Automotive panel structure and manufacturing method thereof

Abstract

This panel structure (10) for an automobile is provided with: a plate-shaped outer panel member (1); a resin member (2) disposed on the inner surface of the outer panel member (1); and an adhesive part (3) which adheres the outer panel member (1) and the resin member (2). The outer panel member (1) is provided with a base material (12) and a coating film (14) provided on the base material (12), the base material (12) has a plate thickness of 0.3 mm to 0.5 mm, the resin member (2) has a bending rigidity of 0.3×106 N·mm2 or more, and the adhesive part (3) contains a cured product of a room-temperature curable adhesive.

Description

[Technical field]

[0001] The present disclosure relates to an automotive panel structure and a method for manufacturing an automotive panel structure. This application claims priority based on Japanese Patent Application No. 2021-143779, filed on September 3, 2021, the contents of which are incorporated herein by reference. [Background technology]

[0002] Currently, there is a demand for technology to reduce the weight of automobiles. It is believed that if the outer panels of an automobile, such as the roof, hood, or doors, can be strengthened, sufficient strength can be maintained even if the outer panels are made thin. Therefore, in order to reduce the weight of automobiles, technology to strengthen the outer panels is being developed.

[0003] However, making the outer panel thinner brings about the problem of insufficient tensile rigidity. Tension rigidity is a characteristic that indicates how resistant an outer panel is to bending. For example, when you place your hand on the outer panel of a car, if the outer panel has high tensile rigidity, the outer panel will not bend easily.

[0004] As a countermeasure to the lack of tension rigidity, for example, Patent Document 1 describes a technology related to a reinforcement structure for an automobile body, which is formed by placing an inner panel on an outer panel via a foam layer, where the foam layer is a thermosetting resin foam with an expansion ratio of 1.03 to 1.30. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Publication No. 63-258274 Summary of the Invention [Problem to be solved by the invention]

[0006] In the method of Patent Document 1, the foam layer and the outer plate are heated at high temperature to bond them together. When the thickness of the outer plate is 0.6 mm or more, the outer plate is thick and surface distortion due to the difference in linear expansion coefficient between the members is unlikely to occur during bonding. However, when the outer plate (outer panel member) is made thin (for example, 0.3 mm to 0.5 mm thick) to reduce weight, surface distortion may occur in the outer plate due to the difference in linear expansion coefficient between the members during bonding, which may deteriorate the appearance.

[0007] The present invention has been made in consideration of the above circumstances, and has an object to provide an automobile panel structure that is lightweight, has excellent tensile stiffness, and has an excellent appearance, and a method for manufacturing an automobile panel structure. [Means for solving the problem]

[0008] In order to solve the above problems, the present invention proposes the following means. (1) An automobile panel structure according to one aspect of the present invention includes a plate-shaped outer panel member, a resin member disposed on an inner surface of the outer panel member; an adhesive portion that adheres the outer panel member and the resin member; Equipped with The outer panel member includes a base material and a paint film provided on the base material, The thickness of the base material is 0.3 mm to 0.5 mm, The bending rigidity of the resin member is 0.3×10 6 N mm 2 That's all. The adhesive portion contains a hardened product of a room temperature hardening adhesive. death, The resin member is a foamed resin. . (2) In the automobile panel structure described in (1) above, the area of ​​the resin member disposed on the inner surface of the outer panel member may be 50% or more of the total area of ​​the inner surface of the outer panel member. (3) In the automobile panel structure described in (2) above, an area of ​​the adhesive portion relative to an area of ​​the resin member may be 5% or more by area. (4) The automobile panel structure described in any one of (1) to (3) above may further include an inner member arranged opposite the inner surface of the outer panel member, and at least a portion of the inner member may be embedded in the resin member. (5) In the automobile panel structure described in (4) above, the inner member may extend along one direction in an in-plane direction of the outer panel member. (6) In the automobile panel structure according to any one of (1) to (5) above, the resin member may be made of a thermosetting resin. (7) In the automobile panel structure according to any one of (1) to (5) above, the resin member may be made of a thermoplastic resin. (8) In the automobile panel structure described in any one of (1) to (7) above, the room-temperature curing adhesive may be an acrylic adhesive. (9) In the automobile panel structure described in any one of (1) to (8) above, the outer panel member may have a tensile strength of 440 MPa or more. (10) In the automobile panel structure described in any one of (1) to (9) above, the thickness of a portion of the resin member whose dimension perpendicular to the in-plane direction of the outer panel member is maximum may be 3 mm or more and 60 mm or less. (11) In the automobile panel structure according to any one of (1) to (10) above, the resin member may not be painted.

[0009] (12) A method for manufacturing an automobile panel structure according to one aspect of the present invention includes the steps of: a coating process for coating a base material of the plate-shaped outer panel member; an adhesive application step of applying a room temperature curing adhesive to at least one of the inner surface of the outer panel member and the resin member after the painting step; and a bonding step of bonding an inner surface of the outer panel member and the resin member after the adhesive application step. The resin member is a foamed resin. . (13) In the manufacturing method for an automobile panel structure described above in (12), the area of ​​the resin member placed on the inner surface of the outer panel member may be 50% or more of the total area of ​​the inner surface of the outer panel member. (14) In the manufacturing method for an automobile panel structure described in (13) above, an application area of ​​the room-temperature curing adhesive may be 5 area % or more of the arrangement area of ​​the resin member. (15) In the manufacturing method for an automobile panel structure described in any one of (12) to (14) above, in the adhesive application process, the room temperature curing adhesive may be applied to the entire surface of at least one of the arrangement areas of the inner surface of the outer panel member and the resin member. (16) In the manufacturing method for an automobile panel structure described in any one of (12) to (14) above, in the adhesive application process, the room temperature curing adhesive may be applied in a line shape to at least one of the arrangement areas of the inner surface of the outer panel member and the resin member. (17) In the manufacturing method for an automobile panel structure described in any one of (12) to (14) above, in the adhesive application process, the room temperature curing adhesive may be applied in dot form to at least one of the arrangement areas of the inner surface of the outer panel member and the resin member. Effect of the Invention

