Vehicle floor structure and method for manufacturing a vehicle

Abstract

The present invention relates to a vehicle floor structure and a method for manufacturing a vehicle. A vehicle floor structure according to an aspect of the present disclosure includes a disc-shaped floor, an upper surface side reinforcement member joined to an upper surface of the disc-shaped floor, and a lower surface side reinforcement member joined to a lower surface of the disc-shaped floor. The disc-shaped floor is formed of a resin-coated steel sheet, and a resin layer of the resin-coated steel sheet includes a first resin layer formed on the upper surface of the disc-shaped floor and a second resin layer formed on a portion of the lower surface of the disc-shaped floor that is in contact with the lower surface side reinforcement member.

Description

Technical Field

[0001] This disclosure relates to a vehicle floor structure and a method for manufacturing a vehicle. Background Technology

[0002] As disclosed in Japanese Unexamined Patent Application Publication No. 2015-202686, resin-coated steel sheets with a resin layer on the surface are used in automobiles, thus having rust-resistant properties. Summary of the Invention

[0003] However, resin-coated steel sheets are more expensive than ordinary steel sheets, so the selection of automotive parts that use resin-coated steel sheets needs to be done carefully.

[0004] It should be noted that the vehicle floor structure consists of a disc-shaped floor (also known as a "floor panel") and reinforcing members, such as transverse and lateral floor members that attach to the disc-shaped floor. It should also be noted that because the contact surfaces in the joints (e.g., the surfaces where the reinforcing members contact the disc-shaped floor) are not electrocoated, there is a possibility that moisture may enter the gaps between the contact surfaces of the joints and rust may occur.

[0005] Meanwhile, the inventors discovered that the surface of the disc-shaped floor inside the vehicle is corroded by de-icing agents, for example, those adhering to the occupants' shoes.

[0006] In view of these circumstances, this disclosure provides a vehicle floor structure that can suppress corrosion on the contact surfaces between the disc floor and the upper surface side reinforcement member and between the disc floor and the lower surface side reinforcement member, and also suppress corrosion on the upper surface of the disc floor that would otherwise be caused by de-icing agents.

[0007] A first exemplary aspect is a vehicle floor structure comprising:

[0008] Disc-shaped floor;

[0009] An upper surface side reinforcement member, which is joined to the upper surface of the disc-shaped floor; and

[0010] A lower surface side reinforcement member is attached to the lower surface of the disc-shaped floor, wherein...

[0011] The disc floor is formed from a resin-coated steel sheet, and the resin layer of the resin-coated steel sheet includes a first resin layer formed on the upper surface of the disc floor and a second resin layer formed on the lower surface of the disc floor at the portion in contact with the lower surface side reinforcement member.

[0012] In a vehicle floor structure according to one aspect of this disclosure, the disc-shaped floor is formed of a resin-coated steel sheet, and the resin layer of the resin-coated steel sheet includes a first resin layer formed on the upper surface of the disc-shaped floor and a second resin layer formed on the lower surface of the disc-shaped floor at the portion in contact with the lower surface-side reinforcing member. Therefore, corrosion on the contact surfaces between the disc-shaped floor and the upper surface-side reinforcing member, and between the disc-shaped floor and the lower surface-side reinforcing member, can be suppressed, and corrosion originally caused by de-icing agents on the upper surface of the disc-shaped floor can also be suppressed.

[0013] The first resin layer may be formed on the entire upper surface of the disc floor, and the second resin layer may be formed only on a portion of the lower surface of the disc floor, including the portion of the disc floor surface that contacts the lower surface side reinforcement member.

[0014] It should be noted that the disc floor can be formed from customized blank materials, wherein a first resin-coated steel plate with only a first resin layer and a second resin-coated steel plate with a first resin layer and a second resin layer are welded to each other.

[0015] The upper surface side reinforcement member can be formed from a resin-coated steel plate, and the thickness of the resin layer of the resin-coated steel plate forming the upper surface side reinforcement member can be less than the thickness of the resin layer of the resin-coated steel plate forming the disc floor.

