２０Ａ内に充填される第１充填部材６１を介してそれぞれ一体形成されて充填部材６０となる。 Similarly, the front pillar corresponding portion 72 is pressed along the inner surface of the upper range 20a of the front pillar 20 to be in close contact with the front pillar corresponding portion 72, and the front pillar corresponding portion 72 is heated and melted to foam the internal space of the upper range 20a of the front pillar 20. Filled and cured by the block-shaped second filling member 62 made of the resin material 52, the side rail corresponding portion 73 is pressed and closely adhered to the inner surface of the front range 25a of the side rail 25, and the side rail corresponding portion 73 is pressed. Is heated and melted, and the internal space of the front range 25a of the side rail 25 is filled and cured by the block-shaped second filling member 63 made of the foamed resin material 52, and the front rail corresponding portion 74 is located on the front rail 30 side. The front rail corresponding portion 74 is melted by being pressed in close contact with the inner surface of the end range 30a, and the front rail 3 is melted. The internal space of the side end portion ranges 30a is cured is filled with the second filler member 64 block-shaped made of foamed resin material 52. The second filling member 62 filled in the upper range 20 a of the center pillar 20, the second filling member 63 filled in the front range 25 a of the side rail 25, and the side end range 30 a of the front rail 30. The second filling member 64 to be filled is integrally formed via the first filling member 61 filled in the connecting portion 20 A to become the filling member 60.

ここで、発泡樹脂素材５３の発泡膨張に必要な温度では袋体５５が溶解することなく、発泡過程において発泡する発泡樹脂材５２の形状が袋体５５の連結部対応部分７１によって保持されて連結部２０Ａ内の形状に倣った形状の第１充填部材６１が確保できる。同様にフロントピラー対応部分７２、サイドレール対応部分７３、フロントレール対応部分７４にそれぞれ保持されてフロントピラー２０の上部範囲２０ａ、サイドレール２５の前部範囲２５ａ、フロントレール３０の側端範囲３０ａ内の形状に倣った形状の第２充填部材６２、６３、６４が確保できる。 Here, at the temperature necessary for the foaming expansion of the foamed resin material 53, the shape of the foamed resin material 52 that foams in the foaming process is held by the connecting portion corresponding portion 71 of the bag body 55 without being melted. The first filling member 61 having a shape following the shape in the portion 20A can be secured. Similarly, it is held by the front pillar corresponding portion 72, the side rail corresponding portion 73, and the front rail corresponding portion 74, respectively, and is within the upper range 20a of the front pillar 20, the front range 25a of the side rail 25, and the side end range 30a of the front rail 30. The second filling members 62, 63, 64 having a shape following the shape of the above can be secured.

これにより、図１０に示すように、比較的大きな剛性が要求される複雑な形状のフロントピラー２０とサイドレール２５とフロントレール３０との連結部２０Ａ内に比較的剛性の高い中空金属球５１が充填され、かつ各中空金属球５１間及び中空金属球５１と連結部２０Ａの内面との間に発泡樹脂材５２によって形成され第１充填部材６１によって充填され、連結部２０Ａの断面変形が抑制されて比較的大きな剛性が確保される。これによりフロントピラー２０とサイドレール２５とフロントレール３０の結合部の剛性が向上する。また、連結部２０Ａにおける遮音及び振動抑制得られる。 As a result, as shown in FIG. 10, the hollow metal sphere 51 having a relatively high rigidity is formed in the connecting portion 20 A of the front pillar 20, the side rail 25, and the front rail 30 having a complicated shape that requires a relatively large rigidity. Filled and formed between the hollow metal spheres 51 and between the hollow metal spheres 51 and the inner surface of the connecting portion 20A and filled with the foamed resin material 52, and filled with the first filling member 61, the cross-sectional deformation of the connecting portion 20A is suppressed. Relatively large rigidity is ensured. Thereby, the rigidity of the joint part of the front pillar 20, the side rail 25, and the front rail 30 is improved. Further, sound insulation and vibration suppression at the connecting portion 20A can be obtained.

一方、比較的遮音及び振動抑制が要求されるフロントピラー２０の上部範囲２０ａ、サイドレール２５の前部範囲２５ａ、フロントレール３０の側端範囲３０ａ内に、遮音性及び制振機能に優れた発泡樹脂材５１からなる第２充填部材６２、６３、６４を充填することで、フロントピラー２０の上部範囲２０ａ、サイドレール２５の前部範囲２５ａ、フロントレール３０の側端範囲３０ａの断面変形が抑制されて剛性が確保されると共に、該部における遮音及び振動抑制が得られる。 On the other hand, foam having excellent sound insulation and vibration control functions is provided in the upper range 20a of the front pillar 20, the front range 25a of the side rail 25, and the side end range 30a of the front rail 30 that require relatively sound insulation and vibration suppression. By filling the second filling members 62, 63, 64 made of the resin material 51, cross-sectional deformation of the upper range 20 a of the front pillar 20, the front range 25 a of the side rail 25, and the side end range 30 a of the front rail 30 is suppressed. Thus, rigidity is ensured, and sound insulation and vibration suppression are obtained in the portion.

