Mounting structure for electrical components and method for manufacturing the mounting 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 portion, for example. In this way, when forming mounting holes for attaching clips and components, the processing positions of the mounting holes differ 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 unused mounting holes 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 a notch is 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 a notch remains, 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 for electrical components according to claim 1 of the present invention comprises a first mounting surface provided at a position in a vehicle where electrical components are mounted and having a mounting hole formed therein, and a second mounting surface having a score-machined hole formed therein, which is notched along the shape of the hole to be penetrated, wherein the first mounting surface and the second mounting surface are formed at a different height from other areas.

[0007] In the mounting structure for electrical components according to the present invention as described in claim 1, a mounting hole is formed on a first mounting surface provided at a position in the vehicle where the electrical component is to be mounted, and a score-machined hole is formed on a second mounting surface, which is notched to match the shape of the hole to be penetrated. That is, a mounting hole is formed at a position in the vehicle where it is necessary to mount the electrical component, and a score-machined hole is formed at a position in the vehicle where it is not necessary to mount the electrical component. Since the score-machined hole is notched but does not penetrate, a cover is not required to close the mounting hole that is not needed in the vehicle. This makes it possible to suppress the increase in installation time and cost that would otherwise be required for the cover.

[0008] Furthermore, in the mounting structure for electrical components according to the present invention as described in claim 1, the first mounting surface and the second mounting surface are formed at different heights from other areas. As a result, stress is distributed on the second mounting surface where the score-machined holes are formed, stress concentration in the score-machined holes is mitigated, and it is possible to prevent stress concentration in the score-machined holes from causing cracks. This makes it possible to suppress a decrease in strength in the score-machined holes.

[0009] The mounting structure for electrical components according to the present invention as described in claim 2 is the configuration described in claim 1, wherein the mounting hole is formed by punching out the inside of a score-machined hole that has been notched in accordance with the shape of the hole to be penetrated.

[0010] In the mounting structure for electrical components according to claim 2, the mounting holes are formed by punching out the inside of a notched hole, so that mounting holes can be formed from scored holes as needed.

[0011] The mounting structure for electrical components according to the present invention as described in claim 3 is configured as described in claim 1 or claim 2, wherein the first mounting surface and the second mounting surface are formed at substantially the same height.

[0012] In the mounting structure for electrical components according to claim 3, since the first mounting surface and the second mounting surface are formed at approximately the same height, a mounting hole at approximately the same level as the mounting hole formed in the first mounting surface can be formed at the position where the second mounting surface is provided, if necessary, by punching out the inside of the score-machined hole formed in the second mounting surface.

[0013] The mounting structure for electrical components according to claim 4 of the present invention is characterized in that at least one of the mounting hole and the score-machined hole has at least two or more different shapes.

[0014] In the mounting structure for electrical components according to claim 4, at least one of the mounting hole and the score-machined hole has at least two different shapes, so that a mounting hole of a shape corresponding to the type of electrical component to be mounted can be provided.

[0015] The method for manufacturing a mounting structure according to claim 5 of the present invention comprises: a seat surface forming step of forming a plurality of mounting seat surfaces in a vehicle at a location where electrical components may be mounted and at a different height from other areas; a scoring step of forming a scored hole by cutting a notch in the plurality of mounting seat surfaces along the shape of a hole to be made through; and a punching step of forming a mounting hole by punching out the inside of the scored hole provided at a location where the mounting of electrical components has been determined.

[0016] In the method for manufacturing the mounting structure according to the present invention as described in claim 5, a score-machined hole, which is notched along the shape of the hole to be penetrated, is formed on a mounting surface that is formed at a different height from other areas. Since the score-machined hole is notched but not penetrates, a cover is not required to close the hole, which is not needed in the vehicle. This suppresses the increase in installation time and cost that would otherwise be required for a cover. Furthermore, since stress is distributed on the mounting surface, stress concentration in the score-machined hole is alleviated, preventing cracking caused by stress concentration in the score-machined hole. In other words, a decrease in strength in the score-machined hole can be suppressed. [Effects of the Invention]

[0017] The mounting structure for electrical components and the method for manufacturing the mounting structure according to the present invention can suppress a decrease in strength while suppressing an increase in installation man-hours and costs. [Brief explanation of the drawing]

