JP4351383B2 - Manufacturing method for vehicle body components - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a technique for improving a method for manufacturing a vehicle body component such as a hard top.
[0002]
[Prior art]
Due to the diversification of the appearance of vehicles, a technique for showing streaks on the surface has been developed, and one of them is a technique for showing the lines of reinforcing fiber sheets. This technique will be described below.
[0003]
FIGS. 13A to 13C are explanatory diagrams of the structure of a conventional hardtop.
(A) shows the vehicle 102 provided with the hardtop 101 which can be removed.
(B) shows the hardtop 101 in a removed state, and an enlarged view of part c of FIG.
[0004]
(C) is an enlarged view of part c of (b), the hard top 101 is surface-finished with reinforcing fiber sheets 103 and 104, and the thread 105 (... indicates a plurality. The same applies hereinafter). It is intended to enhance the appearance design by showing.
[0005]
[Problems to be solved by the invention]
As shown in (c) above, in the splicing portion 107, a deviation occurs between the yarn stitches 105 of the reinforcing fiber sheet 103 and the yarn stitches 105 of the reinforcing fiber sheet 104, and this deviation is caused by the overall undulation at the end portion. This undulation may impair the overall design.
[0006]
SUMMARY OF THE INVENTION An object of the present invention is to provide a manufacturing technique that does not cause a waviness that impairs the design of a joint portion in a vehicle component having a type that shows a thread.
[0007]
[Means for Solving the Problems]
In order to achieve the above object, the present invention provides a method for manufacturing a vehicle body component covered with a reinforcing fiber sheet in which a thread can be seen. This method includes a step of forming a positioning hole in the reinforcing fiber sheet, and a positioning recess in the core material in advance. A step of forming a reinforcing fiber sheet in the positioning recess of the core material with a core, a step of covering the core material with the reinforcing fiber sheet while positioning with the core, and the core and the reinforcing fiber sheet. And a step of collectively setting the core material into a mold, a step of injecting lysine into the mold and impregnating the reinforcing fiber sheet, and affixing to the core material, and a step of removing the core after demolding It is characterized by that.
[0008]
By determining the position of the reinforcing fiber sheet with the core, occurrence of misalignment of the stitches at the seam is prevented.
Since molding and impregnation with lysine are performed with the core fitted, there is no concern that lysine will flow into the positioning recess of the core material, and this positioning recess can be reused as a stop for the fitting part.
[0009]
According to a second aspect of the present invention, the concave portion formed in the core material is constituted by an insert part embedded at the time of molding the core material. In other words, the core material needs to be molded in advance with a molding die, but if the insert part is integrally molded at the time of molding, the concave part is formed and the strength required as a stop part for the subsequent outfitting part is obtained. Can be made.
[0010]
Claim 3 is a method of manufacturing a vehicle body component covered with a reinforcing fiber sheet in which the thread line is visible, which includes a step of forming a positioning hole in the reinforcing fiber sheet, a step of forming a positioning recess in the core material in advance, and a core The step of stopping the positioning hole of the reinforcing fiber sheet in the positioning recess of the material with the insert part, the step of covering the core material with the reinforcing fiber sheet while positioning with the insert part, and the insert part, the reinforcing fiber sheet, and the core material together A step of setting in a mold, injecting lysine into this mold to integrate the insert part into the core material, and affixing the reinforcing fiber sheet to the core material while being impregnated, and a demolding step. Features.
[0011]
By determining the position of the reinforcing fiber sheet with the insert part, occurrence of misalignment of the yarn at the seam is prevented.
By using the insert part used for attaching the fitting later as the positioning member of the reinforcing fiber sheet, the occurrence of the yarn misalignment at the joining portion is prevented.
[0012]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below with reference to the accompanying drawings. The vehicle body components include a hard top, a door, a sunroof, a bonnet, and the like, and the hard top will be described below as a specific example.
[0013]
FIG. 1 is a perspective view of a hardtop according to the present invention, and the hardtop 10 is a typical vehicle body component with the outer surface facing outward, and the cross-sectional structure of the side edge 11 of the hardtop 10 will be described in the following figure. To do.