[0010] According to the above-described aspects of the present invention, it is possible to provide an automobile panel structure that is lightweight, has excellent tensile stiffness, and has an excellent appearance, and a method for manufacturing the automobile panel structure. [Brief description of the drawings]

[0011] [Figure 1] 1 is a plan view of an automobile panel structure according to a first embodiment of the present invention; [Diagram 2] FIG. 2 is an end view taken along line AA of the automotive panel structure of FIG. [Diagram 3] 1 is a flowchart of a manufacturing method for an automobile panel structure according to a first embodiment of the present invention. [Figure 4]FIG. 13 is a diagram for explaining the application position of a room temperature curing adhesive. [Diagram 5] FIG. 4 is a plan view of an automobile panel structure according to a second embodiment of the present invention. [Figure 6] 6 is an end view taken along line BB of the automotive panel structure of FIG. 5. [Figure 7] 6 is an end view taken along line B1-B1 of the automobile panel structure of FIG. 5. [Figure 8] FIG. 11 is a plan view of an automobile panel structure according to a third embodiment of the present invention. [Figure 9] 9 is an end view taken along line CC of the automotive panel structure of FIG. 8. FIG. [Figure 10] 10 is a flowchart of a manufacturing method for an automobile panel structure according to a third embodiment of the present invention. [Figure 11] FIG. 13 is a diagram for explaining the application position of a room temperature curing adhesive. [Figure 12] FIG. 11 is a plan view of an automobile panel structure according to a fourth embodiment of the present invention. [Figure 13] FIG. 13 is an end view taken along line DD of the automotive panel structure of FIG. 12. [Figure 14] 10 is a flowchart of a manufacturing method for an automobile panel structure according to a fourth embodiment of the present invention. [Figure 15] FIG. 13 is a diagram for explaining the application position of a room temperature curing adhesive. [Figure 16] FIG. 11 is a plan view of an automobile panel structure according to a fifth embodiment of the present invention. [Figure 17] 17 is an end view taken along line EE of the automotive panel structure of FIG. 16. [Figure 18] 10 is a flowchart of a manufacturing method for an automobile panel structure according to a fifth embodiment of the present invention. [Figure 19] FIG. 13 is a diagram for explaining the application position of a room temperature curing adhesive. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] First Embodiment The automotive panel structure according to the first embodiment of the present invention will be described in detail below with reference to the drawings. The drawings used in the following description may show characteristic parts in an enlarged scale for the sake of convenience in order to make the characteristics easier to understand, and the dimensional ratios of each component may not necessarily be the same as in reality. Furthermore, the materials, dimensions, etc. exemplified in the following description are merely examples, and the present invention is not limited thereto, and may be appropriately modified and implemented within the scope of the present invention without changing the gist of the present invention. In this specification, a numerical range expressed using "~" means a range including the numerical values ​​before and after "~" as the lower and upper limits.

[0013] Fig. 1 is a plan view of an automobile panel structure according to a first embodiment of the present invention. Fig. 2 is an end view of the automobile panel structure of Fig. 1 taken along line AA. As shown in Figs. 1 and 2, an automobile panel structure 10 according to this embodiment includes a plate-shaped outer panel member 1, a resin member 2 disposed on the inner surface of the outer panel member 1, and an adhesive portion 3 that bonds the outer panel member 1 and the resin member 2. Each element of the automobile panel structure 10 will be described below. The automobile panel structure 10 according to this embodiment is an automobile panel structure applied to a side door.

[0014] (Outer panel member) The outer panel member 1 is a plate-shaped member having a curved surface that is convex toward the outside of the vehicle. In this disclosure, the surface facing the outside of the vehicle may be referred to as the outer surface, and the surface facing the inside of the vehicle may be referred to as the inner surface. The outer panel member 1 is formed by press forming a metal plate such as a steel plate.

[0015] The outer panel member 1 of the present disclosure is a member after painting. That is, the outer panel member 1 includes a base material 12 and a paint film 14 provided on the base material 12. In the present disclosure, the paint film 14 is provided on the outer surface and the inner surface of the base material 12.

[0016] From the viewpoint of dent resistance, the tensile strength of the base material 12 of the outer panel member 1 is preferably 440 MPa or more, and more preferably 590 MPa or more. The tensile strength of the base material 12 can be determined by preparing a No. 5 test piece described in JIS Z 2241:2011 from the base material 12 and using the test method described in JIS Z 2241:2011.

[0017] The coating film 14 is not particularly limited as long as it is formed using an automotive paint. For example, cationic epoxy resin, cationic acrylic resin, anionic acrylic resin, etc. can be used as the coating film 14. The thickness of the coating film 14 is not particularly limited. For example, the thickness of the coating film 14 is 20 μm to 100 μm on one side of the steel plate.

[0018] The plate thickness of the base material 12 of the outer panel member 1 of the present disclosure is 0.3 mm to 0.5 mm. If the plate thickness of the base material 12 of the outer panel member 1 is 0.3 mm to 0.5 mm, the weight of the automobile panel structure 10 can be significantly reduced. If the plate thickness of the base material 12 is less than 0.3 mm, sufficient tensile rigidity cannot be obtained. If the plate thickness of the base material 12 exceeds 0.5 mm, the effect of weight reduction is reduced.

[0019] (Resin material) The bending rigidity of the resin member 2 of the present disclosure is 0.3×10 6 N mm 2 The bending rigidity of the resin member 2 of the present disclosure is 0.3×10 6 N mm 2 If the bending rigidity of the resin member 2 is less than 2×10 6 N mm 2 Even if the bending stiffness exceeds 2×10, the effect is saturated. 6 N mm 2 The resin member 2 has an average bending stiffness of 0.3×10 or less. 6 N mm 2 However, it is preferable that the bending stiffness of one or more parts of the resin member 2 is 0.3×10 or more. 6 N mm 2 It may be less than.