[0018] [Figure 1] This is a perspective view showing an example of a location on a vehicle body where the setting of score-machined holes is being considered. [Figure 2] This is a bottom view showing an example of a location on the roof of a vehicle where the setting of score-machined holes is being considered. [Figure 3] This is an inner side view showing an example of a location where score machining holes are being considered for a vehicle's side door. [Figure 4] This is a plan view and a side view showing an example of a second mounting surface included in a mounting structure for an electrical component according to one embodiment of the present invention. [Figure 5] This is a perspective view showing an example of a score-machined hole. [Figure 6] This is a cross-sectional view along line AA in Figure 2. [Figure 7] This is an explanatory diagram for explaining score processing. [Figure 8] This is a plan view and a side view showing an example of a first mounting surface included in a mounting structure for an electrical component according to one embodiment of the present invention. [Figure 9] It is an explanatory diagram for explaining punching processing. [Figure 10] It is a flowchart showing a series of manufacturing processes of the mounting structure of an electrical component according to an embodiment of the present invention. [Figure 11] It is a plan view and a side view showing an example of spot welding provided on a seating surface. [Figure 12] It is a diagram showing an example of the stress distribution of a spot weld portion in the case where there is no seating surface. [Figure 13] It is a diagram showing an example of the stress distribution of a spot weld portion in the case where there is a seating surface.

Mode for Carrying Out the Invention

[0019] Hereinafter, referring to FIGS. 1 to 9, the mounting 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 hole is being considered in the body 14 of the vehicle 12, FIG. 2 is a bottom view showing an example of a position where the setting of a score hole is being considered in the 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 hole is being considered in the side door 18 of the vehicle. In each figure, the arrow FR shown as appropriate indicates the front direction of the vehicle, and the arrow RH indicates the right direction of the vehicle.

[0021] As shown in Figures 1 to 3, the electrical component mounting structure 10 includes, for example, a plurality of mounting surfaces 20 for forming score-machined holes 30 (described later) at positions P where electrical components (not shown) may be mounted on panels 12A used in the body 14, roof 16, and side doors 18 of a vehicle 12. Here, in Figures 1 to 3, the positions indicated by circles are, for example, positions P where electrical components (not shown) may be mounted. As shown in Figures 1 to 3, positions P are set at various locations in the vehicle 12. In particular, hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), fuel cell electric vehicles (FCEVs), and battery electric vehicles (BEVs) have a larger number of positions P compared to gasoline vehicles.

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

[0023] Specifically, a rectangular frame 24 larger than the mounting surface 20 is set to surround the mounting surface 20. This rectangular frame 24 is set to approximately the same height as the other areas 22, and a slope 26 is provided so that it smoothly connects from the rectangular frame 24 to the mounting surface 20.

[0024] A score-machined hole 30 is formed approximately in the center of the mounting surface 20. In this embodiment, the mounting surface 20 in which the score-machined hole 30 is formed is referred to as the second mounting surface 20A. As shown in Figures 5 and 6, the score-machined hole 30 is notched along the shape of the hole to be drilled through. That is, a notch 32 is formed that is cut in the thickness direction of the panel 12A along the shape of the hole. As shown in Figure 6, the notch 32 is formed to be sharp.

[0025] Here, we will explain the process of forming the score-machined hole 30 by scoring (also called notching). Figure 7 is an explanatory diagram for illustrating scoring.

[0026] As shown in the left diagram of Figure 7, a scoring machine 40 is used for scoring to form the scoring holes 30. The scoring machine 40 is not particularly limited; any machine capable of forming the scoring holes 30 may be used. In this embodiment, as an example, the scoring machine 40 comprises a mold 42 on which the panel 12A is mounted, and a rotating part 44 located above the panel 12A mounted on the mold 42. The rotating part 44 is, for example, a cylindrical box shape with an open top, and is vertically movable by a motor (not shown) and rotatable around an axis 44A. A scoring blade 46 is attached to the bottom surface of the rotating part 44, and the mounting position of this scoring blade 46 can be changed to match the shape of the scoring holes 30 to be formed.

[0027] By bringing the scoring blade 46 into contact with the mounting surface 20 of the panel 12A placed on the mold 42 and rotating the rotating part 44, a scoring hole 30 with a notch 32 formed in the desired hole shape is formed, as shown in the right-hand diagram of Figure 7. In this embodiment, as an example, the scoring hole 30 has two or more different shapes of size and shape depending on the position P where the mounting surface 20 is installed.

[0028] Next, the mounting holes 50 will be described. Figure 8 is a plan view and a side view showing an example of a mounting hole 50 formed on the first mounting surface 20B. In this embodiment, as an example, the mounting hole 50 is formed on the second mounting surface 20A, where the score-machined holes 30 are formed as described above, by punching out the inside of the score-machined holes 30. The mounting surface 20 having the mounting hole 50 formed in this way is referred to as the first mounting surface 20B. That is, the second mounting surface 20A becomes the first mounting surface 20B when the score-machined holes 30 are machined into mounting holes 50.

[0029] Here, we will explain the punching process in which the score-processed hole 30 is processed into a mounting hole 50 by punching. Figure 9 is an explanatory diagram for illustrating the punching process.