これにより、フロントピラー２０に荷重が入力された際には、第２充填部材６２によって剛性が確保されたフロントピラー２０の上部範囲２０ａから中空金属球５１及び発泡樹脂材５２からなる第１充填部材６１によって比較的大きな剛性に補剛された連結部２０Ａに伝達され、連結部２０Ａの歪み乃至変形に伴って充填部材６０内の中空金属球５１が隣接する中空金属球５１に圧接及び摩擦により荷重吸収及び分散して連結部２０Ａ内の広い範囲に荷重分散すると共に連結部２０Ａから第２充填部材６３によって剛性が確保されたサイドレール２５及び第２充填物６４によって補剛されたフロントレール３０に効率的に荷重分散できる。 Thereby, when a load is input to the front pillar 20, the first filling member including the hollow metal sphere 51 and the foamed resin material 52 from the upper range 20 a of the front pillar 20 whose rigidity is secured by the second filling member 62. 61 is transmitted to the connecting portion 20A stiffened to a relatively large rigidity, and the hollow metal sphere 51 in the filling member 60 is loaded on the adjacent hollow metal sphere 51 by pressure contact and friction in accordance with distortion or deformation of the connecting portion 20A. The front rail 30 is stiffened by the second filling member 64 and the side rail 25 and the second filling member 64, which absorbs and disperses and distributes the load over a wide range in the connecting portion 20 A and secures rigidity from the connecting portion 20 A by the second filling member 63. The load can be distributed efficiently.

同様に、サイドレール２５に入力された荷重は、第２充填部材６３によって剛性が確保されたサイドレール２５の前部範囲２０ａから第１充填部材６１によって比較的大きな剛性に補剛された連結部２０Ａに伝達され、連結部２０Ａから第２充填部材６２によって剛性が確保されたフロントピラー２０及び第２充填部材６４によって補剛されたフロントレール３０に効率的に荷重分散できる。また、フロントレール３０に荷重が入力された荷重は、第２充填部材６４によって剛性が確保されたフロントレール３０の側端範囲３０ａから第１充填部材６１によって比較的大きな剛性に補剛された連結部２０Ａに伝達され、連結部２０Ａから第２充填部材６２によって剛性が確保されたフロントピラー２０及び第２充填物６３によって補剛されたサイドレール２５に効率的に荷重分散できる Similarly, the load input to the side rail 25 is a connecting portion stiffened to a relatively large rigidity by the first filling member 61 from the front range 20 a of the side rail 25 where the rigidity is secured by the second filling member 63. The load can be efficiently distributed to the front rail 20 transmitted to 20A and stiffened by the second filling member 64 and the front pillar 20 secured by the second filling member 62 from the connecting portion 20A. In addition, the load input to the front rail 30 is connected to a relatively large rigidity by the first filling member 61 from the side end range 30a of the front rail 30 where the rigidity is secured by the second filling member 64. The load can be efficiently distributed to the side rail 25 stiffened by the second pillar 63 and the front pillar 20 which is transmitted to the portion 20A and secured by the second filling member 62 from the connecting portion 20A.

