Method for manufacturing panel body

Abstract

A manufacturing method, in manufacturing a panel body Dp, the panel body Dp has: a first panel Ip having a structure for butt-joining and joining two panel pieces B1 and B2 with different thicknesses; and a second panel Op disposed on the outside of the first panel Ip and connected by a rolled edge, wherein the first panel Ip is stamped such that the main surfaces of the joined portion W side of the two panel pieces B1 and B2 are coplanar with each other and formed into a state in which an inclined portion S caused by the difference in thickness appears on its inner side, the main surface of the joined portion W side of the first panel Ip is disposed on the side of the second panel Op, and the edge portion of the first panel Ip including the inclined portion S is rolled towards the second panel Op, thereby taking into account the appearance quality of the inner and outer surfaces of the panel body Dp.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a panel having a first panel and a second panel, and particularly to a method for manufacturing a panel having: a first panel having a structure for joining two panel pieces of different thicknesses; and a second panel disposed on the outside of the first panel and joined by a rolled edge. Background Technology

[0002] Currently, as a method for manufacturing the panel body as described above, there is, for example, the method described in Patent Document 1. The method for manufacturing the panel body described in Patent Document 1 is a method for manufacturing a panel body that includes: a first panel, which is composed of a differential thickness member that joins multiple parts of different thicknesses together by welding; and a second panel, which is opposite to the first panel.

[0003] The above manufacturing method involves crimping the edge of the first panel, including the stepped portion obtained based on the thickness difference, towards the second panel in a manner that clamps the edge. In this method, the stepped portion at the edge of the first panel is partially removed, and then the edge is crimped towards the second panel to join the first and second panels, thereby preventing or suppressing strain in the second panel.

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

[0005] However, in the current panel manufacturing method described above, the joints (welding marks) of the components of the first panel are exposed on the surface of the panel, which makes it difficult to balance the appearance quality of the panel inside and out, and there is a problem of solving this problem.

[0006] The present invention addresses the aforementioned problems and aims to provide a manufacturing method that can achieve good appearance quality both inside and outside the panel body during manufacturing. The panel body has: a first panel having a structure for joining two panel pieces of different thicknesses; and a second panel disposed outside the first panel and connected by a rolled edge.

[0007] The present invention relates to a method for manufacturing a panel body comprising: a first panel having a structure for butt-joining and joining two panel pieces of different thicknesses; and a second panel disposed on the outer side of the first panel and connected by a rolled edge. In this method, the first panel is stamped such that the main surfaces of the two panel pieces on the joining side are coplanar and formed such that an inclined portion due to the thickness difference appears on its inner side; the main surface of the first panel on the joining side is then disposed on the second panel side. Furthermore, the method is characterized in that the edge portion of the first panel, including the inclined portion, is rolled towards the second panel, thereby joining the first and second panels.

[0008] The effects of the invention

[0009] Regarding the method for manufacturing a panel body according to the present invention, by adopting the above structure, when manufacturing a panel body having a first panel and a second panel, the joint portion of the panel members of the first panel is 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 that allows two panel members with different thicknesses to be joined together, and the second panel is arranged on the outer side of the first panel and connected by a rolled edge. Attached Figure Description

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

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

[0012] Figure 3 These are cross-sectional views (A) showing the curling process of the forming mold in the vertical direction, and cross-sectional views (B) showing the curling process based on the forming roller in the vertical direction, as specific examples of curling.

[0013] Figure 4 The diagram shows an example of using a forming mold for edge curling in a panel manufacturing method, and is a cross-sectional view (A) showing the state during pre-forming, and a cross-sectional view (B) showing the state during final forming.

[0014] Figure 5This diagram illustrates an example of using a forming roller for edge curling in a panel manufacturing method. It is a graph showing the surface variation of the second panel in cases where the second panel has a curved surface protruding outwards (A), cases where the second panel has a curved surface concave outwards (B), and cases where the second panel is flat (C). Detailed Implementation

[0015] Figures 1-5 This diagram illustrates one embodiment of the manufacturing method of the panel body according to the present invention. The panel body of this embodiment is a car door panel Dp, having 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 pieces B1 and B2 with different thicknesses are butted and joined together. This inner panel Ip is called a so-called tapered blank, with panel piece B1, which has a relatively larger thickness t1, positioned on the upper side of the door, and panel piece B2, which has a relatively smaller thickness t2, positioned on the lower side of the door.

[0017] Furthermore, the inner panel Ip has a structure that allows the two panel pieces B1 and B2 to be joined together, achieving integration through, for example, a well-known friction stir welding (FSW) method. Thus, the inner panel Ip has a joined portion W along the step difference caused by the thickness difference between the two panel pieces B1 and B2. In the case of friction stir welding, the surface of the joined portion W appears as tool marks.