[0030] As shown in Figure 9, a punching machine 60 is used to punch out the mounting holes 50. The punching machine 60 is not particularly limited and any machine can be used as long as it is capable of punching out the inside of the score holes 30. In this embodiment, as an example, the punching machine 60 has a metal punch part 62 and a rotating part 64 that is rotatable around an axis 64A.

[0031] Panel 12A having a second mounting surface 20A with score-processed holes 30 is held in a die section (not shown) and the punch section 62 is rotated, punching through the inside of the score-processed holes 30 and forming a mounting hole 50. The mounting surface 20 having the mounting hole 50 thus formed becomes the first mounting surface 20B. In this embodiment, as an example, the score-processed holes 30 have two or more shapes with different sizes and shapes depending on the position P where the mounting surface 20 is installed. Similarly, when the mounting hole 50 is formed from the score-processed holes 30, it may have two or more shapes with different sizes and shapes depending on the position P where the mounting surface 20 is installed.

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

[0033] First, in step 11, a seat-forming machine (not shown) forms multiple mounting seats 20 in the vehicle 12 at positions P where electrical components may be mounted, and at a different height from other areas 22. The seat-forming machine is not particularly limited and any processing machine capable of forming mounting seats 20 may be used.

[0034] Next, in step S12, the scoring machine 40 cuts out notches in the multiple mounting surfaces 20 according to the shape of the holes to be made through, thereby forming scoring holes 30.

[0035] Next, in step S13, it is determined whether each of the multiple mounting surfaces 20 is a mounting location for an electrical component in the vehicle 12. This determination is performed, for example, by the CPU of a control device that manages a series of manufacturing processes.

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

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

[0038] If all mounting surfaces 20 are completed in step S15 (step S15; YES), the series of manufacturing processes is completed.

[0039] Next, the effects of the mounting structure 10 for the electrical components of the vehicle 12 and the method for manufacturing the mounting structure 10 in this embodiment will be described.

[0040] In the electrical component mounting structure 10 according to this embodiment, a mounting hole 50 is formed in the first mounting surface 20B provided in the vehicle 12 at the position where the electrical component is to be mounted, and a score-machined hole 20 is formed in the second mounting surface 20A, which is notched to match the shape of the hole to be penetrated. That is, the mounting hole 50 is formed in the vehicle 12 at the position necessary for mounting the electrical component, and the score-machined hole 20 is formed in the vehicle 12 at a position unnecessary for mounting the electrical component. Since the score-machined hole 20 is notched but does not penetrate, a cover is not required to close the hole that is not needed in the vehicle 12. This makes it possible to suppress the increase in installation man-hours and costs that would otherwise be required for the cover.

[0041] Furthermore, in the mounting structure 10 for electrical components according to this embodiment, the mounting surface 20, that is, the first mounting surface 20B and the second mounting surface 20A, are formed at a different height from the other areas 22. Here, a conventional example in which stress concentration is mitigated by a mounting surface formed at a different height from the other areas will be described. Figure 11 is a plan view and a side view showing an example of a spot welded part 110 provided on the mounting surface 120, Figure 12 is a diagram showing an example of the stress distribution of the spot welded part 110 when there is no mounting surface 120, and Figure 13 is a diagram showing an example of the stress distribution of the spot welded part 110 when there is a mounting surface 120.

[0042] In conventional designs, as shown in Figure 11, a first sheet metal 100A with a seating surface 120 and a second sheet metal 100B without a seating surface 120 are spot-welded together, forming a spot-welded portion 110 on the seating surface 120, and the seating surface 120 is formed at a different height from the other areas 122. Specifically, similar to the mounting seating surface 20 of this embodiment described above, the seating surface 120 is formed lower than the other areas 122. The spot-welded portion 110 is formed approximately in the center of the seating surface 120. Note that in Figure 11, for convenience, the first sheet metal 100A and the second sheet metal 100B are shown as solid lines, but in reality they have thickness.

[0043] As shown in Figure 12, when there is no seating surface 120, i.e., when the spot weld 110 is at the same height as the other areas 22, stress was concentrated at the joint where the spot weld 110 was formed, as indicated by σ1. In contrast, as shown in Figure 13, when there is a seating surface 120, i.e., when the spot weld 110 is at a different height from the other areas 22, stress was distributed around the seating surface 120, as indicated by σ2. From this, it can be seen that when stress is applied, having a seating surface 120 reduces stress concentration compared to not having a seating surface 120.