[0020] The bending stiffness of the resin member 2 can be measured, for example, by the following method. For example, using an autograph AG-100KND manufactured by SHIMAZU Corporation, the test piece size, bending indenter radius, and support distance are modified based on JIS A1408:2017 so that a test piece of the resin member 2 cut out from the automotive panel structure 10 can be measured, and a three-point bending test is performed to measure the maximum load and stroke of the bending indenter. Specifically, the test piece is 100 mm wide and 200 mm long, the support distance L is 180 mm, and the bending radius of the indenter is 50 mm. The stroke speed of the bending indenter is 5 mm / min. The average value of two measurements is calculated. The bending stiffness in each measurement can be calculated by the formula (1). Bending rigidity = E (Young's modulus) × I (moment of inertia)…(1) Young's modulus: E=L 3 / 4bh 3 ×ΔF / Δs…(2) [E: Young's modulus (MPa), I: moment of inertia (mm 4 ), L: support distance (mm), b: specimen width (mm), h: specimen thickness (mm), ΔF: load increase (N), Δs: deformation increment (mm)]

[0021] In the resin member 2, the thickness of a portion where the dimension in a direction perpendicular to the in-plane direction of the outer panel member 1 is maximum (thickest portion) is preferably 3 mm or more and 60 mm or less. It is preferable that the thickness of the resin member 2 at the maximum thickness portion is 3 mm or more, since this can compensate for the lack of rigidity that occurs when the outer panel member 1 is made thinner. On the other hand, even if the thickness of the maximum thickness portion of the resin member 2 exceeds 60 mm, the effect is saturated, and therefore, it is preferable that the thickness is 60 mm or less.

[0022] The material of the resin member 2 may be any resin, and either a thermosetting resin or a thermoplastic resin may be used. Examples of the thermosetting resin include epoxy resin, unsaturated polyester resin, and vinyl ester resin. Examples of the thermoplastic resin include polyolefins (polyethylene, polypropylene, etc.) and acid-modified products thereof, polyamide resins such as nylon 6 and nylon 66, thermoplastic aromatic polyesters such as polyethylene terephthalate and polybutylene terephthalate, polycarbonate, polyethersulfone, polyphenylene ether and modified products thereof, polyarylate, polyether ketone, polyether ether ketone, polyether ketone ketone, vinyl chloride, styrene-based resins such as polystyrene, and phenoxy resins. The resin may be formed of a plurality of types of resin materials. The content of the thermoplastic resin in the resin member 2 is preferably 90% by mass or more with respect to the total mass of the resin member 2. The content of the thermoplastic resin in the resin member 2 may be 100% by mass.

[0023] The resin member 2 may be a foamed resin obtained by foaming the above-mentioned resin. By using a foamed resin, the automobile panel structure 10 can be made lighter. When the resin member 2 is a foamed resin, the foaming ratio is preferably 5 to 50 times. When the foaming ratio is 5 to 50 times, the bending rigidity of the resin member 2 can be reduced to 0.3×10 6 N mm 2 While achieving the above, weight reduction can be achieved.

[0024] The specific gravity of the resin member 2 is preferably 0.1 or less in order to reduce the weight. 6 N mm 2 By setting the specific gravity to be equal to or greater than this, it is possible to make the automobile panel structure 10 lighter while maintaining the tensile rigidity of the automobile panel structure 10. The specific gravity of the resin member 2 may be equal to or greater than 0.03.

[0025] The resin member 2 does not need to be painted. Usually, heat applied during painting after adhesion causes surface distortion in the outer plate, deteriorating the appearance. Since the resin member 2 is adhered to the painted outer panel member 1, no surface distortion occurs due to baking during electrodeposition painting after adhesion. Therefore, the automobile panel structure 10 has an excellent appearance. The resin member 2 may be painted at room temperature (5 to 35°C).

[0026] It is preferable that the arrangement area of ​​the resin member 2 arranged on the inner surface of the outer panel member 1 is 50 area % or more of the total area of ​​the inner surface of the outer panel member 1. When the arrangement area of ​​the resin member 2 arranged on the inner surface of the outer panel member 1 is 50 area % or more of the total area of ​​the inner surface of the outer panel member 1, the rigidity of the automobile panel structure 10 is improved. Here, the arrangement area of ​​the resin member 2 refers to the area of ​​the portion of the area of ​​the outer panel member 1 where the resin member 2 is arranged. More preferably, the arrangement area of ​​the resin member 2 is 70 area % or more of the total area of ​​the inner surface of the outer panel member 1. There is no particular limit to the upper limit of the arrangement area of ​​the resin member 2, but it is 100 area %. The arrangement area of ​​the resin member 2 is preferably 90 area % or less.

[0027] In the first embodiment, one resin member 2 covers 50% or more of the area of ​​the inner surface of the outer panel member 1. When electrodeposition coating is performed as in the conventional method, surface distortion occurs, but in the case of this embodiment, the resin member 2 is bonded to the outer panel member 1 after electrodeposition coating at room temperature, so no surface distortion occurs even if the entire surface is covered. Therefore, more than half of the inner surface of the outer panel member 1 can be covered with the resin member 2. This can greatly improve the tensile rigidity of the automotive panel structure 10.

[0028] (Adhesive part 3) The adhesive portion 3 of the present disclosure contains a cured product of a room temperature curing adhesive. The room temperature curing adhesive is an adhesive that cures at 10°C to 30°C. Whether or not the adhesive has cured can be determined by leaving the adhesive at 10°C to 30°C for 24 hours and checking whether or not the flexural modulus has increased by at least two times compared to before leaving (before curing). The flexural modulus can be measured, for example, in accordance with JIS K 7171-1:2016 (measurement temperature: 23°C). As the room temperature curing adhesive, an acrylic adhesive is preferable. As the acrylic adhesive, there is SGA (Second Generation Acrylic Adhesive). As long as the effect of the present invention is not impaired, an anaerobic adhesive, an instant adhesive, or an elastomer-containing acrylic adhesive can be used as the room temperature curing adhesive. The room temperature curing adhesive refers to a state before curing. The adhesive portion 3 of the present disclosure contains a cured product of the room temperature curing adhesive that has cured. Since the painted outer panel member 1 and the resin member 2 are bonded at room temperature, no in-plane distortion occurs in the outer panel member 1. As a result, an automobile panel structure 10 with excellent appearance can be obtained.

