Method for manufacturing panel body

Abstract

Provided is a manufacturing method for manufacturing a panel body Dp, the panel body Dp having: a first panel Ip having a structure in which two panel members B1, B2 having different plate thicknesses are butted and joined; and a second panel Op disposed on the outside of the first panel Ip and connected by crimping, the first panel Ip is pressed so that the main surfaces of the two panel members B1, B2 on the joined portion W side are coplanar with each other and are molded in a state in which an inclined portion S caused by a plate thickness difference appears on the inner side thereof, the main surface of the first panel Ip on the joined portion W side is disposed on the second panel Op side, and the second panel Ip on the joined portion W side is molded in a state in which the main surfaces of the two panel members B1, B2 are molded in a state in which the inclined portion S appears on the inner side of the two panel members B1, B2 on the joined portion W side. The edge part of the first panel Ip including the inclined part S is curled towards the second panel Op, so that the appearance quality of the interior and exterior of the panel body Dp is considered.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a panel body having a first panel and a second panel, and in particular to a method for manufacturing a panel body having: a first panel having a structure for joining two panel members with different plate thicknesses; and a second panel arranged on the outer side of the first panel and joined by curling. Background Art

[0002] Currently, as a method for manufacturing the above-mentioned panel body, there is a method described in Patent Document 1, for example. The method for manufacturing the panel body described in Patent Document 1 is a method for manufacturing the following panel body, that is, having: a first panel, which is composed of a plurality of parts with different plate thicknesses butted and joined by welding; and a second panel, which is opposite to the first panel.

[0003] The manufacturing method is to hem the edge of the first panel including the step portion obtained based on the plate thickness difference toward the second panel so as to sandwich the edge portion. At this time, in the manufacturing method, the step portion at the edge of the first panel is partially cut off, and then the first panel and the second panel are hemmed toward the second panel to join them, thereby preventing or suppressing the generation of strain in the second panel.

[0004] Patent Document 1: Japanese Patent Application Publication No. 2013-86153 Summary of the invention

[0005] However, in the above-mentioned conventional panel manufacturing method, the joined parts (welding marks) of the first panel components are exposed on the surface of the panel body, making it difficult to achieve a good balance between the appearance quality inside and outside the panel body. There is a problem of solving this problem.

[0006] The present invention is proposed with a view to the above-mentioned current problems, and its purpose is to provide a manufacturing method that can take into account the good appearance quality of the inside and outside of the panel body when manufacturing the panel body. The panel body comprises: a first panel, which has a structure for joining two panel parts with different plate thicknesses; and a second panel, which is arranged on the outside of the first panel and is connected by curling.

[0007] The manufacturing method of the panel body involved in the present invention is a method for manufacturing the following panel body, that is, having: a first panel having a structure for docking and joining two panel members with different plate thicknesses; and a second panel, which is arranged on the outer side of the first panel and connected by curling. Regarding the manufacturing method of the panel body, the first panel is subjected to stamping so that the main surfaces of the two panel members on the side of the joined portion are coplanar with each other, and are formed into a state in which an inclined portion caused by the plate thickness difference appears on the inner side thereof, and the main surface of the first panel on the side of the joined portion is arranged on the side of the second panel. Moreover, the manufacturing method of the panel body is characterized in that the edge portion of the first panel including the inclined portion is curled toward the second panel, thereby joining the first panel and the second panel.

[0008] Effects of the Invention

[0009] Regarding the manufacturing method of the panel body involved in the present invention, by adopting the above-mentioned structure, when manufacturing a panel body having a first panel and a second panel, the joined parts of the panel parts of the first panel are arranged on the inner side of the panel body, which can take into account the good appearance quality of the inside and outside of the panel body. The first panel has a structure for joining two panel parts with different plate thicknesses, and the second panel is arranged on the outer side of the first panel and connected by curling. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 In the first embodiment of the method for manufacturing a panel body according to the present invention, there is shown an oblique view (A) of the first panel, an oblique view (B) of the first panel after stamping, and an oblique view (C) of the main part of the panel body.

[0011] Figure 2 It is a top view of the lower die of the stamping die (A), a cross-sectional view of the stamping die based on the AA line in Figure A (B), and a cross-sectional view of the stamping die based on the BB line in Figure A (C, D), and is a cross-sectional view (C) showing the main parts before forming, and a cross-sectional view (D) showing the main parts after forming.

[0012] Figure 3 As specific examples of curling, it is a cross-sectional view (A) showing a curling process of a forming mold in the vertical direction, and a cross-sectional view (B) showing a curling process by a forming roll in the vertical direction.