FIG. 2 is a cross-sectional view taken along line 2-2 of FIG. 1, and the side edge portion 11 of the hard top 10 has reinforcing fiber sheets 15 on both sides of a solid foam core material 14 in which an insert part 12 is integrally formed in advance. , 16 and the ends of the reinforcing fiber sheets 15 and 16 are overlapped at the joining portion 17 and then impregnated with lysine. Carbon fibers, glass fibers, and resin fibers can be used as the fibers constituting the reinforcing fiber sheets 15 and 16.
In addition, lysine uses a transparent thermosetting resin from the viewpoint of showing the texture of the reinforcing fiber sheet.
[0014]
A method of manufacturing the hardtop having the above structure will be described next.
FIG. 3 is an explanatory diagram of a process of making positioning holes in the reinforcing fiber sheet according to the present invention, and a necessary number of positioning holes 18 are formed in the reinforcing fiber sheet 15 cut into a predetermined shape. Of course, it is not hindered to provide holes other than the positioning holes 18 and notches.
[0015]
4 (a) and 4 (b) are explanatory views of a process of forming a positioning recess in advance in the core material according to the present invention.
In (a), what inserts the pin part 23a of the 1st core 23 in the insert part 12 which consists of the collar part 21 and the nut part 22 as a positioning recessed part is preset to the predetermined location of the cavity 24 of the core shaping | molding die 19. FIG. Then, a resin 27 is injected into the cavity 24 by a pump 26 from a tank 25 containing a raw material such as urethane. When the resin 27 is hardened, the mold is released.
[0016]
(B) shows the foam core material 14 after demolding, and shows that the insert part 12 can be integrally formed. Then, the used first core 23 is removed.
Thus, it is possible to obtain the core material 14 integrally provided with the positioning recess (nut portion 22).
[0017]
FIG. 5 is an explanatory view of the process of stopping the positioning hole of the reinforcing fiber sheet with the core in the positioning recess of the core material according to the present invention, and positioning the reinforcing fiber sheet 15 on the insert part 12 integrally formed with the foam core material 14. The pin 18 of the second core 28 is communicated with the positioning hole 18 and the nut portion 22 of the insert part 12 so that the positioning hole 18 is positioned in the nut portion 22 as a positioning recess. .
[0018]
FIG. 6 is an explanatory view of the process of covering the core material with the reinforcing fiber sheet while positioning with the core according to the present invention. The foam core is formed by pulling the reinforcing fiber sheet 15 to the right while positioning with the second core 28. It is attached to the upper surface of the material 14. Then, the reinforcing fiber sheet 16 is attached to the lower surface of the foam core material 14, and the end of the reinforcing fiber sheet 16 is overlapped with the reinforcing fiber sheet 15 as shown by the arrow (1). It is still desirable to bond the sheet 16 to the sheet 15 with an appropriate adhesive at the time of the arrow (1).
[0019]
What is important here is that since the reinforcing fiber sheet 15 is positioned by the second core 28, the yarns of the reinforcing fiber sheet 16 can be accurately and easily aligned with the yarns of the reinforcing fiber sheet 15. .
[0020]
FIG. 7 is an explanatory view of the step of collectively setting the core, the reinforcing fiber sheet and the core material according to the present invention and the step of impregnating lysine, and the impregnation die 31 includes the second core 28 and the reinforcement. The fiber sheets 15 and 16 and the foam core material 14 (including the nut portion 22 and the like) are collectively stored.
[0021]
Next, lysine in the lysine container 32 is injected into the impregnation mold 31 by the pump 33. The lysine is impregnated in the gaps between the reinforcing fiber sheets 15 and 16 and hardened, and also serves as an adhesive for attaching the reinforcing fiber sheets 15 and 16 to the foam core material 14.
At this time, there is no possibility that lysine will enter the nut portion 22 due to the closing action of the pin portion 29. When the lysine is sufficiently hardened, the impregnation die 31 is disassembled (separated) and the used second core 28 is removed.
This completes the manufacture of the hardtop 10 shown in FIG.