[0016] Furthermore, the lower surface side reinforcing member can be formed from a resin-coated steel plate, and the thickness of the resin layer of the resin-coated steel plate forming the lower surface side reinforcing member can be less than the thickness of the resin layer of the resin-coated steel plate forming the disc floor.

[0017] Meanwhile, each of the upper surface side reinforcing member and the lower surface side reinforcing member can be formed from a steel plate that is not coated with resin.

[0018] Furthermore, the thickness of the resin layer formed on the upper surface of the disc floor can be greater than the thickness of the resin layer formed on the lower surface of the disc floor.

[0019] The above structure can reduce production costs and inhibit corrosion.

[0020] Each of the upper and lower surface side reinforcement members may have a cap-like shape in a cross section perpendicular to its longitudinal direction and may be joined to the disc-shaped floor at a pair of flange portions extending along the longitudinal direction.

[0021] It should be noted that the outer periphery of the pair of flange portions that join to the disc floor may not be coated with any rust-preventive sealant.

[0022] Furthermore, the overall shape of the flange portion can be flat.

[0023] Another exemplary aspect is a method for manufacturing a vehicle, the method comprising electrocoating a disc-shaped floor together with an upper surface-side reinforcement member and a lower surface-side reinforcement member, the upper surface-side reinforcement member being joined to an upper surface of the disc-shaped floor, and the lower surface-side reinforcement member being joined to a lower surface of the disc-shaped floor, wherein...

[0024] The disc-shaped floor is formed from a resin-coated steel plate, and the resin layer of the resin-coated steel plate is formed on the upper surface of the disc-shaped floor and on the lower surface of the disc-shaped floor in contact with the lower surface side reinforcement member.

[0025] In a method for manufacturing a vehicle according to one aspect of this disclosure, a disc-shaped floor is formed from a resin-coated steel sheet, and a resin layer of the resin-coated steel sheet is formed on the upper surface of the disc-shaped floor and on the lower surface of the disc-shaped floor at the portion in contact with the lower surface-side reinforcing member. Therefore, corrosion on the contact surfaces between the disc-shaped floor and the upper surface-side reinforcing member, and between the disc-shaped floor and the lower surface-side reinforcing member, can be suppressed, and corrosion originally caused by de-icing agents on the upper surface of the disc-shaped floor can also be suppressed.

[0026] According to this disclosure, a vehicle floor structure can be provided that can suppress corrosion on the contact surfaces between the disc floor and the upper surface side reinforcement member and between the disc floor and the lower surface side reinforcement member, and also suppress corrosion on the upper surface of the disc floor that was originally caused by de-icing agent.

[0027] The above and other objects, features and advantages of the present invention will be more fully understood from the detailed description given below and the accompanying drawings, which are given by way of illustration only, and therefore should not be considered as limiting the present disclosure. Attached Figure Description

[0028] Figure 1 This is a schematic cross-sectional view of the vehicle floor structure according to the first embodiment;

[0029] Figure 2 yes Figure 1 A schematic partial cross-sectional view of region II shown;

[0030] Figure 3 yes Figure 2 A schematic partial cross-sectional view of region III shown;

[0031] Figure 4 This is a schematic partial cross-sectional view of the vehicle floor structure according to the second embodiment; and

[0032] Figure 5 This is a schematic partial cross-sectional view of the vehicle floor structure according to the third embodiment. Detailed Implementation

[0033] Specific embodiments of the present disclosure will be described in detail below with reference to the accompanying drawings. However, the present disclosure is not particularly limited to the following embodiments. Furthermore, the following description and drawings have been appropriately simplified for clarity of explanation.

[0034] (First Embodiment)

[0035] <Structure of Vehicle Floor Structure>

[0036] First, refer to Figure 1 The structure of the vehicle floor structure according to the first embodiment is described. Figure 1 This is a schematic cross-sectional view of the vehicle floor structure according to the first embodiment.

[0037] like Figure 1 As shown, the vehicle floor structure according to this embodiment includes a disc-shaped floor 10, an upper floor side member 21, a passageway side frame 22, a floor transverse member 23, and a lower floor side member 30.

