Note: Descriptions are shown in the official language in which they were submitted.
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DESCRIPTION
TAILORED BLANK ARTICLE AND
MANUFACTURING METHOD OF THE SAME
Technical Field
This invention relates to a tailored blank article and a manufacturing
method thereof, which is manufactured by a tailored blank obtained by
welding a plurality of blanks, and, for example, is applied to an article used
at
the position where the inside and the outside are partitioned or an article
having a portion for partitioning the inside and the outside, such as a
dashboard panel of an automobile.
Background Art
A dashboard panel of an automobile is a partition article for
partitioning the inside and the outside since it partitions an engine room to
be
exposed to the outside air and a car room to be cut off from the air. As
disclosed in Japanese Utility Model Laid-open No. Sho 59-172678, in a
conventional dashboard panel, a lower panel made of a thick plate and an
upper panel made of a thin plate are joined together by a spot welding.
This kind of dashboard panel is manufactured by pressing a thick plate
blank and a thin plate blank into predetermined shapes to produce the lower
panel and the upper panel, joining these panels by the spot welding,
performing a waterproofing to a space between these panels, and coating an
entire body.
When manufacturing an article for a car body of the automobile other
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than the dashboard panel, which is used at the position where the inside and
the outside of the car room are partitioned, by spot welding a plurality of
panels produced by the blanks, it was conventionally manufactured by
undergoing the same process as that of the aforesaid dashboard panel.
According to this conventional technology, the spot welding is
performed after a plurality of the blanks are subjected to the pressing to
manufacture a plurality of the panels in predetermined shapes, which makes it
necessary to prepare a press die for each blank, thus causing the disadvantage
that its cost becomes high. Further, since the panels between a plurality of
spot welding portions which are scattered about are not joined together, it is
necessary to perform an extra waterproofing in order to prevent a formation of
rust by an entering of the waterdrop thereinto, which causes the disadvantage
that the productivity becomes difficult to be increased.
An object of the present invention is to provide a tailored blank article
and a manufacturing method thereof, which is capable of reducing the number
of the press dies compared with the conventional art and making it
unnecessary to perform the extra waterproofing in order to prevent the
formation of rust.
Disclosure of the Invention
A tailored blank article according to the present invention is
manufactured by using two blanks with these overlapped end portions joined
together by a mash-seam welding and pressed as at least a part of material for
manufacturing, and a portion made of the two blanks makes a partition
portion for partitioning the inside and the outside.
In this tailored blank article, since the overlapped end portions of the
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two blanks are joined by the mash-seam welding, a pressing into a
predetermined shape is performed after the blanks are joined by the mash-
seam welding. Therefore, it is unnecessary to prepare a press die for each
blank. Further, even if a portion made of the two blanks makes a portion for
partitioning the inside and outside, the blanks are joined together without
leaving any space therebetween by the mash-seam welding, which makes it
unnecessary to perform an extra waterproofing in order to prevent a formation
of rust.
Moreover, in the tailored blank article, the blanks are joined together
by the mash-seam welding so that higher joining strength can be obtained
than in a spot welding, and further, an overlap margin of the end portions can
be reduced more than in the spot welding so that the weight reduction and the
improvement of material yield can be achieved.
In the tailored blank article, when the two blanks are a thick plate
blank and a thin plate blank and the mash-seam welding is performed while
the end portion of an outer surface of the thick plate blank to be exposed to
the outside is overlaid on the end portion of an inner surface of the thin
plate
blank, the thin plate blank may be bent until the inner surface of the thin
plate
blank is made flush or almost flush with an inner surface of the thick plate
blank.
Thereby, even if the two blanks are the thick plate blank and the thin
plate blank which differ in thickness, the inner surfaces of these blanks are
made flush or almost flush with each other, and hence the inner surfaces
thereof can be attaching surfaces for attaching other parts.
Further, the tailored blank article according to the present invention is
manufactured by using two blanks with these matched end portions joined
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together by a laser welding and pressed as at least a part of material for
manufacturing, and a portion made of the two blanks make a partition portion
for partitioning the inside and the outside.