[0022]
If the main part of the above Example is put together, the process of forming a positioning hole in a reinforcing fiber sheet, the process of forming a positioning recess in the core material in advance, and the positioning hole of the reinforcing fiber sheet in the positioning recess of the core material with a core A step of stopping, a step of covering the core material with the reinforcing fiber sheet while positioning with the core, a step of collectively setting the core, the reinforcing fiber sheet and the core material into the mold, and injecting lysine into the mold Thus, the present invention can provide a method of manufacturing a vehicle body component comprising a step of impregnating a reinforcing fiber sheet and attaching the reinforcing fiber sheet to a core material, and a step of removing the core after demolding.
[0023]
FIG. 8 is an explanatory view of attaching a fitting component to the hardtop manufactured by the method of the present invention. In the side edge portion 11 of the hardtop 10, a positioning hole 18 is opened in the reinforcing fiber sheet 15 as a skin, At the back of the positioning hole 18 is a flange 21 and a nut portion 22.
Therefore, by screwing the screw 35 into the nut portion 22, the weather strip stopper 36 can be fixed to the insert part 12, and the weather strip 37 as a fitting part can be fixed to the weather strip stopper 36. .
[0024]
Although an external force acts on the weather strip 37, since the insert part 12 is integrally formed with the foam core material 14, high strength can be expected. Therefore, there is no worry that the hard top 10 is damaged.
[0025]
Next, another embodiment of FIGS. 4 to 7 will be described with reference to FIGS. In addition, the code | symbol is diverted for the element which is common in FIGS.
FIGS. 9A and 9B are explanatory views of another embodiment of the step of forming the positioning recess in advance in the core material according to the present invention.
In (a), the third core 39 provided with the cylindrical pin 38 is preset at a predetermined position of the cavity 24 of the core mold 19. Then, a resin 27 is injected into the cavity 24 by a pump 26 from a tank 25 containing a raw material such as urethane. When the resin 27 is hardened, the mold is released.
[0026]
(B) shows the foam core material 14 after demolding, and shows that the positioning recess 41 can be simultaneously formed in the foam core material 14 by removing the third core 39.
[0027]
FIG. 10 is an explanatory view of the process of stopping the positioning hole of the reinforcing fiber sheet with the insert part in the positioning recess of the core material according to the present invention. The positioning hole 18 of the reinforcing fiber sheet 15 is made to face the foam core material 14. The positioning hole 18 is positioned in the positioning recess 41 by communicating the nut portion 22 of the insert part 12 with the positioning hole 18 and the positioning recess 41.
If the barb 22a protruding radially outward is provided in the nut portion 22, the barb 22a will not bite into the foam core material 14 and the insert part 12 will not float later (see FIG. 11).
[0028]
FIG. 11 is an explanatory view of a process of covering the core material with the reinforcing fiber sheet while positioning with the insert component according to the present invention. When the end portion of the reinforcing fiber sheet 16 is overlapped with the reinforcing fiber sheet 15 positioned with the insert component 12. The reinforcing fiber sheets 15 and 16 are placed on the core material 14. And the 4th core 42 is attached to the foam core material 14 so that the pin part 43 of the 4th core 42 may be inserted in the insert component 12. FIG.
[0029]
What is important here is that the reinforcing fiber sheet 15 is positioned by the insert part 12, so that the yarns of the reinforcing fiber sheet 16 can be accurately and easily aligned with the yarns of the reinforcing fiber sheet 15.
[0030]
FIG. 12 is an explanatory diagram of the process of setting the insert part, the reinforcing fiber sheet and the core material according to the present invention into a mold and the process of impregnating lysine. The impregnation mold 31 includes a fourth core 42 and a reinforcement. The fiber sheets 15 and 16 and the foam core material 14 (including the nut portion 22 and the like) are collectively stored.
[0031]
Next, lysine in the lysine container 32 is injected into the impregnation mold 31 by the pump 33. Lysine impregnates the gap between the nut part 22 of the insert part and the preform material 14 to integrate them, and impregnates the gap between the reinforcing fiber sheets 15 and 16, and the reinforcing fiber sheets 15 and 16 are put into the foam core material 14. It plays a role as an adhesive.