[0038] It should be noted that the upper floor side member 21, the passage side frame 22, and the floor transverse member 23 constitute an upper surface side reinforcement member that is joined to the upper surface (inner surface of the vehicle) of the disc floor 10. Meanwhile, the lower floor side member 30 is a lower surface side reinforcement member that is joined to the lower surface (outer surface of the vehicle) of the disc floor 10.

[0039] Naturally, Figure 1 The right-handed xyz orthogonal coordinate system shown in the other figures is universal in all figures and is only for the purpose of explaining the positional relationships between components. In the example shown in the figures, the positive x-axis represents the forward direction of the vehicle; the y-axis represents the width direction of the vehicle; and the positive z-axis represents the vertical upward direction.

[0040] Furthermore, when viewed from the front of the vehicle (positive x-axis direction), the vehicle floor structure according to this embodiment has a bilaterally symmetrical structure, and Figure 1 Only the left half of the vehicle floor structure is shown in the image.

[0041] Furthermore, the vehicle floor structure according to this embodiment only needs to include at least one upper surface side reinforcement member engaged with the upper surface of the disc-shaped floor 10 and at least one lower surface side reinforcement member engaged with the lower surface of the disc-shaped floor 10. The upper surface side reinforcement member and the lower surface side reinforcement member are not particularly limited to... Figure 1 Those shown.

[0042] The disc-shaped floor 10 is a plate-shaped steel component that forms a major part of the vehicle floor structure. For example... Figure 1As shown, the disc-shaped floor 10 includes a floor channel 11 at the center in the vehicle width direction (y-axis direction), which extends along the vehicle front / rear direction (x-axis direction) and extends upward from the flat portion in a channel shape.

[0043] At each of the two ends of the disc-shaped floor 10 in the vehicle width direction (y-axis direction), a flange portion 12 rises upward from the flat portion. The flange portion 12 engages, for example, a side beam (not shown).

[0044] The disc-shaped floor 10 is formed by pressing, for example, a steel plate.

[0045] The upper floor side member 21 is an upper surface side reinforcement member that is joined to the upper surface of the disc floor 10. For example... Figure 1 As shown, the upper floor side member 21 extends, for example, in the middle portion of the disc-shaped floor 10 between the floor channel 11 and the flange portion 12, along the vehicle front / rear direction (x-axis direction).

[0046] It should be noted that Figure 2 yes Figure 1 A schematic partial cross-sectional view of region II is shown. (See diagram.) Figure 2 As shown, the upper floor side member 21 is a steel plate member with a cap-shaped cross-section perpendicular to the longitudinal direction (x-axis direction). That is, the upper floor side member 21 includes a top plate 21a, a pair of sidewalls 21b, and a pair of flange portions 21c.

[0047] It should be noted that these parts in the upper floor side member 21 are defined for illustrative purposes only. Furthermore, the structure of the upper floor side member 21 is not particularly limited to... Figure 1 and Figure 2 The example shown.

[0048] More specifically, a pair of sidewalls 21b are formed downward from the ends of the top plate 21a in the width direction (y-axis), which extends in the vehicle's front / rear direction (x-axis direction). Further, flange portions 21c protrude outward from the lower ends of each of the sidewalls 21b. The upper floor side member 21 is formed, for example, by pressing a single sheet of steel.

[0049] like Figure 2 As shown, a pair of flange portions 21c of the upper floor side member 21 are joined to the upper surface of the flat portion of the disc floor 10 by welding, threaded connection, or the like. The entire flange portion 21c is formed into a flat shape, and the upper floor side member 21 has a simple structure.

[0050] The channel side frame 22 is an upper surface side reinforcement member that is joined to the upper surface of the disc-shaped floor 10. For example... Figure 1As shown, the channel side frame 22 extends along the vehicle's front / rear direction (x-axis direction) across the flat portion of the disc floor 10 and the sidewall of the floor channel 11. In other words, the channel side frame 22 reinforces the floor channel 11 in the disc floor 10.