In the tailored blank article, since the matched end portions of the two
blanks are joined by the laser welding, a pressing into a predetermined shape
is performed after the blanks are joined by the laser welding. Therefore, it
is
unnecessary to prepare a press die for each blank in this tailored blank
article,
too. Further, even if a portion made of the two blanks makes a portion for
partitioning the inside and outside, the blanks are joined together without
leaving any space therebetween by the laser welding, which makes it
unnecessary to perform an extra waterproofing in order to prevent a formation
of rust, similarly to the case of the mash-seam welding.
Moreover, in the tailored blank article, the blanks are joined together
by the laser welding so that higher joining strength can be obtained than in a
spot welding, and further, unlike the spot welding, it is unnecessary to
overlap
the end portions of the blanks so that the further weight reduction and the
improvement of material yield can be achieved.
In the tailored blank article, when the two blanks are a thick plate
blank and a thin plate blank and respective outer surfaces to be exposed to
the
outside of the thick plate blank and the thin plate blank are made flush or
almost flush with each other, the thin plate blank may be bent until an inner
surface of the thin plate blank is made flush or almost flush with an inner
surface of the thick plate blank.
Thereby, even if the two blanks are the thick plate blank and the thin
plate blank which differ in thickness, the inner surfaces of these blanks are
made flush or almost flush with each other, and hence the inner surfaces
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thereof can be the attaching surfaces for attaching other parts.
In the tailored blank article by both of the mash-seam welding and the
laser welding as described above, when a connection part is provided, which
is connected to at least one of an outer surface and the inner surface of the
two
5 blanks over a welding portion, a portion in the connection part which
corresponds to the welding portion is made to be spaced from the welding
portion.
Thereby, when the coating is performed onto the surface connected
with the connection part in order to ensure durability, after the connection
of
the connection part, the welding portion by the mash-seam welding and the
welding portion by the laser welding can be securely coated.
A method for manufacturing the tailored blank article according to the
present invention, which has at least a portion made of the thick plate blank
and the thin plate blank as a partition portion for partitioning the inside
and
the outside, comprising the steps of: joining the end portion of the thick
plate
blank and the end portion of the thin plate blank while the inner surface of
the
thin plate blank is overlaid on the outer surface of the thick plate blank to
be
exposed to the outside by a mash-seam welding, pressing these blanks,
bending the thin plate blank until the inner surface of the thin plate blank
is
made flush or almost flush with the inner surface of the thick plate blank,
and
thereafter coating at least one of the outer surface and the inner surface of
the
thick plate blank and the thin plate blank including the mash-seam welding
portion.
In this method for manufacturing the tailored blank article, the blanks
are subjected to the pressing into the predetermined shape after they are
joined by the mash-seam welding, it is unnecessary to prepare the press die
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for each blank. Further, the blanks are joined together without leaving any
space therebetween by the mash-seam welding, which makes it unnecessary
to perform the extra waterproofing in order to prevent the formation of rust.
Moreover, the blanks are joined together by the mash-seam welding with
higher joining strength than in the spot welding, and further, the overlap
margin of the end portions of the blanks can be reduced in the mash-seam
welding than in the spot welding, so that the weight reduction and the
improvement of material yield can be achieved.
Further, in this method for manufacturing the tailored blank article,
when the inner surface of the thin plate blank is overlaid on the outer
surface
of the thick plate blank to be exposed to the outside to perform the mash-seam
welding, the inner surface of the thin plate blank is bent until it is made
flush
or almost flush with the inner surface of the thick plate blank, and hence the
inner surfaces thereof can be the attaching surfaces for attaching other
parts.
Furthermore, the method for manufacturing the tailored blank article
according to the present invention, which has at least a portion made of the
thick plate blank and the thin plate blank as the partition portion for
partitioning the inside and the outside, comprising the steps of: joining the
matched end portions of the thick plate blank and the thin plate blank with
the
respective outer surfaces of these blanks made flush or almost flush with each
other by the laser welding, then pressing these blanks, bending the thin plate
blank until the inner surface of the thin plate blank is made flush or almost
flush with the inner surface of the thick plate blank, and subsequently
coating
at least one of the outer surface and the inner surface of the thick plate
blank
and the thin plate blank including the laser welding portion.
In this method for manufacturing the tailored blank article, the blanks
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are subjected to the pressing into the predetermined shape after they are
joined by the laser welding, and therefore it is unnecessary to prepare the
press die for each blank similarly to the case of the mash-seam welding.