[0032]
In the figure, the ridge 21 of the insert part appears to protrude from the reinforcing fiber sheet 15, but the action of the barb 22a can prevent the insert part 12 from being pulled out and lifted. As a result, the insert part 12 and the fourth middle Appropriate clearance can be secured between the child 42 and lysine is allowed to flow through this clearance, whereby the insert part 12 is buried in the lysine together with the reinforcing fiber sheets 15 and 16. As a result, there is no possibility of flooding into the preform material 14 from the outside due to the waterproof action of lysine.
[0033]
On the other hand, there is no possibility that lysine will enter the nut portion 22 due to the closing operation of the pin portion 43 of the fourth core 42. When the lysine is sufficiently hardened, the impregnation mold 31 may be disassembled (separated) and the used fourth core 42 may be removed.
This completes the manufacture of the hardtop 10 shown in FIG.
[0034]
3 and FIGS. 9 to 12 are summarized as follows: a step of forming a positioning hole in the reinforcing fiber sheet, a step of forming a positioning recess in the core material in advance, and a step of forming the reinforcing fiber sheet in the positioning recess of the core material. A step of stopping the positioning hole with the insert component, a step of covering the core material with the reinforcing fiber sheet while positioning with the insert component, a step of collectively setting the insert component, the reinforcing fiber sheet and the core material in the mold, The present invention provides a method of manufacturing a vehicle body component comprising a step of injecting lysine into a mold to integrate an insert part into a core material and affixing the reinforcing fiber sheet to the core material while being impregnated, and a demolding step can do.
[0035]
By this method, the position of the reinforcing fiber sheet is determined by the insert part, thereby preventing the occurrence of yarn misalignment at the seam.
By using the insert part used for attaching the fitting later as the positioning member of the reinforcing fiber sheet, the occurrence of the yarn misalignment at the joining portion is prevented.
In addition, the insert part can be covered with lysine together with the reinforcing fiber sheet, and the waterproof action of the lysine can effectively prevent water from entering the foam core material from the outside. Since flooding can be prevented, deterioration and weight increase of the foam core material can be prevented in advance.
[0036]
In the first and third aspects, the step of forming the positioning hole in the reinforcing fiber sheet and the step of forming the positioning recess in the core material in advance may be performed in reverse order or simultaneously. Moreover, if a core is a shape corresponding to a positioning recessed part, a shape is arbitrary.
[0037]
In claim 2, which is a dependent claim of claim 1, the insert part is integrally formed with the foam core material (see FIG. 4). In this case, since the insert part is firmly bonded to the foam core material, a high-load type outfitting part (such as a lock part for locking the hard cover to the vehicle body) can be attached to such an insert part.
Further, in claim 3, the insert part is bonded to the foam core material with lysine (see FIGS. 11 and 12). In this case, since the insert component is slightly weakly bonded to the foam core material, a low-load type outfitting component may be attached to such an insert component.
[0038]
As described above, the vehicle body component has been described by taking the hard top as an example. However, the vehicle body component may be a door, a sunroof, a bonnet, or the like, and there is no particular limitation on the type or shape.
[0039]
Also, the outfitting parts are not limited to weather strips, and any type or shape can be used as long as they are interior parts and attachments (including parts) of a vehicle.
[0040]
【The invention's effect】
The present invention exhibits the following effects by the above configuration.
According to the manufacturing method of claim 1, by determining the position of the reinforcing fiber sheet with the core, it is possible to prevent waviness of the entire design surface and the like from occurring in the seam shift prevention arrangement of the end portions in the joint portion. The appearance of the component can be easily improved.
In addition, since the molding and lysine impregnation are carried out with the core fitted, there is no concern that lysine will flow into the positioning recess of the core material, and this positioning recess can be reused as a stop for the fitting part. .
[0041]
The manufacturing method of claim 2 is characterized in that the recess formed in the core material is constituted by an insert part embedded at the time of molding the core material. In other words, the core material needs to be molded in advance with a molding die, but if the insert part is integrally molded at the time of molding, the concave part is formed and the strength required as a stop part for the subsequent outfitting part is obtained. Can be made.
