JP5962899B2 - Manufacturing method of body frame - Google Patents

Description

  The present invention relates to a method for manufacturing a vehicle body frame provided under a vehicle floor.

  Since the body frame provided under the floor of a vehicle such as an automobile forms a skeleton of the vehicle, it is necessary to ensure a sufficiently high strength. Conventionally, for example, the strength of the body frame has been increased by joining a reinforcing member to a predetermined position of the body frame by spot welding or the like. Although this can improve the strength of the body frame, there is a problem that the weight of the vehicle increases.

  Further, in order to suppress deformation of the body frame, there is one in which a closed cross-sectional space between an outer panel constituting the body frame and a reinforcing member disposed inside the outer panel is filled with a foamed resin material (for example, , See Patent Documents 1 and 2).

  By filling the inside of the body frame with the foam filler (foamed resin material) in this way, deformation of the body frame can be suppressed.

Japanese Patent No. 3525890 JP 2009-120161 A

  By the way, inside the foaming filler (filling member) obtained by foaming the filler, there may be a large number of holes due to foaming, which may absorb moisture. A body frame made of a metal material may be gradually corroded by moisture absorbed by the filling member. For this reason, it is preferable that the contact surface of the body frame with the filling member is preliminarily subjected to rust prevention treatment, for example, painting.

  Applying rust prevention treatment to each part of the body frame is inefficient in work efficiency and increases the manufacturing cost. For this reason, for example, electrodeposition coating as an antirust treatment may be performed on the inner surface of the body frame or the like in a state where the filler or the base material is disposed in the body frame.

  Here, when electrodeposition coating is applied to the body frame, it is necessary to form a gap necessary for the electrodeposition coating to adhere between the filler and the body frame. After electrodeposition coating, this gap is filled by foaming the filler. For this reason, there exists a problem that the usage-amount of a filler will increase by that much when a clearance gap is wide.

  The present invention has been made in view of such circumstances, and an object of the present invention is to provide a method of manufacturing a vehicle body frame that can suppress the amount of filler used and can suppress corrosion of the vehicle body frame.

According to a first aspect of the present invention for solving the above-described problems, a plurality of U-shaped frame members are arranged below a vehicle floor, and the substrate is interposed between the substrate and the frame member. the reinforcing member constituted by the filling member made of filled foamed filler, a manufacturing method of a body frame provided in the frame member, the distance between the frame member and the filler unfoamed at least In one direction, the unfoamed filling is performed so that the proximity portion gradually increases from the closest portion of the gap toward the outside of the unfoamed filler, and the proximity portion faces the corner of the frame member. A base material to which a material is fixed is fixed to the frame member, and in this state, electrodeposition coating of the frame member is performed, and then the filler is foamed to form a space between the frame member and the base material. Fill the filling member with In the production method of the body frame, wherein the door.

  According to a second aspect of the present invention, in the method for manufacturing a vehicle body frame according to the first aspect, the unfoamed filler and the frame member are spaced apart from the adjacent portion in a plurality of directions. The vehicle body frame manufacturing method is characterized in that the base member is fixed to the frame member so as to gradually increase toward the outside of the vehicle body.

  According to a third aspect of the present invention, in the method for manufacturing a vehicle body frame according to the first or second aspect, the surface of the unfoamed filler facing the frame member is formed as a curved surface with the base material side convex. The method of manufacturing a vehicle body frame is characterized by the above.

  According to a fourth aspect of the present invention, in the method for manufacturing a vehicle body frame according to any one of the first to third aspects, when the base is fixed to the frame member, the unfoamed filler is used in the proximity portion. The vehicle body frame manufacturing method is characterized by contacting the frame member.

  According to a fifth aspect of the present invention, in the method for manufacturing a vehicle body frame according to the fourth aspect, the unfoamed filler is brought into line contact or point contact with the frame member at the proximity portion. It is in the manufacturing method of a frame.