[0029] It is preferable that the area of ​​the adhesive portion 3 is 5 area % or more relative to the arrangement area of ​​the resin member 2. By making the area of ​​the adhesive portion 3 5 area % or more relative to the arrangement area of ​​the resin member 2, the tensile rigidity of the automobile panel structure 10 can be improved. More preferably, the area of ​​the adhesive portion is 25 area % or more relative to the arrangement area of ​​the resin member 2. In this embodiment, since the arrangement area of ​​the resin member 2 and the adhesive area of ​​the adhesive portion 3 are equal, the area of ​​the adhesive portion 3 relative to the arrangement area of ​​the resin member 2 is 100 area %.

[0030] (Bending rigidity of automotive panel structure 10) In the automotive panel structure 10, the outer panel member 1 is made thinner to reduce its weight, and the resin member 2, which compensates for the lack of rigidity caused by the thinner outer panel member 1, is bonded at room temperature to prevent the occurrence of in-plane distortion in the outer panel member 1. In this way, the automotive panel structure 10 is able to achieve both weight reduction and rigidity, and therefore has excellent bending rigidity per unit weight. For example, when the resin member 2 is 3 mm thick, the bending rigidity of the automotive panel structure 10 per 1 kg is 0.57×10 6 N mm 2 When the thickness of the resin member 2 is 20 mm, the bending rigidity of the automobile panel structure 10 per 1 kg is 1.47×10 6 N mm 2 When the thickness of the resin member 2 is 40 mm, the bending rigidity of the automobile panel structure 10 per 1 kg is 1.46×10 6 N mm 2 When the thickness of the resin member 2 is 60 mm, the bending rigidity of the automobile panel structure 10 per 1 kg is 1.49×10 6 N mm 2 The flexural rigidity of the automobile panel structure 10 can be measured in the same manner as the flexural rigidity of the resin member 2.

[0031] <Manufacturing method for automobile panel structure> Next, an example of a manufacturing method for an automobile panel structure 10 according to the first embodiment will be described. Fig. 3 is a flow chart of the manufacturing method S10 for the automobile panel structure according to the first embodiment. As shown in Fig. 3, the manufacturing method S10 for the automobile panel structure according to the first embodiment includes a painting process S1 for painting a base material of a plate-shaped outer panel member, an adhesive application process S2 for applying a room temperature curing adhesive to at least one of the inner surface of the outer panel member 1 and the resin member 2 after the painting process S1, and an adhesion process S3 for adhering the inner surface of the outer panel member 1 and the resin member 2 after the adhesive application process S2. Each process will be described below.

[0032] (Painting process) In the painting step S1, painting is performed on the base material 12 press-formed into the shape of the outer panel member 1. As a result, a coating film 14 is formed on the base material 12. The painting method is not particularly limited as long as it is a painting method used in automotive applications. An example of the painting method is electrodeposition painting. When electrodeposition painting is performed, for example, the base material 12 is subjected to degreasing, surface conditioning, chemical conversion treatment, electrodeposition painting, and baking to form the coating film 14. Note that it is preferable that the degreasing, surface conditioning, chemical conversion treatment, electrodeposition painting, and baking are common methods used in automotive applications.

[0033] (Adhesive application process) In the adhesive application step S2, after the painting step S1, a room temperature curing adhesive is applied to at least one of the inner surface of the outer panel member 1 and the resin member 2. FIG. 4 is a diagram for explaining the application position of the room temperature curing adhesive. It is preferable to apply the room temperature curing adhesive to the entire surface of the arrangement area of ​​at least one of the inner surface of the outer panel member 1 and the resin member 2. By applying the room temperature curing adhesive to the entire surface of the arrangement area 20 of at least one of the inner surface of the outer panel member 1 and the resin member 2, the tensile rigidity of the automotive panel structure 10 can be improved. In this embodiment, the application area 30 where the room temperature curing adhesive is applied is the same range as the arrangement area 20. In this embodiment, the room temperature curing adhesive is applied to the entire surface of the arrangement area 20 of the inner surface of the outer panel member 1, but it may be applied to the arrangement area of ​​the resin member 2. In addition, the room temperature curing adhesive may be applied to the entire surface of the arrangement area 20 of the inner surface of the outer panel member 1 and the arrangement area of ​​the resin member 2. Here, the arrangement area 20 of the outer panel member 1 refers to the area of ​​the inner surface of the outer panel member 1 where the resin member 2 is to be arranged. The arrangement area of ​​the resin member 2 refers to the area of ​​the surface that is joined to the outer panel member 1. In this embodiment, since the arrangement area of ​​the resin member 2 and the bonding area of ​​the adhesive portion 3 are equal, the area of ​​the adhesive portion 3 relative to the arrangement area of ​​the resin member 2 is 100%.

[0034] In the adhesive application step S2, the arrangement area of ​​the resin member 2 arranged on the inner surface of the outer panel member 1 is preferably 50 area% or more of the total area of ​​the inner surface of the outer panel member 1. When the arrangement area of ​​the resin member 2 arranged on the inner surface of the outer panel member 1 is 50 area% or more of the total area of ​​the inner surface of the outer panel member 1, the rigidity of the automotive panel structure 10 is improved. Here, the arrangement area of ​​the resin member 2 refers to the area of ​​the portion of the area of ​​the outer panel member 1 where the resin member 2 is arranged. More preferably, the arrangement area of ​​the resin member 2 is 70 area% or more of the total area of ​​the inner surface of the outer panel member 1. The upper limit of the arrangement area of ​​the resin member 2 is not particularly limited, but is 100 area%. The arrangement area of ​​the resin member 2 is preferably 90 area% or less.

[0035] (Adhesion process) In the bonding process S3, after the adhesive application process S2, the inner surface of the outer panel member 1 is bonded to the resin member 2. Specifically, the arrangement area of ​​the outer panel member 1 to which the room-temperature curing adhesive has been applied is bonded to the arrangement area of ​​the resin member 2, and the room-temperature curing adhesive is cured at room temperature for a predetermined time to obtain the automotive panel structure 10.

