Vehicle resin panels

Abstract

To provide a vehicle resin panel which can suppress deformation derived from thermal strain.SOLUTION: An outer panel 3 has a fixed peripheral end part. The outer panel 3 includes a thin part 41 having prescribed thickness, a thick part 42 thicker than the thin part 41, and a thickness changing part 43 whose the thickness gradually changes between the thin part 41 and the thick part 42. In a cross-sectional view in the thickness direction of the outer panel 3, the thickness changing part 43 is formed so that an end edge 45 of the outer panel 3 draws a curve C with no step S.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present invention relates to a vehicle resin panel. [Background Art]

[0002] Conventionally, vehicle resin panels have been used in the fields of vehicle outer panels and vehicle inner panels. A resin panel is formed of a resin material, and is used, for example, as a part of a vehicle door panel.

[0003] More specifically, the following vehicle door has been proposed. The vehicle door is a back door. The back door includes an outer panel portion positioned on the vehicle outer side and an inner panel portion positioned on the vehicle inner side. The outer panel portion is a resin panel portion formed by injection-molding polycarbonate. The outer panel portion is bonded to the inner panel portion, so that the outer panel portion and the inner panel portion are integrated (see, for example, Patent Document 1). [Prior Art Documents] [Patent Documents]

[0004] [Patent Document 1] Japanese Unexamined Patent Publication No. 2009-67360 [Summary of the Invention] [Problem to be Solved by the Invention]

[0005] On the other hand, a change in wall thickness may be required for the resin panel portion (the above-mentioned outer panel portion) in some cases. For example, from the viewpoint of fluidity of a resin material (resin moldability) in injection molding, an increase in thickness may be required for a part of the resin panel portion in some cases. Further, for example, from the viewpoint of designability, a reduction in thickness may be required for a part of the resin panel portion in some cases.

[0006] However, when the wall thickness of the resin panel portion (the above-mentioned outer panel portion) changes, there is a problem that deformation resulting from thermal strain is likely to occur.

[0007] The present invention relates to a vehicle resin panel that can suppress deformation caused by thermal strain. [Means for solving the problem]

[0008] The present invention [1] is a vehicle resin panel whose peripheral end is fixed, the vehicle resin panel comprising a thin portion having a predetermined thickness, a thick portion having a thickness greater than the thickness of the thin portion, and a thickness-changing portion between the thin portion and the thick portion in which the thickness gradually changes, wherein the thickness-changing portion is formed such that, in a cross-sectional view along the thickness direction of the vehicle resin panel, the edge of the vehicle resin panel forms a curve without steps. [Effects of the Invention]

[0009] According to the vehicle resin panel of the present invention, deformation caused by thermal strain can be suppressed.

[0010] In other words, conventionally, when the thickness of a vehicle resin panel changes, the region where the thickness changes (the thickness change portion) is formed such that, in a cross-sectional view along the thickness direction of the vehicle resin panel, the edge of the vehicle resin panel forms a step (see, for example, Figure 6).

[0011] On the other hand, in vehicles, the vehicle's resin panels may expand due to heat. However, the peripheral edges of the vehicle's resin panels are usually fixed to the vehicle. Therefore, when the vehicle's resin panels expand due to heat, the expanded portion cannot move outward, but instead generates stress directed inward. In other words, stress originating from thermal strain is generated.

[0012] In such cases, if the edges of the vehicle's resin panel are formed with a step (see Figure 6), this step can concentrate stress, leading to deformation of the vehicle's resin panel.

[0013] In contrast, in the above-mentioned vehicle resin panel, a section of thickness variation is formed such that, in a cross-sectional view along the thickness direction of the vehicle resin panel, the edge of the vehicle resin panel forms a smooth, step-free curve.

[0014] Therefore, the above-mentioned vehicle resin panel can suppress the occurrence of stress concentration due to steps. As a result, the above-mentioned vehicle resin panel can suppress deformation caused by thermal strain. [Brief explanation of the drawing]

[0015] [Figure 1] Figure 1 is an exploded perspective view of a vehicle panel comprising one embodiment of the vehicle resin panel of the present invention. [Figure 2] Figure 2 is a partially enlarged perspective view of the vehicle's resin panel shown in Figure 1. [Figure 3] Figure 3 is a partial cross-sectional view along the thickness direction of the vehicle resin panel shown in Figure 1. [Figure 4] Figure 4 is a schematic diagram showing the flow direction of the resin material in injection molding. [Figure 5] Figure 5 is a cross-sectional view of the vehicle resin panel in Figure 1, along the thickness direction. [Figure 6] Figure 6 is a cross-sectional view of a conventional vehicle resin panel along its thickness direction. [Modes for carrying out the invention]

[0016] 1. Overall configuration of the vehicle's resin panel Figure 1 shows one embodiment of the vehicle resin panel of the present invention. Figure 1 also shows one embodiment of a vehicle panel comprising the vehicle resin panel.