[0013] Figure 4 The figures show an example of using a molding die for curling in a method of manufacturing a panel body, and are a cross-sectional view (A) showing a state during pre-molding, and a cross-sectional view (B) showing a state during full molding.

[0014] Figure 5It is a diagram showing an example of using a curling forming roller in a panel body manufacturing method, and is a graph showing the surface change amount of the second panel when the second panel has a curved surface convex toward the outside of the room (A), when the second panel has a curved surface concave toward the outside of the room (B), and when the second panel is flat (C). DETAILED DESCRIPTION

[0015] Figure 1 to Figure 5 1 is a diagram showing an embodiment of a method for manufacturing a panel body according to the present invention. The panel body of this embodiment is a door panel Dp of an automobile, and includes an inner panel Ip as a first panel and an outer panel Op as a second panel.

[0016] like Figure 1 As shown in (A), the inner panel Ip has a structure in which two panel parts B1 and B2 of different plate thicknesses are butted and joined. The inner panel Ip is called a so-called tapered blank, and the panel part B1 with a relatively large plate thickness t1 is arranged on the upper side of the door, and the panel part B2 with a relatively small plate thickness t2 is arranged on the lower side of the door.

[0017] In addition, the inner panel Ip has a structure in which two panel members B1 and B2 are butted and integrated by, for example, the well-known friction stir welding (FSW) etc. Thus, the inner panel Ip has a joined portion W along the step difference caused by the difference in plate thickness between the two panel members B1 and B2. In the case of friction stir welding, the joined portion W appears as a tool mark on its surface.

[0018] The outer panel Op is a metal plate that forms the appearance of the door panel Dp and is arranged to face the outer side of the inner panel Ip. Figure 1 As shown in (C), the edge portion is connected to the inner panel Ip by curling.

[0019] In the manufacturing method of the panel body, the inner panel Ip is subjected to a stamping process, such as Figure 1 As shown in (B), the main surfaces of the two panel members B1 and B2 on the side of the joined portion W are formed to be coplanar with each other. As a result, the inner panel Ip forms an inclined portion S caused by the difference in plate thickness between the two panel members B1 and B2 on the inner side of the joined portion W. In addition, in the accompanying drawings, the difference in plate thickness between the two panel members B1 and B2 is exaggerated for easy understanding, and the actual slope of the inclined portion S is smaller than the slope shown in the drawings.

[0020] Able to use Figure 2 The stamping die shown in the figure performs the stamping process of the inner panel Ip. The stamping die has Figure 2 The fixed lower mold 51 shown in (A) and (B), and the upper mold 52 opposite to the lower mold 51 and capable of being raised and lowered, as shown in FIG. Figure 2 As shown in (C) and (D), in the portion where the joined portion W of the inner panel Ip is molded, the upper surface of the lower mold 51 is flat, and the lower surface of the upper mold 52 has a reverse shape of the surface on the joined portion W side of the inner panel Ip.

[0021] Moreover, if Figure 2 As shown in (C), the stamping die is arranged in the lower die 51 so that the surface of the inner panel Ip on the side of the joined portion W faces downward, and then the upper die 52 is lowered, thereby Figure 2 As shown in (D), the surface of the inner panel Ip on the side of the joined portion W is flattened, and an inclined portion S is formed on the back side of the joined portion W.

[0022] Next, in the manufacturing method of the panel body, as Figure 1 As shown in (C), the main surface of the inner panel Ip on the side of the joined portion W is arranged on the outer panel Op side, and the edge portion of the inner panel Ip including the inclined portion S is rolled toward the outer panel Op, thereby connecting the inner panel Ip and the outer panel Op.

[0023] Regarding the curling of the outer panel Op, you can use Figure 3 (A) The curling of the molding die 11 shown in FIG. Figure 3 (B) The curling of the forming rollers 21 and 22 shown. In this case, no matter which curling method is adopted, the flange F is formed on the edge of the outer panel Op in the previous step.

[0024] The curling by the molding die 11 uses a lower mold 12, a preforming mold 13 disposed on the upper mold side (not shown), and a main molding die 14 disposed on the upper mold side. The preforming mold 13 has an inclined surface 13A for preliminary bending.

[0025] Then, in order to perform the curling, the outer panel Op is arranged on the lower mold 12 with the flange F facing upward, and then the edge of the inner panel Op is arranged in correspondence with the vicinity of the flange F. Then, as shown in FIG. Figure 3 As shown in the upper side of (A), the flange F is preliminarily bent at an appropriate angle (for example, 45 degrees) using the inclined surface 13A of the preforming die 13. Figure 3 As shown in the lower side of (A), the flange F is bent by the main molding die 14 so as to sandwich the edge of the inner panel Ip to complete the curling.