[0036] The above has described in detail the automobile panel structure 10 according to the first embodiment. The outer panel member 1 of the first embodiment has the paint film 14 on the outer surface and the inner surface, but the paint film may be formed only on the outer surface of the outer panel member 1.

[0037] Second embodiment Next, an automobile panel structure 10A according to a second embodiment of the present invention will be described with reference to Figs. 5 and 6. Fig. 5 is a plan view of the automobile panel structure 10A according to the second embodiment of the present invention. Fig. 6 is an end view of the automobile panel structure of Fig. 5 along line BB. Fig. 7 is an end view of the automobile panel structure of Fig. 5 along line B1-B1. As shown in Figs. 5, 6, and 7, the automobile panel structure 10A according to this embodiment includes a plate-shaped outer panel member 1, a resin member 2A disposed on the inner surface of the outer panel member 1, and an adhesive portion 3A that bonds the outer panel member 1 and the resin member 2A. In this second embodiment, the same reference numerals are used for the same components as those in the first embodiment, and their description is omitted, and only the differences are described.

[0038] (Resin material 2A) The bending rigidity of the resin member 2A of the present disclosure is 0.3×10 6 N mm 2 The bending rigidity of the resin member 2A of the present disclosure is 0.3×10 6 N mm 2 If the bending rigidity of the resin member 2A is less than 2×10 6 N mm 2 Even if the bending stiffness exceeds 2×10, the effect is saturated. 6 N mm 2 The following is preferred:

[0039] It is preferable that the thickness of the resin member 2A at a maximum thickness portion, where the dimension in a direction perpendicular to the in-plane direction of the outer panel member 1 is maximum, is 3 mm or more and 60 mm or less. It is preferable that the thickness of the resin member 2A at the maximum thickness portion is 3 mm or more, since this can compensate for the lack of rigidity that occurs when the outer panel member 1 is made thinner. On the other hand, even if the thickness of the maximum thickness portion of the resin member 2A exceeds 60 mm, the effect is saturated, so that it is preferably 60 mm or less.

[0040] The resin member 2A may be made of the same resin as the resin member 2.

[0041] The resin member 2A does not have to be painted. Since the resin member 2A is bonded to the painted outer panel member 1, it is preferable because no surface distortion occurs due to baking during electrodeposition painting after bonding. In addition, the resin member 2A may be painted at room temperature.

[0042] The arrangement area of ​​the resin member 2A arranged on the inner surface of the outer panel member 1 is preferably 50% or more of the total area of ​​the inner surface of the outer panel member 1. When the arrangement area of ​​the resin member 2A arranged on the inner surface of the outer panel member 1 is 50% or more of the total area of ​​the inner surface of the outer panel member 1, the rigidity of the automobile panel structure 10 is improved. Here, the arrangement area of ​​the resin member 2A refers to the area of ​​the portion of the area of ​​the outer panel member 1 where the resin member 2A is arranged. More preferably, the arrangement area of ​​the resin member 2A is 70% or more of the total area of ​​the inner surface of the outer panel member 1. The arrangement area of ​​the resin member 2A is preferably 90% or less.

[0043] 7, the resin member 2A is preferably disposed along the direction in which the curvature of the outer panel member 1 increases. That is, by disposing the resin member 2A along the direction in which the curvature increases in this manner, the tensile rigidity can be increased.

[0044] In the second embodiment, a plurality of (seven in FIG. 5) resin members 2A are arranged on the inner surface of the outer panel member 1. By arranging a plurality of resin members 2A, it is possible to reduce the weight of the automobile panel structure 10 while increasing the tensile rigidity in necessary locations.

[0045] (Adhesive part) The adhesive portion 3A of the present disclosure contains a cured product of a room temperature curing adhesive. The room temperature curing adhesive may be the same adhesive as that of the adhesive portion 3.

[0046] It is preferable that the area of ​​the adhesive portion 3A relative to the arrangement area of ​​the resin member 2A is 5 area % or more. By making the area of ​​the adhesive portion 3A relative to the arrangement area of ​​the resin member 2A 5 area % or more, the tensile rigidity of the automobile panel structure 10 can be improved. More preferably, the area of ​​the adhesive portion 3A relative to the arrangement area of ​​the resin member 2A is 25 area % or more. In this embodiment, since the arrangement area of ​​the resin member 2A and the adhesive area of ​​the adhesive portion 3A are equal, the area of ​​the adhesive portion 3A relative to the arrangement area of ​​the resin member 2A is 100 area %.

[0047] Third embodiment Next, an automobile panel structure 10B according to a third embodiment of the present invention will be described with reference to Figs. 8 and 9. Fig. 8 is a plan view of the automobile panel structure 10B according to the third embodiment of the present invention. Fig. 9 is an end view along the line CC of the automobile panel structure of Fig. 8. As shown in Figs. 8 and 9, the automobile panel structure 10B according to this embodiment includes a plate-shaped outer panel member 1, a resin member 2 disposed on the inner surface of the outer panel member 1, and an adhesive portion 3B that bonds the outer panel member 1 and the resin member 2. In this third embodiment, the same components as those in the first embodiment are denoted by the same reference numerals, and their description is omitted, and only the differences will be described.

[0048] (Adhesive part 3B) The adhesive portion 3B of the present disclosure contains a cured product of a room-temperature curing adhesive. The cured product of the room-temperature curing adhesive used in the adhesive portion 3B is the same as that in the adhesive portion 3.

[0049] The adhesive portion 3B is provided in a linear shape. By providing the adhesive portion 3B in a linear shape, the working efficiency can be improved.

[0050] It is preferable that the area of ​​the adhesive portion 3B is 5% or more of the area of ​​the arrangement of the resin member 2. By making the area of ​​the adhesive portion 3B 5% or more of the area of ​​the arrangement of the resin member 2, it is possible to improve the tensile rigidity of the automobile panel structure 10. More preferably, the area of ​​the adhesive portion 3B is 25% or more of the area of ​​the arrangement of the resin member 2.

