Attachment structure of electrical component and manufacturing method of attachment structure

Abstract

To obtain an attachment structure of an electric component which can inhibit deterioration of strength while inhibiting increase of attachment work hours and costs, and to obtain a manufacturing method of the attachment structure.SOLUTION: An attachment structure 10 of an electrical component, includes: plural first attachment seating surfaces which are provided at positions at which the electrical component is attached at a vehicle 12 and each of which is formed with an attachment hole; and plural second attachment seating surfaces 20A, each of which is formed with a score processing hole 30 on which notch processing has been performed along a shape of a hole to be penetrated. The plural first attachment seating surfaces and the plural second attachment seating surfaces 20A are formed at heights different omfr a height of other regions 22.SELECTED DRAWING: Figure 4

Description

Technical Field

[0001] The present invention relates to an attachment structure for electrical components and a method for manufacturing the attachment structure.

Background Art

[0002] Patent Document 1 discloses that electrical components such as antenna feeder lines are fixed using clips to mounting holes provided in panel materials on the roof side, for example. In this way, when forming mounting holes for attaching clips and components, the processing positions of the mounting holes vary depending on the vehicle type and specifications. Therefore, conventionally, a plurality of mounting holes are formed in consideration of a plurality of vehicle types and specifications, and the mounting holes not used for each vehicle are covered with covers or the like.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in the method of covering unused mounting holes with covers or the like, the mounting man-hours and costs increase by the amount of the covers. On the other hand, score processing is known in which notches are provided along the shape of a desired hole at the installation position of the mounting hole. By punching out the inside of the hole subjected to score processing, a mounting hole is formed as needed. However, at positions where the mounting hole is unnecessary, the score processing remains and notches remain, so the strength may decrease, and there is room for improvement in terms of strength.

[0005] The present disclosure has been made in view of the above circumstances, and an object thereof is to provide an attachment structure for electrical components and a method for manufacturing the attachment structure that can suppress an increase in attachment man-hours and costs and suppress a decrease in strength.

Means for Solving the Problems

[0006] The mounting structure of the electrical component according to the present invention described in claim 1 is provided at a position in the vehicle where the electrical component is to be mounted, and includes a first mounting seat surface provided with mounting holes and a second mounting seat surface provided with a score processing hole formed by notch processing along the shape of the hole to be penetrated, and the first mounting seat surface and the second mounting seat surface are formed at different heights from other regions.

[0007] In the mounting structure of the electrical component according to the present invention described in claim 1, mounting holes are formed in the first mounting seat surface provided at a position in the vehicle where the electrical component is to be mounted, and score processing holes formed by notch processing along the shape of the hole to be penetrated are formed in the second mounting seat surface, respectively. That is, mounting holes are formed at positions necessary for mounting the electrical component in the vehicle, and score processing holes are formed at positions unnecessary for mounting the electrical component in the vehicle. Since the score processing holes are subjected to notch processing but not penetrated, a cover for closing mounting holes unnecessary in the vehicle is not required. Thereby, an increase in the mounting man-hours and cost required for the cover can be suppressed.

[0008] Further, in the mounting structure of the electrical component according to the present invention described in claim 1, the first mounting seat surface and the second mounting seat surface are formed at different heights from other regions. Therefore, since stress is dispersed in the second mounting seat surface where the score processing hole is formed, stress concentration in the score processing hole is alleviated, and it is possible to prevent stress from concentrating in the score processing hole and causing cracks. Thereby, a decrease in the strength of the score processing hole can be suppressed.

[0009] The mounting structure of the electrical component according to the present invention described in claim 2 is formed by punching out the inside of a score processing hole formed by notch processing along the shape of the hole to be penetrated in the configuration described in claim 1.

[0010] In the mounting structure of the electrical component according to the present invention described in claim 2, since the mounting hole is formed by punching out the inside of the hole shape subjected to the notch processing, the mounting hole can be formed from the score processing hole as needed.

[0011] The mounting structure of the electrical component according to the present invention described in claim 3 is configured such that, in the configuration described in claim 1 or claim 2, the first mounting seat surface and the second mounting seat surface are formed at substantially the same height.

[0012] In the mounting structure of the electrical component according to the present invention described in claim 3, since the first mounting seat surface and the second mounting seat surface are formed at substantially the same height, by punching out the inside of the score processing hole formed in the second mounting seat surface, if necessary, a mounting hole at substantially the same level as the mounting hole formed in the first mounting seat surface can be formed at the position where the second mounting seat surface is provided.