[0017] In FIG. 1, vehicle panel 1 is, for example, a vehicle door panel. Examples of the door panel include a side door panel and a back door panel. A back door panel is preferably mentioned as the door panel. When vehicle panel 1 is a back door panel, vehicle panel 1 is attached to a vehicle body (not shown) via, for example, a hinge (not shown). Accordingly, vehicle panel 1 is openably and closably connected to the vehicle body. FIG. 1 shows an exploded view of the back door panel.

[0018] In FIG. 1, vehicle panel 1 includes an inner panel 2 and an outer panel 3 as a vehicle resin panel.

[0019] Inner panel 2 is an inner plate of vehicle panel 1. The shape of inner panel 2 is appropriately set according to the shape of vehicle panel 1.

[0020] Inner panel 2 is, for example, a plate member having a desired uneven shape. More specifically, as referred to the left view on the paper of FIG. 1, inner panel 2 includes an opening 20 for fitting a window member. Further, inner panel 2 includes a high-mount stop lamp connecting portion 22 for connecting a high-mount stop lamp.

[0021] Further, as referred to FIG. 1 and FIG. 3, an adhesion protrusion 21 for applying adhesive 4 is formed on an outer peripheral end portion of inner panel 2 and an inner peripheral end portion of opening 20. Adhesion protrusion 21 is adhered to outer panel 3 via adhesive 4.

[0022] Inner panel 2 is formed of any material. For example, inner panel 2 is made of a metal material and / or a resin material. Preferably, inner panel 2 is made of a resin material. When inner panel 2 is made of a resin material, inner panel 2 is obtained as an integrally molded product, for example, by injection molding. The resin material is not particularly limited, and known resin materials can be used.

[0023] The outer panel 3 is the outer panel of the vehicle panel 1. The shape of the outer panel 3 is set appropriately according to the shape of the vehicle panel 1.

[0024] More specifically, the outer panel 3 comprises an under panel 31, a middle panel 32, and an upper panel 33. The under panel 31, middle panel 32, and upper panel 33 are assembled together and positioned to surround the opening 20, and are bonded to the adhesive protrusions 21 of the inner panel 2. As a result, the entire circumference of the peripheral edge of the outer panel 3 is fixed to the inner panel 2.

[0025] The under panel 31 is, for example, a plate member having a desired uneven shape. More specifically, the under panel 31 has a license plate recess 34 for attaching a license plate, as shown in the right-hand diagram of Figure 1. The under panel 31 is assembled to the middle panel 32. The under panel 31 is also positioned below the opening 20 and is bonded to the adhesive protrusions 21 of the inner panel 2 via adhesive 4.

[0026] The middle panel 32 is, for example, a plate member having a desired uneven shape. More specifically, the middle panel 32 is formed as a pair of plate members, as shown in the right-hand diagram of Figure 1. The pair of middle panels 32 are assembled to the under panel 31 and the upper panel 33. The middle panels 32 are also positioned opposite each other on the left and right sides of the opening 20 and are bonded to the adhesive protrusions 21 of the inner panel 2 via adhesive 4.

[0027] The upper panel 33 is, for example, a plate member having a desired uneven shape. The upper panel 33 includes a spoiler that is adjacent to the roof panel (not shown) and positioned on the upper side of the vehicle. More specifically, the upper panel 33 has a spoiler projection 35 that protrudes toward the rear of the vehicle, as shown in Figures 2 and 3.

[0028] The spoiler protrusion 35 comprises an upper surface portion 36, a lower surface portion 37, and a high-mounted stop lamp mounting portion 39. In other words, the outer panel 3 comprises an upper surface portion 36, a lower surface portion 37, and a high-mounted stop lamp mounting portion 39.

[0029] The upper portion 36 is a plate portion having a predetermined thickness and extending along the vehicle's longitudinal direction. The upper portion 36 is arranged to slope from the upper side to the lower side of the vehicle. The lower portion 37 is a flat portion having a predetermined thickness and is a plate portion folded back from the upper portion 36. The lower portion 37 is formed continuously from the upper portion 36. In other words, the lower portion 37 is formed integrally with the upper portion 36. Furthermore, the lower portion 37 is arranged to be parallel to the vehicle's longitudinal direction (for example, the horizontal direction). The high-mounted stop lamp mounting portion 39 is formed continuously from the lower portion 37. In other words, the high-mounted stop lamp mounting portion 39 is formed integrally with the lower portion 37. The high-mounted stop lamp mounting portion 39 has a shape that bulges outward from the vehicle along the thickness direction of the lower portion 37. More specifically, the high-mounted stop lamp mounting section 39 consists of a plate member that bends outward from the lower surface section 37 and has a box-frame shape that opens to the rear and downward. The high-mounted stop lamp mounting section 39 also has a wiring hole 38 for passing the wiring of the high-mounted stop lamp. The spoiler protrusion 35 (upper surface section 36, lower surface section 37, and high-mounted stop lamp mounting section 39) is formed as a single molded product, for example, by injection molding.