[0051] More specifically, such as Figure 1 As shown, the channel side frame 22 includes an L-shaped main portion with a cross-sectional shape perpendicular to the longitudinal (x-axis) direction, and a pair of flange portions protruding from both ends of the main portion in the vehicle width direction (y-axis). Figure 1 As shown, one of the flange portions of the channel side frame 22 is engaged with the flat portion of the disc floor 10, and the other flange portion of the channel side frame 22 is engaged with the sidewall of the floor channel 11 of the disc floor 10.

[0052] The transverse floor member 23 is an upper surface side reinforcement member that is joined to the upper surface of the disc floor 10. For example... Figure 1 As shown, the floor transverse member 23 extends from the flange portion 12 of the disc floor 10 to the passage side frame 22 along the vehicle width direction (y-axis direction).

[0053] More specifically, similar to the upper floor side member 21, the floor transverse member 23 is a steel plate member with a cap-like shape in its cross-section perpendicular to the longitudinal direction (y-axis direction). That is, the floor transverse member 23 includes a top plate, a pair of sidewalls, and a pair of flange portions. The flange portions of the floor transverse member 23 are joined to the upper surface of the main part of the disc-shaped floor 10 by welding, threaded connections, or the like. The entire flange portion of the floor transverse member 23 is formed into a flat shape, and the floor transverse member 23 has a simple structure.

[0054] The floor transverse member 23 is formed by pressing, for example, a steel plate.

[0055] The lower floor side member 30 is a lower surface side reinforcement member that is joined to the lower surface of the disc floor 10. For example... Figure 1 As shown, the lower floor side member 30 extends, for example, in the middle portion of the disc-shaped floor 10 between the floor channel 11 and the flange portion 12, along the vehicle's front / rear direction (x-axis direction). It should be noted that the lower floor side member 30 is opposite to the upper floor side member 21, with the disc-shaped floor 10 positioned between them. It should also be noted that the lower floor side member 30 can be displaced (i.e., offset) relative to the upper floor side member 21 along the vehicle's width direction (y-axis direction).

[0056] like Figure 2As shown, the lower floor side member 30 has the same shape as the upper floor side member 21 with a vertically reversed shape, and is a steel plate member with a cap-like shape in a cross-section perpendicular to the longitudinal direction (x-axis direction). That is, the lower floor side member 30 includes a base plate 30a, a pair of sidewalls 30b, and a pair of flange portions 30c. It should be noted that the base plate 30a of the lower floor side member 30 corresponds to the top plate 21a of the upper floor side member 21.

[0057] More specifically, a pair of sidewalls 30b form upward from the ends of the base plate 30a in the width direction (y-axis), which extends in the vehicle's front / rear direction (x-axis). Further, flange portions 30c project outward from the upper end of each of the sidewalls 30b. The lower floor side member 30 is formed, for example, by pressing a single sheet of steel.

[0058] like Figure 2 As shown, a pair of flange portions 30c of the lower floor side member 30 are joined to the lower surface of the flat portion of the disc floor 10 by welding, threaded connection, or the like. The entire flange portion 30c is formed into a flat shape, and the lower floor side member 30 has a simple structure.

[0059] It should be noted that in the vehicle floor structure according to this embodiment, the upper surface side reinforcing member (upper floor side member 21, etc.) is joined to the upper surface of the disc-shaped floor 10, and the lower surface side reinforcing member (lower floor side member 30) is joined to the lower surface of the disc-shaped floor 10. Next, the disc-shaped floor 10 to which the upper and lower surface side reinforcing members are joined, i.e., the vehicle floor structure according to this embodiment, is electro-painted. After electro-painting, the vehicle floor structure can be further coated, for example, for intermediate and top coatings.

[0060] It should be noted that Figure 3 yes Figure 2 A schematic partial cross-sectional view of region III is shown. (See diagram.) Figure 2 and Figure 3 As shown, the disc-shaped floor 10 is made of resin-coated steel plate. In the disc-shaped floor 10, the upper surface of the steel plate SS1 is coated with a resin layer (first resin layer) RL11, and the portion of the lower surface of the steel plate SS1 that contacts the lower surface side reinforcing member (lower floor side member 30) is coated with another resin layer (second resin layer) RL12. That is, as Figure 2 and Figure 3 As shown, resin layer RL11 is formed on the surface of the disc-shaped floor 10 that contacts the upper surface side reinforcing member (upper floor side member 21, etc.). Further, resin layer RL12 is formed on the portion of the surface of the disc-shaped floor 10 that contacts the lower surface side reinforcing member (lower floor side member 30).