Further, the blanks are joined together without leaving any space
therebetween by the laser welding, which makes it unnecessary to perform the
extra waterproofing in order to prevent the formation of rust. Moreover, the
blanks are joined together by the laser welding with higher joining strength
than in the spot welding, and further, unlike the spot welding, it is
unnecessary to overlap the end portions of the blanks in the laser welding, so
that the further weight reduction and the improvement of material yield can be
achieved.
Furthermore, in this method for manufacturing the tailored blank
article, when the laser welding is performed with respective outer surfaces of
the thick plate blank and the thin plate blank made flush or almost flush with
each other, the thin plate blank is bent until the inner surface of the thin
plate
blank is made flush or almost flush with the inner surface of the thick plate
blank, and hence the inner surfaces thereof can be the attaching surfaces for
attaching other parts, similarly to the case of the mash-seam welding.
In the method of manufacturing the tailored blank article by both of
the mash-seam welding and the laser welding as described above, when the
connection part is provided, which is connected to at least one of the outer
surface and the inner surface of the thick plate blank or the thin plate blank
over the welding portion, the connection part is connected to the surface of
the thick plate blank and the thin plate blank to which the connection part is
connected, while the portion to be connected over the welding portion is
spaced from the welding portion, and then the coating is performed.
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Thereby, when the coating is performed to ensure durability onto the
surface of the thick plate blank and the thin plate blank to which the
connection part is connected after the connection of the connection part, the
mash-seam welding portion and the laser welding portion can be securely
coated. Thus, the formation of rust from the welding part can be effectively
prevented by a coating film.
Moreover, in the method of manufacturing the tailored blank article by
both of the mash-seam welding and the laser welding as described above, the
bending of the thin plate blank until the inner surface of the thin plate
blank is
made flush or almost flush with the inner surface of the thick plate blank may
be performed as a part of the working process of the pressing when the joined
thick plate blank and the thin plate blank are subjected to the pressing, or
may
be performed before or after the pressing as a working process which is
different from the pressing.
Furthermore, in the tailored blank article and the manufacturing
method thereof according to the present invention as described above, the
bending of the thin plate blank until the inner surface of the thin plate
blank is
made flush or almost flush with the inner surface of the thick plate blank
means that at a position in the inner surface of the thick plate blank which
is a
flat surface, the inner surface of the thin plate blank is subjected to the
bending to a position which corresponds or almost corresponds to an
extension of a straight line from the inner surface of the thick plate blank
so
that the inner surface of the thin plate blank is made to be a flat surface,
and
further, at a position in the inner surface of the thick plate blank which is
a
curved surface, the thin plate blank is subjected to the bending to a position
which corresponds or almost corresponds to an extension of a curved line
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from the inner surface of the thick plate blank so that the inner surface of
the
thin plate blank is made to be a curved surface.
The blank which can be used in the tailored blank article and the
manufacturing method thereof according to the present invention as described
above is the one of a metallic plate, especially of a hot rolled steel plate
and a
cold rolled steel plate. The present invention can be applied to a steel plate
having a thickness of 0.7 mm to 3.2 mm, and the steel plate may be without a
surface treatment of a plating and the like or may be performed with the
surface treatment of a zinc plating and the like. Further, in the present
invention, the steel plate with various strength, from a soft steel plate to a
high
tensile steel plate of 690 MPA class can be used.
Moreover, in the present invention, the coating may be an
electrodeposition coating or may be a spray coating.
The present invention can be applied to an article having a part for
partitioning the inside and the outside at least in part thereof. An example
is
a dashboard panel in the case of a car body of an automobile. Other
examples of the car body of the automobile are an article made of a front
wheel house and a front side frame, an article made of a rear wheel house and
a rear side panel inner, and so on.
When the tailored blank article according to the present invention is
the dashboard panel, a material of the lower side of the dashboard panel is
the
thick plate blank and a material of the upper side thereof is the thin plate
blank, and the thin plate blank is bent until the inner surface of the thin
plate
blank, which forms a space inside a car room, is made flush or almost flush
with the inner surface of the thick plate blank.