[0044] On the other hand, as shown in Figures 1 to 3, there are many locations P where the setting of score-processed holes 30 is being considered, and the score-processed holes 30 are desired even in locations where strength performance is critical. However, if score-processed holes 30 are installed in locations where stress is applied due to repeated opening and closing operations, such as the side door 18 in Figure 3, the strength may be insufficient due to the notch 32. In this case, measures such as increasing the thickness of the sheet metal used for panel 12A may be necessary, or it may be necessary to skip the scoring process and instead drill holes through as before and then attach a cover to close the holes.

[0045] Therefore, in the mounting structure 10 for electrical components according to this embodiment, the score-machined holes 20 are formed on a second mounting seat surface 20A (mounting seat surface 20) which is formed at a different height from the other areas 22. As a result, when stress is applied, the stress is distributed on the second mounting seat surface 20A, so stress concentration in the score-machined holes 20 is mitigated, and it is possible to prevent stress concentration in the score-machined holes 20 and the occurrence of cracks. This makes it possible to suppress a decrease in strength in the score-machined holes 20.

[0046] Thus, the mounting structure 10 for electrical components according to this embodiment can suppress a decrease in strength while suppressing an increase in installation man-hours and costs.

[0047] Furthermore, in the mounting structure 10 for electrical components according to this embodiment, the mounting hole 50 is formed by punching out the inside of a notched hole, so the mounting hole 50 can be formed from the score-machined hole 20 as needed. That is, the score-machined hole 30 formed in the second mounting seat surface 20A can be machined into a mounting hole 50, thereby converting the second mounting seat surface 20A into the first mounting seat surface 20B.

[0048] Furthermore, in the mounting structure 10 for electrical components according to this embodiment, since the first mounting surface 20B and the second mounting surface 20A are formed at approximately the same height, by punching out the inside of the score-machined hole 30 formed in the second mounting surface 20A, a mounting hole 50 at approximately the same level as the mounting hole 50 formed in the first mounting surface 20B can be formed at the position where the second mounting surface 20A is provided, if necessary.

[0049] Furthermore, in the mounting structure 10 for electrical components according to this embodiment, the mounting holes 50 and the score-machined holes 30 have at least two different shapes, so that mounting holes 50 of a shape corresponding to the type of electrical component to be mounted can be provided.

[0050] Furthermore, in the manufacturing method of the electrical component mounting structure 10 according to this embodiment, a score-machined hole 30, which is notched along the shape of the hole to be penetrated, is formed on the mounting surface 20 which is formed at a different height from the other areas 22. Since the score-machined hole 30 is notched but not penetrates, a cover is not required to close the hole, which is not needed in the vehicle. This suppresses the increase in installation man-hours and costs that would otherwise be required for the cover. In addition, since stress is distributed across the mounting surface 20, stress concentration in the score-machined hole 30 is mitigated, preventing stress concentration in the score-machined hole 30 and subsequent cracking. In other words, a decrease in strength in the score-machined hole 30 can be suppressed.

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

[0052] Furthermore, in the above embodiment, the score processing holes 30 and mounting holes 50 have two or more different shapes depending on the position P on which the mounting seat surface 20 is installed, but the present invention is not limited thereto. For example, either the score processing holes 30 or the mounting holes 50 may have two or more different shapes. Alternatively, both the score processing holes 30 and the mounting holes 50 may have only the same shape.

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

[0054] Furthermore, the configuration of the present invention is not limited to the above-described embodiments, and the configuration can be modified as appropriate, as long as the problem can be solved. [Explanation of Symbols]

[0055] 10. Mounting structure for electrical components, 12. Vehicle, 20. Mounting surface, 20A Second mounting surface, 20B First mounting surface, 30 Scored holes, 50 mounting holes

Claims

1. A first mounting surface is provided in a vehicle at a location where electrical components are to be mounted, and has mounting holes formed therein. It comprises a second mounting surface having a score-machined hole formed by a notch cut to conform to the shape of the hole to be penetrated, A mounting structure for electrical components in which the first mounting surface and the second mounting surface are formed at different heights from other areas.

2. The mounting structure for electrical components according to claim 1, wherein the mounting hole is formed by punching out the inside of a score-machined hole that has been notched in accordance with the shape of the hole to be penetrated.

3. The mounting structure for electrical components according to claim 1, wherein the first mounting surface and the second mounting surface are formed at substantially the same height.

4. The mounting structure for electrical components according to claim 1, wherein at least one of the mounting hole and the score-machined hole has at least two different shapes.

5. A seating surface forming step in a vehicle, in which multiple mounting surfaces are formed at locations where electrical components may be installed and at a different height from other areas, A scoring step in which notches are cut into the plurality of mounting seat surfaces according to the shape of the hole to be made through, thereby forming a scoring hole, In the score-machined hole provided at the position where the mounting of the electrical component has been determined, a punching step is performed to punch out the inside of the score-machined hole to form a mounting hole, A method for manufacturing a mounting structure that includes the above.

Images