[0030] The upper panel 33 (including the spoiler protrusion 35) is assembled to the middle panel 32. The upper panel 33 is also positioned above the opening 20 and is bonded to the adhesive protrusion 21 of the inner panel 2 via adhesive 4.

[0031] The outer panel 3 (under panel 31, middle panel 32, and upper panel 33) is formed from a resin material. Examples of resin materials include polyolefin, polyamide, polyurethane, polyvinyl chloride, polycarbonate, polyether, polyester, and polyacrylic. These can be used individually or in combination of two or more. The resin material may contain additives. Examples of additives include fillers (such as reinforcing fibers), colorants, heat stabilizers, light stabilizers, antioxidants, and mold release agents. These can be used individually or in combination of two or more. The proportion of additives is set appropriately according to the purpose and application. The method for forming the outer panel 3 from the resin material is not particularly limited, and known resin molding methods can be employed. Examples of molding methods include injection molding, compression molding, and inflation molding, with injection molding being preferred.

[0032] 2. Thickness of the outer panel The thickness of the outer panel 3 is set appropriately according to the purpose and application, but the thickness of the outer panel 3 is not constant and is increased or decreased depending on the purpose and application.

[0033] For example, when the outer panel 3 is injection molded, the resin material flows along a certain direction. For example, when the upper panel 33 is injection molded, as shown by arrow F in Figure 4, the resin material fills along the high-mount stop lamp mounting portion 39 and the lower portion 37, and then fills along the upper portion 36.

[0034] In such cases, because the shape of the upper panel 33 is complex, if the thickness of the upper panel 33 is constant, the resin material may not flow sufficiently, which can lead to molding defects.

[0035] Therefore, in order to improve the fluidity (moldability) of the resin material in injection molding, for example, the outer panel 3 (upper panel 33) is partially thickened. By partially thickening the outer panel 3 (upper panel 33), the amount of flowable resin material in that part can be increased, thereby improving the fluidity (moldability) of the resin material.

[0036] In such a case, the outer panel 3 (upper panel 33), as shown in Figure 5, comprises a thin-walled portion 41 having a relatively thin predetermined thickness, a thick-walled portion 42 having a thickness greater than that of the thin-walled portion 41, and a thickness-changing portion 43 between the thin-walled portion 41 and the thick-walled portion 42 in which the thickness gradually changes.

[0037] The thin-walled portion 41, the thick-walled portion 42, and the thickness-changing portion 43 are positioned at any location on the outer panel 3 (upper panel 33). For example, the arrangement of the thin-walled portion 41, the thick-walled portion 42, and the thickness-changing portion 43 is appropriately set according to the shape of the outer panel 3 (upper panel 33) in order to improve the fluidity (resin moldability) of the resin material in the outer panel 3 (upper panel 33).

[0038] The thickness T1 of the thin-walled portion 41 is, for example, constant. The thickness T1 of the thin-walled portion 41 is, for example, 0.5 mm or more, preferably 1.0 mm or more. Alternatively, the thickness T1 of the thin-walled portion 41 is, for example, 10 mm or less, preferably 5.0 mm or less.

[0039] The thickness T2 of the thickened portion 42 is, for example, constant. The thickness T2 of the thickened portion 42 is, for example, 1.0 mm or more, preferably 2.0 mm or more. Alternatively, the thickness T2 of the thickened portion 42 is, for example, 15 mm or less, preferably 10.0 mm or less.

[0040] The difference between the thickness T1 of the thin-walled portion 41 and the thickness T2 of the thick-walled portion 42 (T2-T1) is, for example, 0.5 mm or more, preferably 1.0 mm or more. Also, the difference between the thickness T1 of the thin-walled portion 41 and the thickness T2 of the thick-walled portion 42 (T2-T1) is, for example, 15 mm or less, preferably 10.0 mm or less.

[0041] The thickness of the thickness-changing section 43 changes along the length direction (the flow direction of the resin material). The length L of the thickness-changing section 43 along the flow direction of the resin material is, for example, 5 mm or more, preferably 1 mm or more. Also, the length L of the thickness-changing section 43 along the flow direction of the resin material is, for example, 250 mm or less, preferably 200 mm or less.

[0042] Furthermore, the length L of the thickness-changing portion 43 along the flow direction of the resin material is, for example, 3 times or more, preferably 5 times or more, the difference (T2-T1) between the thickness T1 of the thin portion 41 and the thickness T2 of the thick portion 42. Also, the length L of the thickness-changing portion 43 along the flow direction of the resin material is, for example, 50 times or less, preferably 20 times or less, the difference (T2-T1) between the thickness T1 of the thin portion 41 and the thickness T2 of the thick portion 42.