[0061] As described above, in the prior art, when the disc-shaped floor to which the upper and lower surface reinforcing members are joined is electrocoated, the contact surfaces between the upper and lower surface reinforcing members and the disc-shaped floor cannot be electrocoated, thus posing a risk of corrosion. Therefore, it is necessary to apply an anti-rust sealant to the boundary line between the disc-shaped floor and the upper and lower surface reinforcing members, i.e., to the outer periphery of the flange portions of the upper and lower surface reinforcing members, along which the upper and lower surface reinforcing members are joined to the disc-shaped floor.

[0062] Conversely, in the vehicle floor structure according to this embodiment, such as Figure 2 As shown, the disc-shaped floor 10 is formed from a resin-coated steel sheet. Further, a resin layer RL11 is formed on the surface of the disc-shaped floor 10 at the portion that contacts the upper surface-side reinforcing member (upper floor side member 21, etc.). Further, a resin layer RL12 is formed on the surface of the disc-shaped floor 10 at the portion that contacts the lower surface-side reinforcing member (lower floor side member 30).

[0063] Therefore, due to the resin layer RL11, corrosive substances (such as water, oxygen, and chlorine) hardly reach the steel plate SS1 of the disc floor 10 and the upper surface side reinforcement member (upper floor side member 21, etc.) formed by the steel plate. Similarly, due to the resin layer RL12, corrosive substances hardly reach the steel plate SS1 of the disc floor 10 and the lower surface side reinforcement member (lower floor side member 30) formed by the steel plate. Therefore, corrosion in the contact surfaces between the upper surface side reinforcement member and the disc floor 10, and between the lower floor side member 30 and the disc floor 10, can be suppressed.

[0064] As a result, it is not necessary to apply rust-preventive sealant to the boundary line between the disc-shaped floor 10 and the flange portion of the upper surface side reinforcement member (such as the flange portion 21c of the upper floor side member 21), i.e., the outer periphery of the flange portion. Similarly, it is not necessary to apply rust-preventive sealant to the boundary line between the disc-shaped floor 10 and the flange portion of the lower surface side reinforcement member (such as the flange portion 30c of the lower floor side member 30), i.e., the outer periphery of the flange portion.

[0065] Furthermore, in existing vehicle floor structures, flow channels (mortise and tenon structures) are formed inside the flange portions of the upper floor side member and / or the lower floor side member to supply electrocoating liquid. In contrast, in the vehicle floor structure according to this embodiment, because the disc floor 10 is constructed of resin-coated steel, it is not necessary to provide mortise and tenon structures in the flange portions 21c of the upper floor side member 21 or the flange portions 30c of the lower floor side member 30. Therefore, the entire flange portion 21c of the upper floor side member 21 and the flange portion 30c of the lower floor side member 30 can be formed into a flat shape. That is, the structure of the upper floor side member 21 and the lower floor side member 30 is simplified, and thus manufacturing costs can be reduced.

[0066] Furthermore, since the steel plate SS1 in the disc floor 10 is coated with a resin layer RL11 on its essentially entire upper surface, corrosion of the disc floor 10 caused by, for example, de-icing agents adhering to the occupants' shoes can also be suppressed.

[0067] It should be noted that, as described below, corrosion can be further inhibited when resin layers RL11 and RL12 contain rust-preventing pigments.

[0068] It should be noted that steel plate SS1 is made of ordinary steel or steel containing additive elements such as chromium, but is not particularly limited to these. Furthermore, a coating may be applied to the surface of steel plate SS1 to enhance rust resistance. That is, steel plate SS1 can be electroplated steel. Examples of coatings include, but are not particularly limited to, coatings containing any one of metallic elements such as zinc, aluminum, cobalt, tin, and nickel, as well as alloy coatings containing at least one of these metallic elements.