  According to the present invention, even when the distance between the frame member and the base material, that is, the distance between the frame member and the filler is narrowed, the electrodeposition coating can be satisfactorily performed on the frame member. Moreover, since the space which fills with a filler becomes narrow by narrowing the space | interval of a frame member and a base material, the usage-amount of a filler can be suppressed.

1 is a schematic view showing a vehicle body structure of a vehicle according to an embodiment. It is the schematic which shows an example of the rear suspension which comprises a vehicle. It is a side view which shows the frame member which concerns on one Embodiment. It is a schematic perspective view which shows the frame member which concerns on one Embodiment. It is sectional drawing which shows the structure of the frame member which concerns on one Embodiment. It is an expanded sectional view showing a manufacturing process of a body frame concerning one embodiment. It is an expanded sectional view which shows the manufacturing process of the vehicle body frame which concerns on a prior art. It is sectional drawing which shows the modification of the manufacturing process of the frame member which concerns on one Embodiment. It is sectional drawing which shows the modification of the manufacturing process of the frame member which concerns on one Embodiment. It is the schematic which shows the modification of the shape of the filler which concerns on one Embodiment. It is sectional drawing which shows the modification of the manufacturing process of the frame member which concerns on one Embodiment.

  First, a vehicle body frame structure of a vehicle according to the present invention will be described with reference to the drawings.

  As shown in FIG. 1, a vehicle 10, which is an automobile, includes a vehicle body frame 20 that forms a skeleton of a lower body of a vehicle body 11 below the floor (below the passenger compartment). The vehicle body frame 20 is composed of a plurality of frame members. For example, in the present embodiment, the vehicle body frame 20 includes a pair of side members 21 extending in the front-rear direction of the vehicle 10 and a plurality of cross members 22 extending in the vehicle width direction of the vehicle 10. Yes. Each side member 21 is formed by, for example, connecting a plurality of members, and in this embodiment, a front side member 23 that forms the front side of the vehicle 10 and a rear side member 24 that forms the rear side of the vehicle 10. It consists of and. Each cross member 22 is fixed to a predetermined position of the side member 21 by spot welding or the like.

  The structure of the vehicle body frame 20 is not particularly limited. However, since it forms a skeleton of the vehicle 10, it is preferable that its rigidity is relatively high. The vehicle body frame 20 preferably has a high overall rigidity, and in particular, it is desirable that the rigidity of the portion to which other members are connected is high.

  For example, in the present embodiment, the front wheel 30 (see FIG. 1) of the vehicle 10 is supported on the vehicle body 11 (vehicle body frame 20) by a front suspension (not shown). The rear wheel 31 of the vehicle 10 is supported on the vehicle body 11 (vehicle body frame 20) by a rear suspension. As shown in FIG. 2, as the rear suspension 40, for example, a multi-link type rear suspension can be cited. The rear suspension 40 extends in the front-rear direction of the vehicle 10 to determine the front-rear position of the rear wheel 31 and swings in the up-down direction, and includes a plurality of links extending in the vehicle width direction. 42, 43, 44, a shock absorber 45 extending in the vertical direction of the vehicle 10, and a strut 47, etc., that sheathes the coil spring 46. Each link 42, 43, 44 is attached to a suspension cross member (not shown in FIG. 2) that forms the skeleton of the rear suspension 40. The suspension cross member is attached to the vehicle body frame 20.

  Specifically, as shown in FIG. 3, the rear side member 24 constituting the vehicle body frame 20 is inclined at a portion facing the rear wheel 31 of the vehicle 10 so that the rear end side is positioned above the front end side. It has a kick-up portion 24a. The kick-up portion 24a is provided to avoid interference with the rear suspension 40 and the like. A suspension cross member 48 constituting the rear suspension 40 is coupled to the kick-up portion 24a of the rear side member 24 via a suspension bracket 50. That is, a part of the rear suspension 40 is connected to the kick-up portion 24 a of the rear side member 24. In the present embodiment, the suspension cross member 48 is formed of a cross-shaped pipe frame, and is fixed to the rear side member 24 and the suspension bracket 50 by fastening members 51 such as bolts.