[0026] The curling by the forming rolls uses the lower die 12, the preforming roll 21, and the main forming roll 22. The preforming roll 21 has a conical surface 21A, and the main forming roll 22 is formed in a cylindrical shape.

[0027] Furthermore, in order to perform the curling, the outer panel Op and the inner panel Ip are arranged in the same manner as the molding die 11, as shown in FIG. Figure 3As shown in the upper side of (B), the preforming roller 21 is rolled along the edge of the outer panel OP, and the flange F is preliminarily bent at an appropriate angle (for example, 45 degrees) by the conical surface 21A. Figure 3 As shown in the lower side of (B), the flange F is bent by the main forming roller 22 so as to sandwich the edge of the inner panel Ip, thereby completing the curling.

[0028] Regarding the manufacturing method of the panel body according to the present invention, when the outer panel Op is curled by using the molding die 11, as shown in FIG. Figure 4 As shown on the upper side of the figure, the flange F is pre-bent at an appropriate angle (e.g., 45 degrees) using the lower mold 12 and the pre-molding mold 13 having a stepped molding surface FS corresponding to the two panel parts B1, B2 and the inclined portion S of the inner panel Op. The molding surface FS can also be formed into a structure having an inclined surface along the inclined portion S, but even a stepped shape as shown in the example shown in the figure can achieve good curling. In addition, Figure 4 is based on Figure 1 (C) is a cross-sectional view taken along line AA.

[0029] Then, if Figure 4 As shown on the lower side, a formal molding die 14 having a stepped molding surface FS corresponding to the two panel parts B1, B2 and the inclined portion S of the inner panel Op is used to bend the flange F in a manner that clamps the edge of the inner panel Ip to complete the curling.

[0030] In addition, in the method for manufacturing a panel body according to the present invention, when the outer panel Op is curled by the pre-forming roller 21 and the main forming roller 22, as shown in FIG. Figure 3 As shown in (B), a pre-forming roller 21 and a formal forming roller 22 are used to roll along the arrangement direction of the two panel parts B1 and B2. At this time, in the manufacturing method of the panel body, as a more preferred embodiment, each forming roller 21, 22 is rolled in the direction from the panel part B2 with a smaller plate thickness to the panel part B1 with a larger plate thickness via the inclined portion S to be rolled toward the outer panel Op.

[0031] Here, in the present embodiment, the panel body is the door panel Dp, so the outer panel Op has a curved surface in many cases. In this case, it is preferred that the inclined portion S of the inner panel Ip is arranged within the range of the curved surface.

[0032] The reason is that when the hemming is performed using the forming rollers 21 and 22, Figure 5 As shown, as the feeding direction of the forming roller, if the direction from the panel part B2 with a smaller plate thickness via the inclined portion S to the panel part B1 with a larger plate thickness is set as the positive direction, and the opposite direction is set as the negative direction, the surface change amount of the outer panel Op will be different depending on the bending direction of the outer panel Op.

[0033] Specifically, if Figure 5 As shown, when the outer panel Op has a curved surface that bulges toward the outside (outside the vehicle), the surface change amount of the outer panel Op in the positive direction is reduced compared to the reverse direction. In addition, when the outer panel Op has a curved surface that is recessed toward the outside, the surface change amount of the outer panel Op in both the positive and reverse directions is reduced compared to the case where it bulges toward the outside, and in particular, the surface change amount of the outer panel Op in the positive direction is reduced compared to the reverse direction. Furthermore, when the outer panel Op is flat, the appearance quality of the outer panel Op may be impaired in the reverse direction, but if it is set to the positive direction, the surface change amount of the outer panel Op is extremely small.

[0034] According to the above, when curling is performed using a forming roller, not only when the outer panel Op is flat, but also when the outer panel Op has a curved surface, by setting the feed direction of the forming roller to the positive direction, even if the forming roller rolls in the direction from the panel part B2 with a smaller plate thickness via the inclined portion S to the panel part B1 with a larger plate thickness, it is possible to suppress the generation of strain in the outer panel Op and obtain good appearance quality.

[0035] Regarding the manufacturing method of the above-mentioned panel body, when manufacturing a door panel (panel body) Dp having an inner panel (first panel) Ip and an outer panel (second panel) Op, the inner panel Ip is stamped so that the main surfaces on the side of the joined portion W are coplanar with each other and are formed in a state where an inclined portion S appears on the inner side thereof, and the main surface of the inner panel Ip on the side of the joined portion W is arranged on the side of the outer panel Op, and the edge portion of the inner panel Ip including the inclined portion S is rolled toward the outer panel Op to connect the inner panel Ip and the outer panel Op.