[0043] Furthermore, in a cross-sectional view along the thickness direction of the outer panel 3 (upper panel 33) (i.e., Figure 5), the thickness change portion 43 is formed such that the edge 45 of the outer panel 3 (upper panel 33) forms a smooth curve C without any steps.

[0044] In other words, in the cross-sectional view along the thickness direction of the outer panel 3 (upper panel 33) (i.e., Figure 5), the edge 45 of the outer panel 3 (upper panel 33) does not have a step S, but rather a curve C without a step S.

[0045] Furthermore, the edge 45 of the outer panel 3 (upper panel 33) has an inner edge 45a and an outer edge 45b. Both the inner edge 45a and the outer edge 45b form a curve C without any step S.

[0046] 3. Effects According to the outer panel 3 described above, deformation caused by thermal strain can be suppressed.

[0047] In other words, conventionally, when the thickness of the outer panel 3 changes, the region where the thickness changes (thickness change portion) is formed such that the edge in the thickness direction forms a step S (see, for example, Figure 6).

[0048] On the other hand, in a vehicle, the outer panel 3 may expand due to heat. However, the peripheral edges of the outer panel 3 are usually fixed to the inner panel 2 of the vehicle via adhesive 4 (see Figure 3).

[0049] Therefore, when the outer panel 3 expands due to heat, the expanded portion cannot move outward and instead generates stress moving inward. In other words, stress originating from thermal strain is generated. In such a case, if the outer panel 3 is formed such that its edge in the thickness direction forms a step S (see Figure 6), the above step concentrates stress and causes deformation of the outer panel 3, which is a problem.

[0050] In contrast, in the outer panel 3 (upper panel 33) described above, a thickness change portion 43 is formed such that, in a cross-sectional view (Figure 5) along the thickness direction of the outer panel 3 (upper panel 33), the edge 45 in the thickness direction draws a smooth curve C without any steps.

[0051] Therefore, the outer panel 3 (upper panel 33) described above can suppress the occurrence of stress concentration due to the step S. As a result, deformation caused by thermal strain can be suppressed by the outer panel 3 (upper panel 33) described above.

[0052] 4. Variations In the above explanation, the upper panel 33 was used as an example of a vehicle resin panel, but the vehicle resin panel is not particularly limited as long as it is a panel made of resin material with its peripheral edges fixed. For example, the under panel 31 can be used as a vehicle resin panel. The middle panel 32 can also be used as a vehicle resin panel. The inner panel 2 can also be used as a vehicle resin panel.

[0053] Furthermore, while the above description describes varying the thickness of the vehicle resin panel (outer panel 3) from the viewpoint of the fluidity (resin moldability) of the resin material in injection molding, the present invention is not limited to the above. For example, the thickness of the vehicle resin panel may be varied from the viewpoint of design. Also, for example, the thickness of the vehicle resin panel may be varied from the viewpoint of mounting electrical and / or electronic components.

[0054] In such cases, the vehicle resin panel is formed with a thin section 41, a thick section 42, and a section with a change in thickness 43. Furthermore, if the vehicle resin panel is formed such that the edge in the thickness direction forms a step S (see Figure 6), the above-mentioned step concentrates stress, causing deformation in the outer panel 3.

[0055] In contrast, if the thickness-changing portion 43 is formed such that the edge 45 in the thickness direction of the vehicle resin panel forms a smooth curve without any steps, the vehicle resin panel can suppress the occurrence of stress concentration due to steps S. As a result, such a vehicle resin panel can suppress deformation caused by thermal strain. [Explanation of Symbols]

[0056] 1 Vehicle Panel 2 Inner Panel 3 Outer Panel 4. Adhesive 41 Thin-walled section 42 Thick wall part 43. Section with change in wall thickness 45 Edge

Claims

[Claim 1] It is a vehicle resin panel whose peripheral edges are fixed, The aforementioned vehicle resin panel is an outer panel that constitutes the vehicle's back door panel. The outer panel is integrally provided with a spoiler protrusion that projects toward the rear of the vehicle. The aforementioned vehicle resin panel is A thin-walled portion having a predetermined thickness, A thick-walled portion having a thickness greater than the thickness of the thin-walled portion, A thickness-changing section in which the thickness gradually changes between the thin-walled section and the thick-walled section. Equipped with, In the cross-sectional view of the aforementioned vehicle resin panel along the thickness direction, The thickness variation portion is formed such that the edge of the vehicle's resin panel forms a smooth, step-free curve. The difference between the thickness of the thin-walled portion and the thickness of the thick-walled portion is 1.0 mm or more and 15 mm or less. Vehicle resin panel.

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