[0051] <Manufacturing method for automobile panel structure> Next, an example of a manufacturing method of an automobile panel structure 10B according to the third embodiment will be described. FIG. 10 is a flowchart of the manufacturing method S10B of the automobile panel structure according to the third embodiment. As shown in FIG. 10, the manufacturing method S10B of the automobile panel structure according to the third embodiment includes a painting process S1 for painting a base material of a plate-shaped outer panel member, an adhesive application process S2B for applying a room temperature curing adhesive to at least one of the inner surface of the outer panel member 1 and the resin member 2 after the painting process S1, and an adhesion process S3 for adhering the inner surface of the outer panel member 1 and the resin member 2 after the adhesive application process S2B. Each process will be described below.

[0052] (Adhesive application process) In the adhesive application step S2B, after the painting step S1, a room-temperature curing adhesive is applied to at least one of the inner surface of the outer panel member 1 and the resin member 2. FIG. 11 is a diagram for explaining the application position of the room-temperature curing adhesive. It is preferable to apply the room-temperature curing adhesive linearly to at least one of the arrangement areas of the inner surface of the outer panel member 1 and the resin member 2. The application area of ​​the room-temperature curing adhesive to the arrangement area of ​​the resin member 2 may be 5 area % or more. By applying the room-temperature curing adhesive linearly to at least one of the arrangement areas 20 of the inner surface of the outer panel member 1 and the resin member 2, the tensile rigidity of the automobile panel structure 10 can be improved while improving workability. In the third embodiment, the application areas 30B where the room-temperature curing adhesive is applied are provided evenly apart within the arrangement area 20. In this embodiment, the room-temperature curing adhesive is applied linearly to the arrangement area 20 of the inner surface of the outer panel member 1, but it may be applied linearly to the arrangement area of ​​the resin member 2. The room temperature curing adhesive may be applied in a line shape to the arrangement area 20 of the inner surface of the outer panel member 1 and the arrangement area of ​​the resin member 2. Note that applying in a line shape means applying in a line width of about 1 cm to 5 cm, for example.

[0053] (Fourth embodiment) Next, an automobile panel structure 10C according to a fourth embodiment of the present invention will be described with reference to Figs. 12 and 13. Fig. 12 is a plan view of the automobile panel structure 10C according to the fourth embodiment of the present invention. Fig. 13 is an end view along the line DD of the automobile panel structure of Fig. 12. As shown in Figs. 12 and 13, the automobile panel structure 10C according to this embodiment includes a plate-shaped outer panel member 1, a resin member 2 disposed on the inner surface of the outer panel member 1, and an adhesive portion 3C that bonds the outer panel member 1 and the resin member 2. In this fourth embodiment, the same components as those in the first embodiment are denoted by the same reference numerals, and their description is omitted, and only the differences will be described.

[0054] (Adhesive part 3C) The adhesive portion 3C of the present disclosure contains a cured product of a room-temperature curing adhesive. The cured product of the room-temperature curing adhesive used in the adhesive portion 3C is the same as that in the adhesive portion 3.

[0055] The adhesive parts 3C are provided in a dotted pattern. By providing the adhesive parts 3C in a dotted pattern, the working efficiency can be improved.

[0056] It is preferable that the area of ​​the adhesive portion 3C is 5% or more of the area of ​​the arrangement of the resin member 2. By making the area of ​​the adhesive portion 3C 5% or more of the area of ​​the arrangement of the resin member 2, it is possible to improve the tensile rigidity of the automobile panel structure 10. More preferably, the area of ​​the adhesive portion 3C is 25% or more of the area of ​​the arrangement of the resin member 2.

[0057] <Manufacturing method for automobile panel structure> Next, an example of a manufacturing method of an automobile panel structure 10C according to the fourth embodiment will be described. Fig. 14 is a flow chart of the manufacturing method S10C of the automobile panel structure according to the fourth embodiment. As shown in Fig. 14, the manufacturing method S10C of the automobile panel structure according to the fourth embodiment includes a coating process S1 for coating a base material of a plate-shaped outer panel member, an adhesive application process S2C for applying a room temperature curing adhesive to at least one of the inner surface of the outer panel member 1 and the resin member 2 after the coating process S1, and a bonding process S3 for bonding the inner surface of the outer panel member 1 and the resin member 2 after the adhesive application process S2C.

[0058] (Adhesive application process) In the adhesive application step S2C, after the painting step S1, a room temperature curing adhesive is applied to at least one of the inner surface of the outer panel member 1 and the resin member 2C. FIG. 15 is a diagram for explaining the application position of the room temperature curing adhesive. It is preferable to apply the room temperature curing adhesive in dots to at least one of the arrangement areas of the inner surface of the outer panel member 1 and the resin member 2. By applying the room temperature curing adhesive in dots to at least one of the arrangement areas 20 of the inner surface of the outer panel member 1 and the resin member 2, the tensile rigidity of the automotive panel structure 10 can be improved while improving workability. In the fourth embodiment, a plurality of application areas 30C to which the room temperature curing adhesive is applied are provided at equal intervals within the arrangement area 20. In this embodiment, the room temperature curing adhesive is applied in dots to the arrangement area 20 of the inner surface of the outer panel member 1, but it may be applied in dots to the arrangement area of ​​the resin member 2. In addition, the room temperature curing adhesive may be applied in dots to the arrangement area 20 of the inner surface of the outer panel member 1 and the arrangement area of ​​the resin member 2. Note that dot application means that the diameter of the dots is about 0.1 to 5 mm and the amount of adhesive is about 0.001 to 3 mg.

[0059] Fifth embodiment Next, an automobile panel structure 10D according to a fifth embodiment of the present invention will be described with reference to Figs. 16 and 17. Fig. 16 is a plan view of the automobile panel structure 10D according to the fifth embodiment of the present invention. Fig. 17 is an end view along the line EE of the automobile panel structure of Fig. 16. As shown in Figs. 16 and 17, the automobile panel structure 10D according to this embodiment includes a plate-shaped outer panel member 1, a resin member 2D arranged on the inner surface of the outer panel member 1, an adhesive portion 3D that bonds the outer panel member 1 and the resin member 2D, and an inner member 4. In this fifth embodiment, the same components as those in the first embodiment are denoted by the same reference numerals, and their description is omitted, and only the differences will be described.