  As shown in FIGS. 4 and 5, in the kick-up portion 24a of the rear side member 24, a filling member 61 formed of a thermosetting foaming filler and a filling member provided on the filling member 61 are provided. A reinforcing member 60 composed of a base material 62 fixed to the rear side member 24 by 61 is provided. The rear side member 24 according to the present embodiment is formed in a substantially U-shaped cross section to define a groove portion 25, and a reinforcing member 60 is provided in the groove portion 25. On the rear side member 24, a rear side member upper 70 which is another frame member constituting the vehicle body frame 20 is joined by spot welding or the like, and the groove portion 25 is closed by the rear side member upper 70.

  Thus, by providing the reinforcing member 60 in the kick-up portion 24a of the rear side member 24, the collision performance of the kick-up portion 24a is improved. Thereby, even when a collision (rear collision) occurs from the rear of the vehicle, the energy of the collision is effectively absorbed by the filling member 61. Therefore, deformation of the body frame 20 is suppressed, and the safety of the vehicle 10 is improved.

  The shape of the filling member 61 is not particularly limited, and may be appropriately determined according to the shape of the rear side member 24 and the like. In the present embodiment, the filling member 61 is provided at each of the two corners of the groove 25 defined by the rear side member 24. Each corner of the groove 25 has a large load (energy) load in the event of a collision from the rear of the vehicle. For this reason, by providing the filling member 61 at each corner, the energy at the time of the collision can be absorbed by the filling member 61 and the deformation of the vehicle body frame 20 can be effectively suppressed.

  Here, as a material of the filling member 61 constituting the reinforcing member 60, for example, an epoxy thermosetting foam filler is used. That is, the filling member 61 is formed, for example, by heating and foaming a thermosetting filler.

  The base material 62 is for temporarily holding an unfoamed (before heating and foaming) filler and guiding the foamed area, and is formed of, for example, a relatively hard plate material such as a metal material or a resin material. . In the present embodiment, the base material 62 is formed along the shape of the rear side member 24. That is, the interval between the base member 62 and the rear side member 24 is provided so as to be substantially constant except for a protruding portion 63 described later.

  Moreover, the base material 62 is provided with the protrusion part 63 which protrudes to the rear side member 24 side (lower side in a figure) in the center part of the width direction (refer FIG. 4, FIG.5 (b) etc.). In the present embodiment, the protruding portion 63 is provided at the center in the longitudinal direction of the base material 62. The base material 62 is held in a state where the protruding portion 63 is in contact with the rear side member 24. In addition, the shape of the protrusion part 63 is not specifically limited, For example, the protrusion part 63 may be provided continuously over the longitudinal direction of the base material 62. FIG. Moreover, the number of the protrusion parts 63 is not specifically limited, For example, the some protrusion part 63 may be provided with respect to the one base material 62. FIG.

  Further, the protruding portion 63 of the base material 62 is provided with a first through hole 64 that penetrates the base material 62. On the other hand, a second through hole 26 that penetrates the rear side member 24 and communicates with the first through hole 64 is provided at a portion where the protruding portion 63 of the rear side member 24 abuts. And the base material 62 is hold | maintained at the rear side member 24 by mounting | wearing the clip member 80 with these 1st through-holes 64 and 2nd through-holes 26 (refer FIG.5 (b)). The clip member 80 is made of an elastic material such as a resin material or a rubber material, for example.

  As a manufacturing method of such a vehicle body frame 20, as shown in FIG. 6, first, the base material 62 to which the unfoamed filler 610 is fixed is arranged and fixed to the rear side member 24 at a predetermined interval D. For example, in the present embodiment, the base member 62 is fixed to the rear side member 24 with the clip member 80 described above (see FIG. 5B). Thus, a filling portion 27 is defined between the rear side member 24 and the base material 62, which is a space filled with the foamed filler.