従って、比較的剛性が要求される連結部２０Ａ内に嵌装可能な連結部対応部分７１、連結部対応部分７１から分岐して比較的遮音機能が要求されるフロントピラー２０の上部範囲２０ａ内、サイドレール２５の前部範囲２５ａ内、及びフロントレール３０の側端範囲３０ａ内にそれぞれ嵌装可能なフロントピラー対応部分７２、サイドレール対応部分７３、フロントレール対応部分７４を有し、連結部対応分７１と各フロントピラー対応部分７２、サイドレール対応部分７３、フロントレール対応部分７４を区画する中空金属移動規制部材７５、７６、７７を有する袋体７０を準備し、袋体７０の連結部対応部分７１に粒状の中空金属球５１を充填し、かつ袋体７０内に未発泡状態の発泡樹脂素材５３を収容する。この中空金属球５１及び発泡樹脂素材５３を収容した袋体７０を連結部２０Ａに連結部対応部分７１、フロントピラー２０の上部範囲２０ａにフロントピラー対応部分７２、サイドレール２５の前部範囲２５ａにサイドレール対応部分７３、フロントレール３０の側端範囲３０ａにフロントレール対応部分７４をそれぞれ嵌合して設置し、塗装乾燥工程の際の熱源、例えば乾燥熱で発泡樹脂素材５３を発泡膨張させることで、連結部２０Ａの内部空間が中空金属球５１及び発泡樹脂材５２からなる第１充填部材６１によって充填されて比較的高剛性が得られ、フロントピラー２０の上部範囲２０ａ、サイドレール２５の前部範囲２５ａ、フロントレール３０の側端範囲３０ａ内が発泡樹脂材５２からなる第２充填部材６２、６３、６４によって充填されて該部の遮音効果が得られる。 Accordingly, the connecting portion corresponding portion 71 that can be fitted into the connecting portion 20A that requires relatively rigidity, the upper portion 20a of the front pillar 20 that branches from the connecting portion corresponding portion 71 and that requires a relatively sound insulation function, It has a front pillar corresponding portion 72, a side rail corresponding portion 73, and a front rail corresponding portion 74 that can be fitted in the front range 25a of the side rail 25 and the side end range 30a of the front rail 30, respectively. And a bag body 70 having hollow metal movement restricting members 75, 76, 77 that define the minute portions 71, the front pillar corresponding portions 72, the side rail corresponding portions 73, and the front rail corresponding portions 74. Part 71 is filled with granular hollow metal sphere 51, and unfoamed foamed resin material 53 is accommodated in bag 70. The bag 70 containing the hollow metal sphere 51 and the foamed resin material 53 is connected to the connecting portion 20A to the connecting portion corresponding portion 71, to the upper range 20a of the front pillar 20 to the front pillar corresponding portion 72, and to the front range 25a of the side rail 25. The front rail corresponding portion 74 is fitted and installed in the side rail corresponding portion 73 and the side end range 30a of the front rail 30, and the foamed resin material 53 is expanded and expanded by a heat source in the paint drying process, for example, drying heat. Thus, the internal space of the connecting portion 20A is filled with the first filling member 61 made of the hollow metal sphere 51 and the foamed resin material 52 to obtain relatively high rigidity, and the upper range 20a of the front pillar 20 and the front of the side rail 25 are obtained. The second filling members 62, 63, 64 made of the foamed resin material 52 in the part range 25 a and the side end range 30 a of the front rail 30 The portion of the sound insulation is filled is obtained.

また、フロントピラー２０とサイドレール２５とフロントレール３０との連結部２０Ａ及びフロントピラー２０の上部範囲２０ａ、サイドレール２５の前部範囲２５ａ、フロントレール３０の側端範囲３０ａにおけるリンホース等の強部材等の削減や省略が可能になり、かつ充填材を保持するクリップや取付孔等の充填部材を装着する取付手段が不要であり構造構成部品の増加を招くことなく、車体構造の簡素化及び形状等の制限が緩和されると共に、中空金属球が軽量かつ安価であり、発泡樹脂材の必要量の低減と相俟って製造コスト及び質量の増加を招くことなく、効率的な剛性及び遮音効果が得られる。 Further, a strong member such as a phosphorus hose in the connecting portion 20A of the front pillar 20, the side rail 25 and the front rail 30 and the upper range 20a of the front pillar 20, the front range 25a of the side rail 25, and the side end range 30a of the front rail 30. Simplification and shape of the vehicle body structure without the need for mounting means for mounting fillers such as clips and mounting holes to hold the filler, and without increasing the number of structural components Etc., and the hollow metal sphere is lightweight and inexpensive, combined with a reduction in the required amount of foamed resin material, and without causing an increase in manufacturing cost and mass, efficient rigidity and sound insulation effect Is obtained.