[0060] (Resin material 2D) The bending rigidity of the resin member 2D of the present disclosure is 0.3×10 6 N mm 2 The bending rigidity of the resin member 2D of the present disclosure is 0.3×10 6 N mm 2 If the bending rigidity of the resin member 2D is less than 2×10 6 N mm 2 Even if the bending stiffness exceeds 2×10, the effect saturates, so the bending stiffness of the resin material 2D is 2×10 6 N mm 2 The following is preferred:

[0061] It is preferable that the thickness of the resin member 2D at a maximum thickness portion where the dimension in a direction perpendicular to the in-plane direction of the outer panel member 1 is maximum is 3 mm or more and 60 mm or less. It is preferable that the thickness of the resin member 2D at the maximum thickness portion is 3 mm or more, since this can compensate for the lack of rigidity that occurs when the outer panel member 1 is made thinner. On the other hand, even if the thickness of the maximum thickness portion of the resin member 2D exceeds 60 mm, the effect is saturated, so that it is preferably 60 mm or less.

[0062] The resin member 2D may be made of the same resin as the resin member 2.

[0063] The resin member 2D does not have to be painted. Since the resin member 2D is bonded to the painted outer panel member 1, it is preferable that no surface distortion occurs due to baking during electrodeposition painting after bonding. Also, the resin member 2D may be painted at room temperature.

[0064] The arrangement area of ​​the resin member 2D arranged on the inner surface of the outer panel member 1 is preferably 50% or more of the total area of ​​the inner surface of the outer panel member 1. When the arrangement area of ​​the resin member 2D arranged on the inner surface of the outer panel member 1 is 50% or more of the total area of ​​the inner surface of the outer panel member 1, the rigidity of the automobile panel structure 10 is improved. Here, the arrangement area of ​​the resin member 2D refers to the area of ​​the portion of the area of ​​the outer panel member 1 where the resin member 2D is arranged. More preferably, the arrangement area of ​​the resin member 2D is 70% or more of the total area of ​​the inner surface of the outer panel member 1. The arrangement area of ​​the resin member 2D is preferably 90% or less.

[0065] In the fifth embodiment, two resin members 2D are provided so as to sandwich the inner member 4. By arranging them so as to sandwich the inner member 4, the tensile rigidity can be further improved.

[0066] (Adhesive part) The adhesive portion 3D of the present disclosure contains a cured product of a room temperature curing adhesive. The room temperature curing adhesive may be the same adhesive as that of the adhesive portion 3.

[0067] It is preferable that the area of ​​the adhesive portion 3D relative to the arrangement area of ​​the resin member 2D is 5 area % or more. By making the area of ​​the adhesive portion 3D relative to the arrangement area of ​​the resin member 2D 5 area % or more, the tensile rigidity of the automobile panel structure 10D can be improved. More preferably, the area of ​​the adhesive portion 3D relative to the arrangement area of ​​the resin member 2D is 25 area % or more. In this embodiment, since the arrangement area of ​​the resin member 2D and the adhesive area of ​​the adhesive portion 3D are equal, the area of ​​the adhesive portion 3D relative to the arrangement area of ​​the resin member 2D is 100 area %.

[0068] (Inner parts) The inner member 4 is an elongated member disposed opposite the inner surface of the outer panel member 1. The inner member 4 is disposed so as to extend along one direction in the in-plane direction of the outer panel member 1. The inner member 4 is attached to the outer panel member 1 so that its longitudinal direction coincides with the vehicle width direction, thereby serving to reinforce the automobile panel structure 10.

[0069] As shown in Figure 17, the inner member 4 has a generally hat-shaped cross-sectional portion consisting of a top plate portion 121, a pair of side wall portions 123, 123 bending and extending from both ends of the top plate portion 121, and a pair of flange portions 125, 125 bending and extending outward from the ends of the pair of side wall portions 123, 123 opposite the top plate portion 121. In the present disclosure, the width direction of the inner member 4 means a direction parallel to the top plate portion 121 among directions perpendicular to the longitudinal direction of the inner member 4.

[0070] The inner member 4 can be obtained, for example, by press-molding a metal plate such as a steel plate.

[0071] At the longitudinal center of the inner member 4, the widthwise ends of the pair of flange portions 125, 125 of the inner member 4 enter the pair of resin members 2D, 2D from the side surfaces of the pair of resin members 2D, 2D. That is, at least a part of the inner member 4 is embedded in the resin member 2D. In this disclosure, "at least a part of the inner member 4 is embedded in the resin member" means that at least a part of the inner member 4 enters the resin member and is held in surface contact with the resin member. Furthermore, the upper surfaces of the pair of resin members 2D, 2D are joined to the inner surface of the outer panel member 1 via the adhesive portion 3D.

[0072] <Manufacturing method for automobile panel structure> Next, an example of a manufacturing method of an automobile panel structure 10D according to the fifth embodiment will be described. FIG. 18 is a flowchart of the manufacturing method S10D of the automobile panel structure according to the fifth embodiment. As shown in FIG. 18, the manufacturing method S10D of the automobile panel structure according to the fifth embodiment includes a painting process S1 for painting the base material 12 of the plate-shaped outer panel member 1, a resin member molding process S4 for integrally molding the inner member 4 and the resin member 2D, an adhesive application process S2D for applying a room temperature curing adhesive to at least one of the inner surface of the outer panel member 1 and the resin member 2D after the painting process S1 and the resin member molding process S4, and a bonding process S3 for bonding the inner surface of the outer panel member 1 and the resin member 2D after the adhesive application process S2D. Each process will be described below.

[0073] (Resin component molding process) In the resin member molding process S4, a molding die is placed so as to surround a predetermined portion of the inner member 4, and a resin material is injected into the molding die and hardened to integrate the inner member 4 with the pair of resin members 2D, 2D. Either a thermoplastic resin or a thermosetting resin can be used as the resin material. The resin material may also contain a foaming agent. Examples of the foaming agent include N,N'-dinitrosopentamethylenetetramine, azodicarbonamide, 4,4'-oxybis(benzenesulfonylhydrazide), hydrogen carbonate, and sodium hydrogen carbonate. In the resin member molding process S4, a resin material may first be injected into the inside of a molding die and solidified to form an intermediate product of a pair of resin members 2D, 2D, and then slits may be formed in each intermediate product. The flange portion 125 of the inner member 4 may then be inserted into the slits to integrate the intermediate products.