[0069] Furthermore, resin layers RL11 and RL12 are composed of organic resins such as water-based coating compositions or organic solvent-based coating compositions, but are not particularly limited thereto. Examples of organic resins include polyurethane resins, polyester resins, epoxy resins, (meth)acrylic resins, polyolefin resins, modified resins thereof, and mixtures thereof.

[0070] The organic resin contains, for example, rust-preventive pigments and has rust-preventive properties. The rust-preventive pigments contain, but are not limited to, fine particles of at least one of, for example, silicate compounds, phosphate compounds, vanadate compounds, and metal oxides. The rust-preventive pigments are, for example, nanoparticles with a volume average diameter of about 1 to 50 nanometers (nm), fine particles with a volume average diameter of about 0.5 to 10 μm, or mixtures thereof. The amount of rust-preventive pigments added to resin layers RL1 and RL2 can be, for example, 1 to 40 vol% or 2 to 20 vol%.

[0071] Furthermore, the organic resin may contain, for example, conductive pigments, and therefore may be conductive. The conductive pigments comprise, but are not particularly limited to, fine particles of at least one of, for example, metals, alloys, conductive carbon, iron phosphide, carbides, and semiconductor oxides. The volume-average diameter of the fine particles is, for example, about 0.5 to 10 μm. The amount of conductive pigment added to resin layers RL1 and RL2 may be, for example, 1 to 40% by volume or 2 to 20% by volume.

[0072] The thickness of resin layers RL1 and RL2 is, for example, 0.5 to 10 μm. Because the thickness of resin layers RL1 and RL2 is 0.5 μm or greater, corrosion resistance is achieved, and because the thickness of resin layers RL1 and RL2 is 10 μm or less, damage or delamination of resin layers RL1 and RL2 can be suppressed during compression molding and the like. The thickness of resin layers RL1 and RL2 can be, for example, 1 to 5 μm.

[0073] Furthermore, the thicknesses of resin layers RL11 and RL12 are, for example, approximately equal to each other. However, the thickness of resin layer RL11 formed on the upper surface of the disc floor 10 can be greater than the thickness of resin layer RL12 formed on the lower surface of the disc floor 10. This can more effectively suppress corrosion of the disc floor 10 originally caused by de-icing agents.

[0074] It should be noted that, in order to improve the adhesion of resin layer RL11 to steel plate SS1 and the adhesion and corrosion resistance of resin layer RL12 to steel plate SS1, a primer film can be applied between the surfaces of resin layer RL11 and steel plate SS1, and between resin layer RL12 and steel plate SS1. The number and composition of the primer film are not limited to any specific quantity or composition.

[0075] Furthermore, in the disc-shaped floor 10 according to this embodiment, although no resin layer is formed on the end face of the steel plate SS1, a resin layer may be formed on the end face of the steel plate SS1.

[0076] As explained above, in the vehicle floor structure according to this embodiment, the disc-shaped floor 10 is formed of a resin-coated steel sheet. It should be noted that the resin layer of this resin-coated steel sheet is formed on the upper surface of the disc-shaped floor 10 and also on the lower layer of the disc-shaped floor 10 in contact with the lower surface-side reinforcing member (lower floor side member 30). Therefore, corrosion at the contact surfaces between the disc-shaped floor 10 and the upper surface-side reinforcing member (upper floor side member 21, etc.) and between the disc-shaped floor 10 and the lower surface-side reinforcing member (lower floor side member 30) can be suppressed, and corrosion on the upper surface of the disc-shaped floor 10 that was originally caused by de-icing agents can also be suppressed.

[0077] It should be noted that, as described below, at least one of the upper surface side reinforcing member (upper floor side member 21, etc.) and the lower surface side reinforcing member (lower floor side member 30) can be formed from a resin-coated steel sheet.

[0078] However, as Figure 2 As shown, manufacturing costs can be reduced by forming the disc floor 10 from only resin-coated steel sheets and forming each of the upper and lower surface side reinforcing members from ordinary steel sheets without resin coating.

[0079] Furthermore, the resin layer RL12 can be formed on the entire lower surface of the disc-shaped floor 10. However, as Figure 2 As shown, manufacturing costs can be reduced by forming a resin layer RL12 only on a portion of the surface of the disc floor 10 near the part of the disc floor that contacts the lower surface side reinforcement member (lower floor side member 30), that is, only on a portion of the surface of the disc floor 10 including the part of the disc floor that contacts the lower surface side reinforcement member (lower floor side member 30).