[0013] The mounting structure of the electrical component according to the present invention described in claim 4 is such that at least one of the mounting hole and the score processing hole has at least two or more different shapes.

[0014] In the mounting structure of the electrical component according to the present invention described in claim 4, since at least one of the mounting hole and the score processing hole has at least two or more different shapes, a mounting hole having a shape corresponding to the type of the electrical component to be mounted can be provided.

[0015] The manufacturing method of the mounting structure according to the present invention described in claim 5 includes a seat forming step of forming a plurality of mounting seat surfaces at a position in the vehicle where an electrical component may be mounted and at a height different from other regions, a score processing step of performing notch processing along the shape of the hole to be penetrated on the plurality of mounting seat surfaces to form score processing holes, and a punching step of punching out the inside of the score processing hole provided at the position where the mounting of the electrical component is determined to form a mounting hole.

[0016] In the method for manufacturing the mounting structure according to the present invention described in claim 5, a score processing hole that has been notched along the shape of the hole to be penetrated is formed on a mounting seat surface that is formed at a height different from other regions. Since the score processing hole has been notched but not penetrated, a cover for closing a hole that is not necessary in the vehicle is not required. As a result, an increase in the mounting man-hours and cost required for the cover can be suppressed. In addition, since the stress is dispersed on the mounting seat surface, stress concentration in the score processing hole is alleviated, and it is possible to prevent stress from concentrating in the score processing hole and causing cracks. That is, a decrease in the strength of the score processing hole can be suppressed.

Effect of the Invention

[0017] The mounting structure of the electrical component and the method for manufacturing the mounting structure according to the present invention can suppress a decrease in strength while suppressing an increase in mounting man-hours and cost.

Brief Description of the Drawings

[0018]

Figure 1

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Figure 8

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Figure 12

Figure 13

Mode for Carrying Out the Invention

[0019] Hereinafter, with reference to FIGS. 1 to 9, an attachment structure 10 of an electrical component according to an embodiment of the present invention will be described. In the description of the drawings, the same or equivalent elements are denoted by the same reference numerals, and redundant descriptions are omitted.

[0020] FIG. 1 is a perspective view showing an example of a position where the setting of a score processing hole is being considered in a body 14 of a vehicle 12, FIG. 2 is a bottom view showing an example of a position where the setting of a score processing hole is being considered in a roof 16 of the vehicle 12, and FIG. 3 is an inner side view showing an example of a position where the setting of a score processing hole is being considered in a side door 18 of the vehicle. In each figure, the arrow FR appropriately shown indicates the front direction of the vehicle, and the arrow RH indicates the right direction of the vehicle, respectively.

[0021] As shown in FIGS. 1 to 3, the mounting structure 10 of the electrical component is provided with a plurality of mounting seat surfaces 20 for forming score processing holes 30 described later at positions P where electrical components (not shown) may be mounted in panels 12A and the like used for the body 14, roof 16, side door 18, etc. of the vehicle 12, for example. Here, in FIGS. 1 to 3, the position shown as a circle, for example, is defined as the position P where electrical components (not shown) may be mounted. As shown in FIGS. 1 to 3, in the vehicle 12, the position P is set everywhere. In particular, in hybrid electric vehicles (HEV), plug-in hybrid electric vehicles (PHEV), fuel cell electric vehicles (FCEV), battery electric vehicles (BEV), etc., the number of positions P is larger compared to gasoline vehicles.

[0022] FIG. 4 is a plan view and a side view showing an example of the score processing hole 30 formed in the second mounting seat surface 20A, FIG. 5 is a perspective view showing an example of the score processing hole 30, and FIG. 6 is a cross-sectional view taken along line A-A of FIG. 5. As shown in FIG. 4, the mounting seat surface 20 is formed in a rectangular shape, for example, and is formed at a height different from that of the other region 22. In the present embodiment, for example, the mounting seat surface 20 is formed lower than the other region 22 by a height H.

[0023] Specifically, a rectangular frame 24 larger than the mounting seat surface 20 is set so as to surround the mounting seat surface 20. This rectangular frame 24 is set at substantially the same height as the other region 22, and an inclination 26 is provided so as to smoothly connect from the rectangular frame 24 to the mounting seat surface 20.

[0024] At approximately the center of the mounting seat surface 20, a score processing hole 30 is formed. Here, in the present embodiment, the mounting seat surface 20 in which the score processing hole 30 is formed is defined as the second mounting seat surface 20A. As shown in FIGS. 5 and 6, the score processing hole 30 is subjected to a notch processing along the shape of the hole to be penetrated. That is, a notch 32 is formed by cutting along the thickness direction of the panel 12A along the shape of the hole. As shown in FIG. 6, the notch 32 is formed to be sharp.