[0036] Therefore, according to the manufacturing method of the panel body, Figure 1 As shown by the dotted line in (C), the joined portion (tool mark) W of the panel parts B1 and B2 of the inner panel Ip is arranged on the inner side of the door panel Dp, and the strain of the outer panel Op is also suppressed, so that the good appearance quality of the inside and outside of the door panel Dp can be taken into account.

[0037] In addition, if Figure 1 As shown by the virtual line in (C), the rubber component G such as the sealing strip is installed on the side showing the thickness of the door panel Dp. At this time, if the joined portion (tool mark) W is exposed on the outside of the inner panel Ip, the rubber component G may contact the joined portion W, resulting in reduced durability. In contrast, the door panel Dp manufactured by the above manufacturing method has the joined portion W arranged inside, thereby eliminating the contact between the joined portion W and the rubber component G, and maintaining the durability of the rubber component G.

[0038] Furthermore, regarding the manufacturing method of the above-mentioned panel body, the outer panel Op is curled using a molding mold 11 having a molding surface FS corresponding to the two panel parts B1, B2 and the inclined portion S of the inner panel Ip, thereby making it difficult to transfer the strain caused by the inclined portion S to the outer surface of the outer panel Op, thereby improving the appearance quality of the curled portion.

[0039] In addition, regarding the manufacturing method of the above-mentioned panel body, the outer panel Op is curled using forming rollers 21 and 22 that roll along the arrangement direction of the two panel parts B1 and B2, thereby making it difficult to transfer the strain caused by the inclined portion S to the outer surface of the outer panel Op, thereby improving the appearance quality of the curled portion.

[0040] Furthermore, with regard to the manufacturing method of the above-mentioned panel body, the forming rollers 21 and 22 are rolled in the direction from the panel part B2 with a smaller plate thickness via the inclined portion S to the panel part B1 with a larger plate thickness to perform curling toward the outer panel Op, thereby further suppressing the strain generated by the inclined portion S, and especially with regard to the structure in which the plate thickness difference between the panel parts B1 and B2 is large, the appearance quality of the curled part can also be further improved.

[0041] Furthermore, regarding the manufacturing method of the above-mentioned panel body, by forming a structure in which the outer panel Op has a curved surface and the inclined portion S of the inner panel Ip is arranged within the range of the curved surface, even if the difference in plate thickness between the panel parts B1 and B2 is large, the strain caused by the inclined portion S can be further suppressed, and the lightweight effect can be further improved.

[0042] Furthermore, the manufacturing method of the above-mentioned panel body is not only suitable for the manufacture of door panels Dp, but also suitable for the manufacture of panel bodies such as the engine hood panel and the trunk lid panel (track lid panel) of the automobile, especially the manufacture of panel bodies that perform opening and closing operations, and can provide a panel body with excellent internal and external appearance quality.

[0043] Description of the label

[0044] B1, B2 panel parts

[0045] Dp door panel (panel body)

[0046] FS molding surface

[0047] IP inner panel (1st panel)

[0048] Op outer panel (2nd panel)

[0049] S inclined part

[0050] W Joined part (tool marks)

[0051] 11 Molding mold

[0052] 21 Preforming roller (forming roller)

[0053] 22 Formal forming roller (forming roller)

Claims

1. A method for manufacturing a panel body, characterized in that: The panel body comprises: a first panel having a structure in which two panel members having different plate thicknesses are butted and joined; and a second panel arranged outside the first panel and connected by curling. When manufacturing the panel body, The first panel is subjected to a press process so that the main surfaces of the two panel members on the side of the joined portion are coplanar with each other and are formed into a state where an inclined portion due to a plate thickness difference appears on the inner side thereof. The main surface of the first panel on the side of the joined portion is arranged on the side of the second panel, The first panel and the second panel are connected to each other by curling the edge of the first panel including the inclined portion on the second panel.

2. The method for manufacturing a panel body according to claim 1, characterized in that: When the second panel is curled, A molding die having molding surfaces corresponding to the two panel members and the inclined portion of the first panel is used.

3. The method for manufacturing a panel body according to claim 1, characterized in that: When the second panel is curled, A forming roller is used which rolls along the arrangement direction of the two panel members.

4. The method for manufacturing a panel body according to claim 3, characterized in that: The forming roller is rolled in a direction from the panel material having a smaller plate thickness to the panel material having a larger plate thickness via the inclined portion to perform curling toward the second panel.

5. The method for manufacturing a panel body according to claim 1, characterized in that: The second panel has a curved surface, The inclined portion of the first panel is arranged within the range of the curved surface.

6. The method for manufacturing a panel body according to claim 1, characterized in that: The panel body is at least one of a door panel, a hood panel, and a trunk lid panel of a car, The first and second panels are an inner panel and an outer panel.

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