[0080] like Figure 2 As shown, the disc-shaped floor 10 is formed from, for example, a resin-coated steel plate (first resin-coated steel plate) 10a with a resin layer RL11 formed only on the upper surface, and a resin-coated steel plate (second resin-coated steel plate) 10b with resin layers RL11 and RL12 formed on the upper and lower surfaces. That is, the disc-shaped floor 10 can be formed from a custom-made blank material in which the resin-coated steel plates 10a and 10b are welded to each other. It should be noted that the type and thickness of the steel plates SS1 forming the resin-coated steel plates 10a and 10b can be the same or different from each other. Furthermore, the type and thickness of the resin layer RL11 of the resin-coated steel plate 10a and the resin layer RL11 of the resin-coated steel plate 10b can be the same or different from each other.

[0081] (Second Embodiment)

[0082] Next, refer to Figure 4 The structure of the vehicle floor structure according to the second embodiment is described. Figure 4 This is a schematic cross-sectional view of the vehicle floor structure according to the second embodiment. Figure 4 Is with Figure 3 The cross section shown corresponds to the cross section.

[0083] The structure of the vehicle floor structure according to this embodiment is similar to... Figure 1 The structure of the vehicle floor structure according to the first embodiment is shown.

[0084] like Figure 4As shown, in the vehicle floor structure according to this embodiment, in addition to the disc-shaped floor 10, the upper surface side reinforcing members (upper floor side members 21, etc.) are also formed of resin-coated steel plates. Figure 4 In the upper floor side member 21 shown, the upper surface of the steel plate SS2 is coated with a resin layer RL21, and the entire lower surface of the steel plate SS2 is coated with a resin layer RL22.

[0085] Steel plate SS2 is a steel plate similar to steel plate SS1, and resin layers RL21 and RL22 are resin layers similar to resin layers RL11 and RL12.

[0086] Due to the resin layer RL21, corrosion originally caused by de-icing agent on the upper surface of the upper floor side component 21 can be suppressed.

[0087] Due to the resin layer RL22, corrosion on the contact surface between the upper floor side member 21 and the disc floor 10 can be further suppressed.

[0088] like Figure 4 As shown, the thicknesses of resin layers RL21 and RL22 are, for example, approximately equal to each other. Furthermore, the thicknesses of resin layers RL21 and RL22 can be less than the thicknesses of resin layers RL11 and RL12 of the disc-shaped floor 10. With the above structure, manufacturing costs can be reduced.

[0089] Furthermore, the thickness of the resin layer RL21 on the upper surface can be greater than the thickness of the resin layer RL22 on the lower surface. Furthermore, only the resin layer RL21 on the upper surface can be formed, and the resin layer RL22 on the lower surface can be omitted. With the above structure, manufacturing costs can be reduced.

[0090] The rest of the construction is similar to the configuration of the vehicle floor structure according to the first embodiment, and therefore its description is omitted.

[0091] (Third Embodiment)

[0092] Next, refer to Figure 5 The structure of the vehicle floor structure according to the third embodiment is described. Figure 5 This is a schematic cross-sectional view of the vehicle floor structure according to the third embodiment. Figure 5 Is with Figure 3 The cross section shown corresponds to the cross section.

[0093] The structure of the vehicle floor structure according to this embodiment is similar to... Figure 1 The structure of the vehicle floor structure according to the first embodiment is shown.

[0094] like Figure 5As shown, in the vehicle floor structure according to this embodiment, in addition to the disc-shaped floor 10, the lower surface side reinforcing member (lower floor side member 30) is also formed of resin-coated steel plate. Figure 5 In the lower floor side member 30 shown, the upper surface of the steel plate SS3 is coated with a resin layer RL31, and the entire lower surface of the steel plate SS3 is coated with a resin layer RL32.

[0095] Steel plate SS3 is a steel plate similar to steel plate SS1, and resin layers RL31 and RL32 are resin layers similar to resin layers RL11 and RL12.