なお、連結部１０Ａやフロントピラー２０、サイドレール２５、フロントレール３０等の要求剛性及び遮音機能に応じて、剛性の異なる種々の中空金属球５１に変更することも可能であり、また、剛性機能を目的とした高剛性タイプ及び遮音性を目的とした遮音タイプ等種々のタイプの発泡樹脂素材５３を適宜選択的に用いることができる。特に、連結部２０Ａの剛性及び遮音機能の要求に応じて剛性の異なる種々の中空金属球５１に変更することも可能であり、また、第１充填部材６１における中空金属球５１の充填によって連結部２０Ａの剛性が確保されることから、発泡樹脂材５２の選択範囲が緩和され、要望に応じた剛性機能を目的とした高剛性タイプ及び遮音性を目的とした遮音タイプ等種々の発泡樹脂素材５３を適宜選択的に用いることが可能になり所望の剛性向上と遮音効果の両立が容易に達成できる。 It is also possible to change to various hollow metal spheres 51 having different rigidity according to required rigidity and sound insulation function of the connecting portion 10A, the front pillar 20, the side rail 25, the front rail 30, and the like. Various types of foamed resin material 53 such as a high-rigidity type for the purpose and a sound insulation type for the purpose of sound insulation can be selectively used as appropriate. In particular, it is possible to change to various hollow metal spheres 51 having different rigidity according to the requirements of the rigidity of the connecting portion 20A and the sound insulation function, and the connecting portion by filling the hollow metal spheres 51 in the first filling member 61. Since the rigidity of 20A is ensured, the selection range of the foamed resin material 52 is relaxed, and various foamed resin materials 53 such as a high-rigidity type for the purpose of a rigid function and a sound insulation type for the purpose of sound insulation are provided. Can be selectively used as appropriate, and a desired improvement in rigidity and a sound insulation effect can be easily achieved.

なお、袋体７０を塗装乾燥工程における熱源で溶解する材料で構成したが、溶解することのない弾性変形可能な材料によって形成することもできる。 In addition, although the bag body 70 was comprised with the material melt | dissolved with the heat source in a coating drying process, it can also form with the material which can be elastically deformed which does not melt | dissolve.

また、上記実施の形態では、フロントピラー２０とサイドレール２５とフロントレール３０との連結部２０Ａを対象に説明したが、発泡樹脂素材５３及び中空金属球５１を充填した袋体７０の設置配意が制限されるこよなく、リヤピラとサイドレールとリヤレールとの連結部等の剛性及び遮音等が要求される他の中空断面構造に適用することができる。更に、中空金属球５１は、中空にして比重を軽減したものであれば、球形に限定されものではなく、立方体や多面体の球形に類似した形状でよく、鉄、炭素鋼、ステンレス鋼等鉄系金属や他の金属によって構成することができる。 In the above embodiment, the connecting portion 20A of the front pillar 20, the side rail 25, and the front rail 30 has been described. However, the installation care of the bag body 70 filled with the foamed resin material 53 and the hollow metal sphere 51 is described. However, the present invention can be applied to other hollow cross-sectional structures that require rigidity, sound insulation, and the like of the connecting portion between the rear pillar, the side rail, and the rear rail. Further, the hollow metal sphere 51 is not limited to a sphere as long as it is hollow and has a reduced specific gravity, and may have a shape similar to a cube or polyhedron sphere, such as iron, carbon steel, and stainless steel. It can be composed of metal or other metals.

１車体
１０Ａ連結部（補剛範囲）
１０サイドシル（中空断面構造）
１５センタピラー（中空断面構造）
２０Ａ連結部（第１補剛範囲）
２０フロントピラー（中空断面構造）
２０ａフロントピラーの上部範囲（第２補剛範囲）
２５サイドレール（中空断面構造）
２５ａサイドレールの前部範囲（第２補剛範囲）
３０フロントピラー（中空断面構造）
３０ａフロントレールの側端範囲（第２補剛範囲）
５０充填部材
５１中空金属球
５２発泡樹脂材
５３発泡樹脂素材
５５袋体
５６サイドシル対応部分
５７センタピラー対応部分
６０充填部材
６１第１充填部材
６２、６３、６４第２充填部材
７０袋体
７１連結部対応部分（中空金属球充填部）
７２フロントピラー対応部分（発泡樹脂材充填部）
７３サイドレール対応部分（発泡樹脂材充填部）
７４フロントレール対応部分（発泡樹脂材充填部）
７５、７６、７７中空金属移動規制部材 1 Car body 10A connecting part (stiffening range)
10 Side sill (hollow section structure)
15 Center pillar (hollow section structure)
20A connecting part (first stiffening range)
20 Front pillar (hollow section structure)
20a Upper range of the front pillar (second stiffening range)
25 Side rail (hollow section structure)
25a Front side range of side rail (second stiffening range)
30 Front pillar (hollow section structure)
30a Side end range of the front rail (second stiffening range)
50 Filling member 51 Hollow metal sphere 52 Foamed resin material 53 Foamed resin material 55 Bag body 56 Side sill corresponding portion 57 Center pillar corresponding portion 60 Filling member 61 First filling members 62, 63, 64 Second filling member 70 Bag body 71 Connecting portion Corresponding part (hollow metal sphere filling part)
72 Front pillar compatible part (Foamed resin material filling part)
73 Side rail compatible part (Foamed resin material filling part)
74 Front rail compatible part (Foamed resin filling part)
75, 76, 77 Hollow metal movement regulating member