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

[0019] In the manufacturing method of the panel body, the aforementioned inner panel Ip is stamped, such as... Figure 1 As shown in (B), the main surfaces of the joined portions W of the two panel pieces B1 and B2 are formed to be coplanar. Consequently, the inner panel Ip forms a slope S on the inside of the joined portion W, caused by the thickness difference between the two panel pieces B1 and B2. Furthermore, the thickness difference between the two panel pieces B1 and B2 is exaggerated in the accompanying drawings for ease of understanding; the actual slope of the slope S is smaller than that shown in the drawings.

[0020] Able to utilize Figure 2 The stamping die shown is used for stamping the aforementioned inner panel Ip. The stamping die has... Figure 2 As shown in (A) and (B), the fixed lower mold 51 and the upper mold 52 opposite to the lower mold 51 and capable of being raised and lowered are as follows: Figure 2 As shown in (C) and (D), in the part where 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 reversed shape of the face of the inner panel Ip on the side where the inner panel Ip is molded.

[0021] Moreover, such as Figure 2 As shown in (C), the stamping die is positioned with the W-side of the inner panel Ip facing downwards on the lower die 51, 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 made flat, and an inclined portion S is formed on the inside side of the joined portion W.

[0022] Next, in the manufacturing method of the panel body, such 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 side of the outer panel Op, and the edge of the inner panel Ip, including the inclined portion S, is rolled towards the outer panel Op, thereby connecting the inner panel Ip and the outer panel Op.

[0023] Regarding the rolled edges of the outer panel Op, a method can be used... Figure 3 (A) The edge of the forming mold 11 shown in (A) is rolled, or using Figure 3 (B) shows the edge curling of forming rollers 21 and 22. At this time, regardless of which type of edge curling is used, a flange F is formed at the edge of the outer panel Op in the previous process.

[0024] Regarding the edge curling using the forming mold 11, a lower mold 12, a pre-forming mold 13 disposed on the upper mold side (not shown), and a formal forming mold 14 disposed on the upper mold side are used. The pre-forming mold 13 has an inclined surface 13A for preparing bending.

[0025] Furthermore, in order to perform edge curling, the outer panel Op is positioned on the lower die 12 with the flange F facing upwards, and then the edge portion of the inner panel Op is positioned correspondingly near the flange F. Then, as... Figure 3 As shown on the upper side of (A), the flange F is pre-bent at an appropriate angle (e.g., 45 degrees) using the inclined surface 13A of the preforming mold 13. Then, as... Figure 3 As shown on the lower side of (A), the flange F is bent by using the formal forming mold 14 to clamp the edge of the inner panel Ip to complete the crimping.

[0026] Regarding the edge curling using the forming roller, the lower die 12, the pre-forming roller 21, and the final forming roller 22 are used. The pre-forming roller 21 has a conical surface 21A, and the final forming roller 22 is formed into a cylindrical shape.

[0027] Furthermore, in order to perform edge curling, the outer panel Op and the inner panel Ip are configured in the same way as the forming mold 11, such as... Figure 3As shown on the upper side of (B), the preforming roller 21 is rolled along the edge of the outer panel OP, and the flange F is pre-bent at an appropriate angle (e.g., 45 degrees) using the conical surface 21A. Then, as shown... Figure 3 (B) is shown on the lower side. The flange F is bent by using the forming roller 22 to clamp the edge of the inner panel Ip to complete the crimping.

[0028] Regarding the method for manufacturing the panel body according to the present invention, when using the forming mold 11 to roll the outer panel Op, such as Figure 4 As shown on the upper side, the flange F is pre-bent at an appropriate angle (e.g., 45 degrees) using a lower mold 12 and a pre-forming mold 13 having a stepped forming surface FS corresponding to the two panel pieces B1 and B2 of the inner panel Op and the inclined portion S. The forming surface FS can also be formed with an inclined surface along the inclined portion S, but even a stepped shape as shown in the illustrated example can achieve good crimping. Furthermore, Figure 4 Based on Figure 1 (C) is a cross-sectional view along line AA.

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

[0030] Furthermore, in the panel manufacturing method of the present invention, when the outer panel Op is rolled using the pre-forming roller 21 and the formal forming roller 22, such as 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 pieces B1 and B2. In this case, in the panel body manufacturing method, as a more preferred embodiment, each forming roller 21 and 22 is rolled towards the outer panel Op in the direction from the panel piece B2 with a smaller plate thickness to the panel piece B1 with a larger plate thickness via the inclined portion S.

[0031] In this embodiment, the panel body is a door panel Dp, so in most cases the outer panel Op has a curved surface. In this case, the inclined portion S of the inner panel Ip is preferably disposed within the range of the curved surface.

[0032] The reason is that, when using forming rollers 21 and 22 for edge curling, such as Figure 5 As shown, if the direction of feeding the forming roller from the thinner panel piece B2 to the thicker panel piece B1 via the inclined part S is set as the positive direction and the opposite direction is set as the negative direction, then the surface change of the outer panel Op will vary depending on the bending direction of the outer panel Op.