[0096] Due to the resin layer RL31, corrosion on the contact surface between the lower floor side member 30 and the disc floor 10 can be further suppressed.

[0097] Due to the resin layer RL32, corrosion on the lower surface of the lower floor side member 30 can be suppressed.

[0098] like Figure 5 As shown, the thicknesses of resin layers RL31 and RL32 are, for example, approximately equal to each other. Furthermore, the thicknesses of resin layers RL31 and RL32 can be less than the thicknesses of resin layers RL11 and RL12 of the disc-shaped floor 10. With the above structure, manufacturing costs can be reduced.

[0099] Furthermore, the thickness of the resin layer RL32 on the lower surface can be greater than the thickness of the resin layer RL31 on the upper surface. Furthermore, only the resin layer RL32 on the lower surface can be formed, and the resin layer RL31 on the upper surface can be omitted. With the above structure, manufacturing costs can be reduced.

[0100] The rest of the construction is similar to the configuration of the vehicle floor structure according to the first embodiment, and therefore its description is omitted.

[0101] It should be noted that this embodiment can be combined with the second embodiment. That is, in addition to the disc-shaped floor 10, both the upper surface side reinforcing member (upper floor side member 21, etc.) and the lower surface side reinforcing member (lower floor side member 30) can be formed from resin-coated steel plates.

[0102] As will be apparent from the present disclosure as described herein, embodiments of the present disclosure can be varied in many ways. These variations should not be considered as departing from the spirit and scope of the present disclosure, and all such modifications that will be apparent to those skilled in the art are intended to be included within the scope of the appended claims.

Claims

1. A vehicle floor structure, comprising: Disc-shaped floor; Upper surface side reinforcement member, which is joined to the upper surface of the disc-shaped floor; as well as A lower surface side reinforcement member is joined to the lower surface of the disc-shaped floor, wherein: The disc-shaped floor is formed from a resin-coated steel plate. The resin layer of the resin-coated steel plate comprises a first resin layer and a second resin layer, the first resin layer being formed on the upper surface of the disc-shaped floor, and the second resin layer being formed on the lower surface of the disc-shaped floor at the portion in contact with the lower surface side reinforcing member. The first resin layer is formed on the entire upper surface of the disc-shaped floor. The second resin layer is formed only on a portion of the lower surface of the disc-shaped floor, said portion of the lower surface of the disc-shaped floor including the portion of the lower surface of the disc-shaped floor that contacts the lower surface side reinforcing member. The disc-shaped floor is formed from a custom-made blank material, in which a first resin-coated steel plate having only the first resin layer formed thereon and a second resin-coated steel plate having both the first and second resin layers formed thereon are welded to each other.

2. The vehicle floor structure according to claim 1, wherein: The upper surface side reinforcing member is formed of resin-coated steel plate. The thickness of the resin layer of the resin-coated steel plate forming the upper surface side reinforcing member is less than the thickness of the first resin layer of the disc-shaped floor.

3. The vehicle floor structure according to claim 1 or 2, wherein: The lower surface side reinforcing member is formed of resin-coated steel plate, and The thickness of the resin layer of the resin-coated steel plate forming the lower surface side reinforcing member is less than the thickness of the second resin layer of the disc-shaped floor.

4. The vehicle floor structure according to claim 1, wherein, Each of the upper surface side reinforcing member and the lower surface side reinforcing member is formed of an uncoated steel plate.

5. The vehicle floor structure according to claim 1 or 2, wherein, The thickness of the first resin layer is greater than the thickness of the second resin layer.

6. The vehicle floor structure according to claim 1 or 2, wherein, Each of the upper surface side reinforcement member and the lower surface side reinforcement member has a cap-like shape in a cross-section perpendicular to its longitudinal direction and is engaged to the disc-shaped floor at a pair of flange portions extending along the longitudinal direction.

7. The vehicle floor structure according to claim 6, wherein, The outer periphery of the pair of flange portions joined to the disc-shaped floor was not coated with any rust-preventive sealant.

8. The vehicle floor structure according to claim 6, wherein, The overall shape of the flange portion is flat.

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