Claims

中空閉断面構造の補剛範囲を発泡樹脂素材が発泡膨張した発泡樹脂材及び中空金属球の充填によって補剛する車体構造の製造方法であって、
未発泡状態の発泡樹脂素材を収容すると共に粒状の中空金属球を充填した袋体を前記中空閉断面構造の補剛範囲内に配置し、
該袋体内の前記発泡樹脂素材を発泡膨張させて前記補剛範囲内に充填する中空金属球と該中空金属球間の隙間を含む補剛範囲内に充填する発泡樹脂材とからなる充填部材で前記補剛範囲内を充填する、ことを特徴とする車体構造の製造方法。 A method for manufacturing a vehicle body structure in which a stiffening range of a hollow closed cross-sectional structure is stiffened by filling a foamed resin material in which a foamed resin material is expanded and hollow metal spheres,
A bag body containing a foamed resin material in an unfoamed state and filled with a granular hollow metal sphere is disposed within the stiffening range of the hollow closed cross-sectional structure,
A filling member comprising a hollow metal sphere that is expanded by foaming and expanding the foamed resin material in the bag body, and a foamed resin material that is filled in a stiffening range including a gap between the hollow metal spheres; A method for manufacturing a vehicle body structure characterized by filling the stiffening range.

中空閉断面構造の連続する第１補剛範囲及び第２補剛範囲をそれぞれ発泡樹脂素材が発泡した発泡樹脂材と中空金属球による第１充填部材の充填及び発泡樹脂素材が発泡した発泡樹脂材からなる第２充填部材の充填によって補剛する車体構造の製造方法であって、
前記中空金属球の通過を阻止すると共に流動性を有する未硬化状態の発泡樹脂材の通過を許容する中空金属規制部材によって前記第１補剛範囲内に装着可能な中空金属球充填部と第２補剛範囲内に装着可能な発泡樹脂材充填部とに区画した袋体を用い、
前記中空金属球充填部に粒状の中空金属球を充填すると共に未発泡状態の発泡樹脂素材を収容した前記袋体を、該中空金属球充填部を前記第１補剛範囲内に発泡樹脂材充填部を第２補剛範囲内に配置して中空閉断面構造に装着し、
該袋体内の前記発泡樹脂素材を発泡膨張させて前記第１補剛範囲内に充填する中空金属球と該中空金属球間の隙間を含む第１補剛範囲内に充填する発泡樹脂材とからなる第１充填部材で前記第１補剛範囲内を充填すると共に発泡樹脂材からなる第２充填部材で前記第２補剛範囲内を充填する、ことを特徴とする車体構造の製造方法。 A foamed resin material in which a foamed resin material is foamed and a foamed resin material in which a foamed resin material is foamed and filled with a hollow metal sphere in the first stiffening range and the second stiffening range of the hollow closed cross-section structure, respectively. A vehicle body structure manufacturing method for stiffening by filling a second filling member comprising:
A hollow metal sphere filling portion that can be mounted in the first stiffening range by a hollow metal regulating member that prevents passage of the hollow metal sphere and allows passage of an uncured foamed resin material having fluidity, and a second filling portion. Using a bag body partitioned into a foamed resin material filling part that can be mounted within the stiffening range,
Filling the hollow metal sphere filling portion with a granular hollow metal sphere and containing the foamed resin material in an unfoamed state, filling the hollow metal sphere filling portion with the foamed resin material within the first stiffening range Place the part in the second stiffening range and attach it to the hollow closed cross-section structure,
A hollow metal sphere that foams and expands the foamed resin material in the bag body to fill the first stiffening range, and a foamed resin material that fills the first stiffening range including a gap between the hollow metal spheres. A method for manufacturing a vehicle body structure comprising: filling the first stiffening range with the first filling member and filling the second stiffening range with a second filling member made of a foamed resin material.

前記発泡樹脂素材は、加熱発泡型であって、塗装乾燥工程における熱源により加熱発泡させることを特徴とする請求項１または２に記載の車体構造の製造方法。 The method for manufacturing a vehicle body structure according to claim 1 or 2, wherein the foamed resin material is a heat-foaming type and is heat-foamed by a heat source in a paint drying process.

前記袋体は、前記発泡樹脂素材の発泡膨張に必要な温度では溶解することのない弾性変形可能な材料製であることを特徴とする請求項１〜３のいずれか１項に記載の車体構造の製造方法。 The vehicle body structure according to any one of claims 1 to 3, wherein the bag body is made of an elastically deformable material that does not melt at a temperature necessary for foaming expansion of the foamed resin material. Manufacturing method.