[0042]
In the manufacturing method according to the third aspect, the position of the reinforcing fiber sheet is determined by the insert part, thereby preventing the occurrence of the yarn misalignment at the joint portion.
By using the insert part used for attaching the fitting later as the positioning member of the reinforcing fiber sheet, the occurrence of the yarn misalignment at the joining portion is prevented.
In addition, the insert component can be covered with lysine together with the reinforcing fiber sheet, and the waterproof action of the lysine can effectively prevent water from entering the foam core material from the outside. Since flooding can be prevented, deterioration and weight increase of the foam core material can be prevented in advance.
[Brief description of the drawings]
FIG. 1 is a perspective view of a hardtop according to the present invention. FIG. 2 is a sectional view taken along line 2-2 of FIG. 1. FIG. 3 is an explanatory diagram of a process of making a positioning hole in a reinforcing fiber sheet according to the present invention. FIG. 5 is an explanatory diagram of a process of forming a positioning recess in the core material in advance according to the present invention. FIG. 5 is an explanatory diagram of a process of stopping the positioning hole of the reinforcing fiber sheet with a core in the positioning recess of the core material according to the present invention. Explanatory drawing of the process which covers a reinforcing fiber sheet on a core material, positioning with the core which concerns on this invention. FIG. 7 The process of setting a core, a reinforcing fiber sheet, and a core material which concern on this invention to a type | mold collectively, and a lysine FIG. 8 is an explanatory view of attaching a fitting part to a hardtop manufactured by the method of the present invention. FIG. 9 is an explanatory view of another embodiment of a step of forming a positioning recess in advance in the core material according to the present invention. FIG. 10 shows the positioning of the core material according to the present invention. FIG. 11 is an explanatory diagram of a process of fixing a reinforcing fiber sheet positioning hole to the core portion with an insert part. FIG. 11 is an explanatory diagram of a process of covering the core material with the reinforcing fiber sheet while positioning with the insert part according to the present invention. Explanatory drawing of the process of setting the insert part, the reinforcing fiber sheet and the core material together into the mold and the impregnation process of lysine. FIG. 13 is a structural explanatory diagram of a conventional hardtop.
DESCRIPTION OF SYMBOLS 10 ... Car body component (hard top), 12 ... Insert part, 14 ... Core material (foam core material), 15, 16 ... Reinforcement fiber sheet, 18 ... Positioning hole, 19 ... Core molding die, 22 ... Positioning recessed part Nuts 28, core used for positioning, 31 impregnation mold, 41 positioning recess.

Claims (3)

In a method for manufacturing a vehicle body component covered with a reinforcing fiber sheet with visible thread lines, this method includes a step of forming a positioning hole in the reinforcing fiber sheet, a step of forming a positioning recess in the core material in advance, and a positioning recess of the core material. The step of stopping the positioning hole of the reinforcing fiber sheet with the core, the step of covering the core material with the reinforcing fiber sheet while positioning with the core, and the core, the reinforcing fiber sheet and the core material are collectively set in the mold A method of manufacturing a vehicle body component comprising: a step, a step of injecting lysine into the mold to impregnate a reinforcing fiber sheet and affixing to a core material; and a step of removing the core after demolding . 2. The method of manufacturing a vehicle body component according to claim 1, wherein the recess formed in the core material is formed of an insert part embedded at the time of molding the core material. In a method for manufacturing a vehicle body component covered with a reinforcing fiber sheet with visible thread lines, this method includes a step of forming a positioning hole in the reinforcing fiber sheet, a step of forming a positioning recess in the core material in advance, and a positioning recess of the core material. The step of stopping the positioning hole of the reinforcing fiber sheet with the insert part, the step of covering the core material with the reinforcing fiber sheet while positioning with the insert part, and the insert part, the reinforcing fiber sheet and the core material are collectively set in the mold A vehicle body structure comprising: a step, a step of injecting lysine into the mold to integrate the insert part into the core material and affixing the reinforcing fiber sheet to the core material while being impregnated, and a demolding step A manufacturing method for parts.

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