[0025] Here, the process of forming the score processing hole 30 by score processing (also referred to as notch processing) will be described. FIG. 7 is an explanatory diagram for explaining the score processing.

[0026] As shown in the left diagram of FIG. 7, a score processing machine 40 is used for the score processing to form the score processing hole 30. Note that any machine may be used as long as it can form the score processing hole 30, and it is not particularly limited. In the present embodiment, as an example, the score processing machine 40 includes a mold 42 on which the panel 12A is placed and a rotating part 44 located above the panel 12A placed on the mold 42. As an example, the rotating part 44 has an open-top cylindrical box shape, is vertically movable by a motor (not shown), and is rotatable about a shaft 44A. A score processing blade 46 is attached to the bottom surface of the rotating part 44, and the attachment position of this score processing blade 46 can be changed according to the shape of the score processing hole 30 to be formed.

[0027] By bringing the score processing blade 46 into contact with the mounting seat surface 20 of the panel 12A placed on the mold 42 and rotating the rotating part 44, as shown in the right diagram of FIG. 7, a score processing hole 30 with a notch 32 formed in the desired hole shape is formed. Note that in the present embodiment, as an example, the score processing hole 30 has two or more different shapes in terms of size and shape according to the position P where the mounting seat surface 20 is installed.

[0028] Next, the mounting hole 50 will be described. FIG. 8 is a plan view and a side view showing an example of the mounting hole 50 formed in the first mounting seat surface 20B. The mounting hole 50 of the present embodiment is formed, as an example, by punching out the inside of the score processing hole 30 in the second mounting seat surface 20A in which the score processing hole 30 is formed as described above. The mounting seat surface 20 having the mounting hole 50 formed in this way is used as the first mounting seat surface 20B. That is, the second mounting seat surface 20A becomes the first mounting seat surface 20B when the score processing hole 30 is processed into the mounting hole 50.

[0029] Here, the punching process of processing the score processing hole 30 into the mounting hole 50 by punching will be described. FIG. 9 is an explanatory diagram for explaining the punching process.

[0030] As shown in FIG. 9, a punching machine 60 is used for the punching process of forming the mounting hole 50. The punching machine 60 may be any machine as long as it can punch out the inside of the score processing hole 30, and is not particularly limited. In the present embodiment, as an example, the punching machine 60 has a metal punch portion 62 and includes a rotating portion 64 formed to be rotatable about a shaft 64A.

[0031] The panel 12A having the second mounting seat surface 20A in which the score processing hole 30 is formed is held by a die portion (not shown), and the punch portion 62 is rotated, so that the inside of the score processing hole 30 is punched and penetrated to form the mounting hole 50. The mounting seat surface 20 having the mounting hole 50 formed in this way becomes the first mounting seat surface 20B. In the present embodiment, as an example, since the score processing hole 30 has two or more types of shapes different in size and shape according to the position P where the mounting seat surface 20 is installed, when the mounting hole 50 is formed from the score processing hole 30, similarly, depending on the position P where the mounting seat surface 20 is installed, there may be two or more types of shapes different in size and shape.

[0032] Next, a manufacturing method of the mounting structure 10 of the electrical components of the vehicle 12 according to an embodiment of the present invention will be described. FIG. 10 is a flowchart showing a series of manufacturing steps of the mounting structure 10 of the electrical components according to an embodiment of the present invention.

[0033] First, in step S11, in the vehicle 12, a seating surface forming machine (not shown) forms a plurality of mounting seating surfaces 20 at a position P where an electrical component may be mounted and at a height different from that of other regions 22. The seating surface forming machine may use any processing machine as long as it can form the mounting seating surface 20, and is not particularly limited.

[0034] Next, in step S12, a scoring machine 40 performs a notching process on the plurality of mounting seating surfaces 20 along the shape of the hole to be penetrated to form scoring holes 30.

[0035] Next, in step S13, for each of the plurality of mounting seating surfaces 20, it is determined whether it is the mounting position of the electrical component in the vehicle 12. This determination is made, for example, by the CPU of a management device that manages a series of manufacturing steps.

[0036] In step S13, if it is the mounting position of the electrical component (step S13; YES), in step S14, a punching machine 60 punches the inside of the scoring hole 30 of the mounting seating surface 20 to form a mounting hole 50, and the process proceeds to step S15.