  At this time, in the present invention, the interval between the unfoamed filler 610 and the rear side member 24 is gradually increased from the closest portion 100 having the smallest interval toward the outside of the unfoamed filler 610 in at least one direction. Further, the base material 62 to which the unfoamed filler 610 is fixed is fixed to the rear side member 24.

  In the present embodiment, the filler 610 fixed to the base material 62 is formed so that the tip end side becomes thinner toward the corner portion of the rear side member 24. That is, the filler 610 is thickest at the center in the width direction and gradually decreases in thickness toward the both ends, and the surface facing the rear side member 24 is outward from the center in the width direction of the filler 610. It is comprised by the inclined surfaces 610a and 610b which incline toward. As a result, the central portion (the corner portion of the rear side member 24) of the filler 610 is the adjacent portion 100 in which the distance between the filler 610 and the rear side member 24 is the smallest, and between the filler 610 and the rear side member 24. A gap A that gradually widens from the proximity portion 100 toward both ends in the width direction of the filler 610 is formed.

  The filler 610 and the rear side member 24 may be separated from each other in the proximity portion 100, but may be in contact with each other. In that case, the contact between the filler 610 and the rear side member 24 may be a surface contact, but it is preferable to make the contact area as small as possible as a line contact or a point contact.

  Thus, the gap between the filler 610 and the rear side member 24 is made relatively narrow by performing electrodeposition coating of the rear side member 24 in a state where the gap A is formed between the filler 610 and the rear side member 24. However, the electrodeposition coating can be satisfactorily adhered to the surface of the rear side member 24 facing the filler 610.

  Thereafter, for example, the electrodeposition coating film is dried by heating in a drying furnace or the like, and at the same time, the filler 610 is heated and foamed. As a result, the filler 610 is filled into the filling portion 27 to form the filling member 61, and the rear side member 24 and the base material 62 are more firmly fixed via the filling member 61. That is, the rear side member 24 and the base material 62 are integrated by the filling member 61 to form the reinforcing member 60 (see FIG. 5).

  As described above, as the distance between the filler 610 and the rear side member 24 is relatively narrow, the filling portion 27 filled with the filling member 61 is also relatively small. Therefore, the amount of filler 610 used can be reduced. Since the filler 610 is relatively expensive, the cost can be effectively reduced by reducing the amount of the filler 610 used.

  When the interval between the filler 610 and the rear side member 24 is made substantially constant as in the prior art, the interval between the filler 610 and the rear side member 24 needs to be a predetermined interval D as shown in FIG. Therefore, the distance between the rear side member 24 and the base material 62 is the sum of the predetermined distance D and the thickness t of the filler 710. For this reason, the filling part 27 becomes comparatively wide, and the usage-amount of the filler 710 will also become quite large.

  Although one embodiment of the present invention has been described above, the present invention is not limited to this embodiment.

  For example, the shape of the filler 610 is not particularly limited, and may be appropriately determined in consideration of various conditions such as the expansion ratio of the filler 610. In the present embodiment, the configuration in which the filler 610 is tapered toward the corner portion of the rear side member 24 is exemplified. However, as shown in FIG. 8A, the flat inner surface of the rear side member 24 is illustrated. You may be provided so that it may taper toward. Furthermore, in this embodiment, the inclined surfaces 610a and 610b of the filler 610 are flat surfaces. However, as shown in FIG. 8B, the inclined surfaces 610a and 610b of the filler 610 are on the base 62 side. It may be a convex curved surface.

  Moreover, the cross-sectional shape of the filler 610 does not need to be substantially triangular, and may be substantially pentagonal as shown in FIG. Further, the cross-sectional shape of the above-described filler 610 is bilaterally symmetric with respect to the proximity portion 100, but both sides of the proximity portion 100 do not necessarily have to be symmetric. For example, as shown in FIG. 9B, one end portion in the width direction of the filler 610 may be the proximity portion 100.