[0033] Specifically, such as Figure 5 As shown, when the outer panel Op has a curved surface bulging outwards (outside the vehicle), the surface change of the outer panel Op in the forward direction is smaller compared to the reverse direction. Furthermore, when the outer panel Op has a curved surface recessed outwards, the surface change of the outer panel Op in both the forward and reverse directions is smaller compared to the bulging outwards case, especially in the forward direction. Moreover, when the outer panel Op is flat, the appearance quality of the outer panel Op may be compromised in the reverse direction, but if it is set to the forward direction, the surface change of the outer panel Op is minimal.

[0034] Based on the above, when using the forming roller for edge curling, 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 piece B2 with a smaller plate thickness to the panel piece B1 with a larger plate thickness via the inclined part S, it is possible to suppress strain on the outer panel Op and obtain good appearance quality.

[0035] Regarding the manufacturing method of the aforementioned 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 of the joined portion W side are coplanar and formed such that an inclined portion S appears on its inner side. The main surfaces of the joined portion W side of the inner panel Ip are placed on the outer panel Op side. The inner panel Ip and the outer panel Op are connected by rolling the edge of the inner panel Ip, including the inclined portion S, toward the outer panel Op.

[0036] Therefore, according to the above-mentioned panel manufacturing method, such as Figure 1 As shown by the dashed line in (C), the joint (tool mark) W of the panel parts B1 and B2 of the inner panel Ip is disposed 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 inner and outer parts of the door panel Dp can be taken into account.

[0037] In addition, such as Figure 1 (C) is shown by a virtual line, where a rubber component G, such as a sealing strip, is installed on the side that reflects the thickness of the door panel Dp. In this case, if the joined portion (tool mark) W is exposed on the outside of the inner panel Ip, the rubber component G may come into contact with the joined portion W, leading to a decrease in durability. In contrast, the door panel Dp manufactured using the above method has the joined portion W disposed internally, thus eliminating contact between the joined portion W and the rubber component G and maintaining the durability of the rubber component G.

[0038] Furthermore, regarding the aforementioned panel manufacturing method, the outer panel Op is rolled using a molding die 11 having two panel parts B1 and B2 corresponding to the inner panel Ip and a molding surface FS corresponding to the inclined portion S. This makes it less likely that the strain caused by the inclined portion S will be transferred to the outer surface of the outer panel Op, thereby improving the appearance quality of the rolled portion.

[0039] Furthermore, regarding the aforementioned panel manufacturing method, forming rollers 21 and 22, which roll along the arrangement direction of the two panel pieces B1 and B2, are used to curl the outer panel Op. This makes it less likely that the strain caused by the tilted portion S will be transferred to the outer surface of the outer panel Op, thereby improving the appearance quality of the curled portion.

[0040] Furthermore, regarding the aforementioned panel manufacturing method, the forming rollers 21 and 22 roll in a direction from the panel piece B2 with a smaller plate thickness to the panel piece B1 with a larger plate thickness via the inclined portion S to perform edge curling on the outer panel Op. This further suppresses strain caused by the inclined portion S, and in particular, for structures with a large difference in plate thickness between panel pieces B1 and B2, it also enables further improvement in the appearance quality of the edge-curled portion.

[0041] Furthermore, regarding the aforementioned panel manufacturing method, 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 disposed within the range of the curved surface, even with a large difference in thickness between panel parts B1 and B2, strain caused by the inclined portion S can be further suppressed, thereby further improving the lightweight effect.

[0042] Furthermore, the aforementioned panel manufacturing method is not only suitable for manufacturing door panels (DP), but also for automotive engine hood panels, trunk lid panels (track lid panel), and other panels, especially those that are opened and closed, providing panels with excellent internal and external appearance quality.

[0043] Explanation of the label

[0044] B1 and B2 panel components

[0045] DP door panel (panel body)

[0046] FS molding surface

[0047] IP inner panel (panel 1)

[0048] Op outer panel (second panel)

[0049] S-shaped inclined section

[0050] W is the joint area (tool marks)

[0051] 11 Molding mold

[0052] 21. Preforming Roller (Forming Roller)

[0053] 22 Forming Roller (Forming Roller)

Claims

1. A method for manufacturing a panel body, characterized in that, The panel body has: a first panel having a structure for butt-joining and frictionally stirring two panel pieces of different thicknesses; and a second panel disposed on the outside of the first panel and connected by a rolled edge. During the manufacture of this panel body, By stamping the first panel, the main surfaces of the two panel pieces on the joining side are made coplanar, and the panel is formed such that an inclined portion due to the thickness difference appears on its inner side. The main surface of the first panel on the side of the joined portion is disposed on the side of the second panel. The edges of the first panel, including the inclined portion, are rolled on the second panel, thereby connecting the first panel and the second panel.

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

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

4. The method for manufacturing a panel body according to claim 3, characterized in that, The forming roller rolls towards the second panel in a direction from the panel with a smaller thickness to the panel with a larger thickness via the inclined portion.

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 disposed 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 the following: a car door panel, an engine hood panel, and a trunk lid panel. The first panel is the inner panel, and the second panel is the outer panel.

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