[0037] On the other hand, in step S13, if it is not the mounting position of the electrical component (step S13; NO), in step S15, for example, the CPU determines whether all of the plurality of mounting seating surfaces 20 have been completed. If all of the mounting seating surfaces 2 have not been completed (step S15; NO), the process proceeds to step S13.

[0038] In step S15, if all of the mounting seating surfaces 20 have been completed (step S15; YES), the series of manufacturing steps ends.

[0039] Next, the operation and effect of the mounting structure 10 of the electrical components of the vehicle 12 and the manufacturing method of the mounting structure 10 in the present embodiment will be described.

[0040] In the mounting structure 10 of the electrical components according to the present embodiment, a mounting hole 50 is formed in the first mounting seat surface 20B provided at the position where the electrical components are mounted in the vehicle 12, and a score processing hole 20 subjected to notch processing along the shape of the hole to be penetrated in the second mounting seat surface 20A is formed. That is, a mounting hole 50 is formed at a position necessary for mounting the electrical components in the vehicle 12, and a score processing hole 20 is formed at a position unnecessary for mounting the electrical components in the vehicle 12. Since the score processing hole 20 is subjected to notch processing but not penetrated, a cover for closing a hole unnecessary in the vehicle 12 is not required. Thereby, an increase in the mounting man-hours and cost required for the cover can be suppressed.

[0041] Further, in the mounting structure 10 of the electrical components according to the present embodiment, the mounting seat surface 20, that is, the first mounting seat surface 20B and the second mounting seat surface 20A, are formed at a height different from that of the other region 22. Here, a conventional example in which stress concentration is alleviated by a seat surface formed at a height different from that of other regions will be described. FIG. 11 is a plan view and a side view showing an example of a spot welding portion 110 provided on the seat surface 120, FIG. 12 is a diagram showing an example of the stress distribution of the spot welding portion 110 when the seat surface 120 is not present, and FIG. 13 is a diagram showing an example of the stress distribution of the spot welding portion 110 when the seat surface 120 is present.

[0042] In the conventional example, as shown in FIG. 11, a first sheet metal 100A provided with a seat surface 120 and a second sheet metal 100B not provided with the seat surface 120 are spot-welded, and a spot welding portion 110 is formed on the seat surface 120. The seat surface 120 is formed at a height different from that of the other region 122. Specifically, similar to the mounting seat surface 20 of the present embodiment described above, the seat surface 120 is formed lower than the other region 122. The spot welding portion 110 is formed at a substantially central portion of the seat surface 120. In addition, in FIG. 11, for the sake of convenience, the first sheet metal 100A and the second sheet metal 100B are shown by solid lines, but actually have a thickness.

[0043] As shown in FIG. 12, when there is no seating surface 120, that is, when the spot weld 110 is provided at the same height as the other region 22, as shown by σ1, stress was concentrated at the joint where the spot weld 110 was formed. On the other hand, as shown in FIG. 13, when there is a seating surface 120, that is, when the spot weld 110 is provided at a different height from the other region 22, as shown by σ2, stress was also dispersed around the seating surface 120. From this, it can be seen that when stress is applied, having the seating surface 120 reduces stress concentration compared to not having the seating surface 120.

[0044] On the other hand, as shown in FIGS. 1 to 3, the position P where the setting of the score hole 30 is being considered exists in many parts, and the score hole 30 is also desired to be installed for parts with strict strength performance requirements. However, for example, when installing the score hole 30 at a position where stress such as repeated opening and closing operations is applied, like the side door 18 in FIG. 3, the strength may be insufficient due to the notch 32. In this case, measures such as increasing the sheet thickness of the sheet metal used for the panel 12A are necessary, or it is necessary to attach a cover that closes the hole after piercing the hole in the conventional manner without performing score processing.

[0045] Therefore, in the mounting structure 10 of the electrical component according to the present embodiment, the score hole 20 is formed on the second mounting seating surface 20A (mounting seating surface 20) formed at a different height from the other region 22. Therefore, when stress is applied, stress is dispersed at the second mounting seating surface 20A, so stress concentration in the score hole 20 is alleviated, and it is possible to prevent stress from concentrating in the score hole 20 and causing cracking. Thereby, a decrease in the strength of the score hole 20 can be suppressed.

[0046] In this way, in the mounting structure 10 of the electrical component according to the present embodiment, it is possible to suppress a decrease in strength while suppressing an increase in mounting man-hours and costs.

[0047] Further, in the mounting structure 10 of the electrical component according to the present embodiment, since the mounting hole 50 is formed by punching out the inside of the hole shape subjected to the notch processing, the mounting hole 50 can be formed from the score processing hole 20 as needed. That is, by processing the score processing hole 30 formed in the second mounting seat surface 20A into the mounting hole 50, the second mounting seat surface 20A can be used as the first mounting seat surface 20B.