  In any configuration, the interval between the filler 610 and the rear side member 24 has a shape that gradually increases from the central portion (proximity portion 100) of the filler 610 toward the outside. Therefore, the electrodeposition coating can be satisfactorily applied to the rear side member 24.

  Moreover, in this embodiment, although the surface which opposes the rear side member 24 of the filler 610 illustrated the structure comprised by the inclined surfaces 610a and 610b which incline toward the outer side from the center part of the width direction of the filler 610, For example, as shown in FIG. 10A, the filler 610 may include inclined surfaces 610c and 610d whose surfaces facing the rear side member are inclined outward from the longitudinal center of the filler 610. Good. Further, as shown in FIG. 10B, the filler 610 includes inclined surfaces 610a and 610b whose surfaces facing the rear side member are inclined outward from the center in the width direction of the filler 610, and from the center in the longitudinal direction. You may be comprised with the inclined surfaces 610c and 610d which incline toward the outer side. That is, the filler 610 may have a substantially quadrangular pyramid shape.

  In the above-described embodiment, the gap between the filler 610 and the rear side member 24 is gradually increased from the proximity portion 100 toward the end of the filler 610 by changing the thickness of the filler 610. However, for example, as shown in FIG. 11, the thickness of the filler 610 may be constant, and the shape of the base material 62 may be changed so that the distance between the two gradually increases from the proximity portion 100.

  Furthermore, in the above-described embodiment, the rear side member is exemplified as the frame member on which the reinforcing member is provided. However, the reinforcing member may be provided on any frame member constituting the vehicle body frame.

  In the above-described embodiment, the multi-link type rear suspension is illustrated as an example of the rear suspension coupled to the kick-up portion. However, the type of the rear suspension is not particularly limited.

DESCRIPTION OF SYMBOLS 10 Vehicle 11 Car body 20 Body frame 21 Side member 22 Cross member 23 Front side member 24 Rear side member 24a Kick-up part 25 Groove part 26 Second through-hole 27 Filling part 30 Front wheel 31 Rear wheel 40 Rear suspension 41 Trailing arm 42 Link 45 Shock absorber 46 Coil spring 47 Strut 48 Suspension cross member 50 Suspension bracket 51 Fastening member 60 Reinforcement member 61 Filling member 62 Base material 63 Projection part 64 First through hole 70 Rear side member upper 80 Clip member 610 Filling material 710 Filling material

Claims (5)

Formed with a plurality of U-shaped frame members arranged under the vehicle floor,
A vehicle body frame manufacturing method comprising a reinforcing member comprising a base material and a filling member made of a foamed filler filled between the base material and the frame member, the frame member comprising:
Distance between the frame member and the filler of non-foaming, at least in one direction, so that gradually increases from the narrowest proximal part of the distance towards the outside of the filler of the unfoamed, and the proximity portion are the Fixing the base material to which the unfoamed filler is fixed to the frame member so as to go to the corner of the frame member,
In this state, electrodeposition coating of the frame member is performed,
Thereafter, the filler is foamed to fill the space between the frame member and the base material with the filler member. In the manufacturing method of the body frame according to claim 1,
The base material is fixed to the frame member so that an interval between the unfoamed filler and the frame member gradually increases from the proximity portion toward the outside of the unfoamed filler in a plurality of directions. A method of manufacturing a vehicle body frame characterized by the above. In the manufacturing method of the vehicle body frame according to claim 1 or 2,
A method of manufacturing a vehicle body frame, wherein a surface of the unfoamed filler facing the frame member is formed into a curved surface having a convex surface on the substrate side. In the manufacturing method of the body frame given in any 1 paragraph of Claims 1-3,
A method for manufacturing a vehicle body frame, comprising: bringing the unfoamed filler into contact with the frame member at the proximity portion when fixing the base member to the frame member. In the manufacturing method of the vehicle body frame according to claim 4,
A method of manufacturing a vehicle body frame, wherein the unfoamed filler is brought into line contact or point contact with the frame member at the proximity portion.

Images