[0074] (Adhesive application process) In the adhesive application step S2D, after the painting step S1 and the resin member molding step S4, a room temperature curing adhesive is applied to at least one of the inner surface of the outer panel member 1 and the resin member 2D. FIG. 19 is a diagram for explaining the application position of the room temperature curing adhesive. It is preferable to apply the room temperature curing adhesive to the entire surface of the arrangement area of ​​at least one of the inner surface of the outer panel member 1 and the resin member 2D. By applying the room temperature curing adhesive to the entire surface of the arrangement area 20 of at least one of the inner surface of the outer panel member 1 and the resin member 2D, the tensile rigidity of the automotive panel structure 10 can be improved. The application area 30D where the room temperature curing adhesive is applied is the same range as the arrangement area 20. In this embodiment, the room temperature curing adhesive is applied to the entire surface of the arrangement area 20 of the inner surface of the outer panel member 1, but it may be applied to the arrangement area of ​​the resin member 2D. In addition, the room temperature curing adhesive may be applied to the entire surface of the arrangement area 20 of the inner surface of the outer panel member 1 and the arrangement area of ​​the resin member 2D.

[0075] In the adhesive application process S2D, the arrangement area of ​​the resin member 2D arranged on the inner surface of the outer panel member 1 is preferably 50% or more of the total area of ​​the inner surface of the outer panel member 1. By having the arrangement area of ​​the resin member 2D arranged on the inner surface of the outer panel member 1 be 50% or more of the total area of ​​the inner surface of the outer panel member 1, the rigidity of the automobile panel structure 10 is improved.

[0076] The fifth embodiment of the automobile panel structure 10D has been described above in detail. In the fifth embodiment, a hat-shaped cross-section member is used as the inner member 4, but a U-shaped cross-section member or a T-shaped cross-section member may be used. In addition, the resin member 2D is provided over the entire length of the inner member 4 in the longitudinal direction, but the resin member 2D may be provided only on a part of the inner member 4 in the longitudinal direction.

[0077] While the automobile panel structure 10 of the present disclosure has been described above based on the first embodiment, second embodiment, third embodiment, fourth embodiment, and fifth embodiment, the automobile panel structure 10 of the present disclosure is not limited thereto. For example, the automobile side door panel structure 10 can also be applied to panel structures such as hoods, roofs, and back doors. [Explanation of symbols]

[0078] 1 Outer panel member 2 Resin parts 3 Adhesive part 4 Inner member 10 Automotive panel structure

Claims

1. A plate-shaped outer panel member; a resin member disposed on an inner surface of the outer panel member; an adhesive portion that adheres the outer panel member and the resin member; Equipped with The outer panel member includes a base material and a paint film provided on the base material, The plate thickness of the base material is 0.3 mm to 0.5 mm, The bending rigidity of the resin member is 0.3×10 ６ N mm ２ That's all. The adhesive portion contains a cured product of a room temperature curing adhesive, The automobile panel structure, wherein the resin member is a foamed resin.

2. 2. The automobile panel structure according to claim 1, wherein an area of ​​the resin member disposed on the inner surface of the outer panel member is 50% or more of a total area of ​​the inner surface of the outer panel member.

3. 3. The automobile panel structure according to claim 2, wherein an area of ​​the adhesive portion with respect to an area of ​​the resin member is 5% or more by area.

4. The outer panel member further includes an inner member disposed opposite to an inner surface of the outer panel member.

3. The automobile panel structure according to claim 1, wherein at least a portion of the inner member is embedded in the resin member.

5. 5. The automobile panel structure according to claim 4, wherein the inner member extends along one direction in a plane of the outer panel member.

6. 3. The automobile panel structure according to claim 1, wherein the resin member is made of a thermosetting resin.

7. 3. The automobile panel structure according to claim 1, wherein the resin member is made of a thermoplastic resin.

8. 3. The automobile panel structure according to claim 1, wherein the room temperature curing adhesive is an acrylic adhesive.

9. 3. The automobile panel structure according to claim 1, wherein the outer panel member has a tensile strength of 440 MPa or more.

10. 3. The automobile panel structure according to claim 1, wherein the thickness of the resin member at a portion where the dimension perpendicular to the in-plane direction of the outer panel member is maximum is 3 mm or more and 60 mm or less.

11. 3. The automobile panel structure according to claim 1, wherein the resin member is unpainted.

12. a coating process for coating a base material of the plate-shaped outer panel member; an adhesive application step of applying a room temperature curing adhesive to at least one of the inner surface of the outer panel member and the resin member after the painting step; a bonding step of bonding an inner surface of the outer panel member and the resin member after the adhesive application step; wherein the resin member is a foamed resin.

13. 13. The method for manufacturing an automobile panel structure according to claim 12, wherein an area of ​​the resin member disposed on the inner surface of the outer panel member is 50% or more of a total area of ​​the inner surface of the outer panel member.

14. The method for manufacturing an automobile panel structure according to claim 13, wherein an application area of ​​the room-temperature curing adhesive with respect to an arrangement area of ​​the resin member is 5 area % or more.

15. In the adhesive application step, The method for manufacturing an automobile panel structure according to claim 12 or 13, wherein the room-temperature curing adhesive is applied to the entire surface of at least one of an inner surface of the outer panel member and an area where the resin member is disposed.

16. In the adhesive application step, The method for manufacturing an automobile panel structure according to claim 12 or 13, wherein the room temperature curing adhesive is applied in a line shape to at least one of the inner surface of the outer panel member and the resin member.

17. In the adhesive application step, The method for manufacturing an automobile panel structure according to claim 12 or 13, wherein the room temperature curing adhesive is applied in dots to an arrangement area of ​​at least one of the inner surface of the outer panel member and the resin member.

Images