[0048] Further, in the mounting structure 10 of the electrical component according to the present embodiment, since the first mounting seat surface 20B and the second mounting seat surface 20A are formed at substantially the same height, by punching out the inside of the score processing hole 30 formed in the second mounting seat surface 20A, as needed, a mounting hole 50 at substantially the same level as the mounting hole 50 formed in the first mounting seat surface 20B can be formed at the position where the second mounting seat surface 20A is provided.

[0049] Further, in the mounting structure 10 of the electrical component according to the present embodiment, since the mounting hole 50 and the score processing hole 30 have at least two or more different shapes, a mounting hole 50 having a shape corresponding to the type of the electrical component to be mounted can be provided.

[0050] Further, in the manufacturing method of the mounting structure 10 of the electrical component according to the present embodiment, the score processing hole 30 subjected to the notch processing along the shape of the hole to be penetrated is formed in the mounting seat surface 20 formed at a height different from that of the other region 22. Since the score processing hole 30 is subjected to the notch processing but does not penetrate, a cover for closing the holes that are not necessary in the vehicle is not required. Thereby, an increase in the mounting man-hours and cost required for the cover can be suppressed. Further, since the stress is dispersed on the mounting seat surface 20, the stress concentration in the score processing hole 30 is alleviated, and it is possible to prevent the score processing hole 30 from cracking due to stress concentration. That is, a decrease in the strength of the score processing hole 30 can be suppressed.

[0051] [Remarks] In the above-described embodiment, the mounting seat surface 20 is rectangular, but the present invention is not limited thereto. For example, it may be circular, rectangular, or the shape is not particularly limited. Similarly, the shapes of the score processing holes 30 and the mounting holes 50 are not limited to circular shapes, and any shape may be used.

[0052] Further, in the above-described embodiment, the score processing holes 30 and the mounting holes 50 have two or more different shapes in terms of size and shape according to the position P where the mounting seat surface 20 is installed, but the present invention is not limited thereto. For example, only one of the score processing holes 30 and the mounting holes 50 may have two or more different shapes. Also, both the score processing holes 30 and the mounting holes 50 may have only the same shape.

[0053] In the above-described embodiment, the first mounting seat surface 20B is formed by punching out the inside of the score processing hole 30 formed in the second mounting seat surface 20A and passing through the mounting hole 50, but the present invention is not limited thereto. In the mounting seat surface 20 formed at a position where the mounting hole 50 is required in advance in the vehicle 12, the mounting hole 50 may be formed by a known hole processing technique, and the mounting seat surface 20 in which the mounting hole 50 is formed may be used as the first mounting seat surface 20B. In this case, the first mounting seat surface 20B and the second mounting seat surface 20A may be formed at different heights.

[0054] The configuration of the present invention is not limited to the above-described embodiment, and the configuration can be appropriately changed as long as the problem can be solved.

Explanation of Reference Numerals

[0055] 10 Mounting structure of electrical components, 12 Vehicle, 20 Mounting seat surface, 20A Second mounting seat surface, 20B First mounting seat surface, 30 Score processing hole, 50 Mounting hole

Claims

1. A first mounting seat surface provided at a position in a vehicle where an electrical component is to be mounted and having a mounting hole formed therein, and a second mounting seat surface having a score processing hole formed by notch processing along the shape of the hole to be penetrated, and comprising: An attachment structure for an electrical component in which the first attachment seat surface and the second attachment seat surface are formed at a height different from other regions.

2. The attachment structure for an electrical component according to claim 1, wherein the attachment hole is formed by punching out the inside of a score processing hole formed by notch processing along the shape of the hole to be penetrated.

3. The attachment structure for an electrical component according to claim 1, wherein the first attachment seat surface and the second attachment seat surface are formed at substantially the same height.

4. The attachment structure for an electrical component according to claim 1, wherein at least one of the attachment hole and the score processing hole has at least two different shapes.

5. In a vehicle, a seat surface forming step of forming a plurality of attachment seat surfaces at a position where an electrical component may be attached and at a height different from other regions, and a score processing step of performing notch processing along the shape of the hole to be penetrated on the plurality of attachment seat surfaces to form score processing holes, and a punching step of punching out the inside of the score processing hole to form an attachment hole in the score processing hole provided at the position where the attachment of the electrical component is determined; A manufacturing method for an attachment structure comprising:

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