With this dashboard panel, the material of the lower side thereof is the
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thick plate blank so that strength in this portion can be set so as to bear a
load
from the front side frame effectively in a collision of the automobiles, and
further, the material of the upper side thereof is the thin plate blank so
that the
entire weight of the dashboard lower panel can be decreased.
5 Moreover, with this dashboard panel, the respective outer surfaces of
the thick plate blank and the thin plate blank, which form an engine room are
made uninterrupted or almost uninterrupted by the mash-seam welding or the
laser welding, and the thin plate blank is bent until the inner surface of the
thin plate blank, which forms the space inside the car room, is made flush or
10 almost flush with the inner surface of the thick plate blank, which makes
it
possible to prevent a formation of a concave portion and a portion with a
difference in level in which the waterdrop is likely to be collected in the
outer
surface of the engine room side. Thereby, the formation of rust can be
prevented from this outer surface to be exposed to the outside.
In order to manufacture the dashboard panel like this according to the
manufacturing method of the tailored blank article as described above, the
thick plate blank is prepared as the material of the lower side of the
dashboard
panel and the thin plate blank is prepared as the material of the upper side
thereof, the thick plate blank and the thin plate blank are joined together by
the mash-seam welding or the laser welding, and the thin plate blank is bent
until the inner surface of the thin plate blank, which forms the space inside
the
car room, is made flush or almost flush with the inner surface of the thick
plate blank.
Further, when the tailored blank article and the manufacturing method
thereof according to the present invention is applied to the dashboard panel,
an example of the connection part connected to at least one of the outer
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surface and the inner surface of the two blanks over the mash-seam welding
portion or the laser welding portion is the front side frame, and other
examples are an insulator panel for sound insulation and a reinforcing panel.
Furthermore, the present invention can be applied to articles other
than the car body of the automobile, for example, to an outer plate of a small
craft, an inner plate of a washing machine tub, an outer plate of a
television,
an outer panel of a kerosene stove, an outer frame of a personal computer, and
so on.
Brief Description of Drawings
FIG. 1 is a perspective view of a part of a car body of an automobile
manufactured by using a dashboard lower panel of a tailored blank article
according to the present invention seen from a car room, in which only the
dashboard lower panel is shown in a full line; FIG. 2 is a plane view of a
thick
plate blank and a thin plate blank as materials for manufacturing the
dashboard lower panel; FIG. 3 is a plane view showing a state of the thick
plate blank and the thin plate blank with these end portions overlapped for a
mash-seam welding; FIG. 4 is a vertical sectional view of the thick plate
blank and the thin plate blank in the mash-seam welding; FIG. 5 is a vertical
sectional view of the thick plate blank and the thin plate blank after the
mash-
seam welding; FIG. 6 is a perspective view of the dashboard lower panel
manufactured by a transfer pressing of the thick plate blank and the thin
plate
blank which are joined by the mash-seam welding seen from the car room;
FIG. 7 is a vertical sectional view showing a state in which the thin plate
blank undergoes a pressing so as to make an inner surface of the thick plate
blank and an inner surface of the thin plate blank flush or almost flush with
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each other; FIG. 8 is a vertical sectional view of the thick plate blank and
the
thin plate blank after the pressing; FIG. 9 is a perspective view of the
dashboard lower panel connected with a front side frame seen from an engine
room side; FIG. 10 is a perspective view of the dashboard lower panel
connected with an insulator panel for sound insulation seen from the car room
side; FIG. 11 is a vertical sectional view of a mash-seam welding portion of
the dashboard lower panel connected with the front side frame to the outer
surface thereof and the insulator panel for sound insulation to the inner
surface thereof; FIG. 12 is a view similar to FIG.11, showing a modified
example in which a portion in the front side frame which corresponds to the
mash-seam welding portion has a different shape from the one in FIG. 11;
FIG. 13 is a perspective view of the dashboard lower panel connected with a
reinforcing panel seen from the car room; FIG. 14 is a vertical sectional view
of a thick plate blank and a thin plate blank when joined together by a laser
welding in an embodiment in which a dashboard panel is manufactured from
the thick plate blank and the thin plate blank joined by the laser welding;
FIG.
15 is a vertical sectional view of the thick plate blank and the thin plate
blank
after the laser welding; FIG. 16 is a vertical sectional view showing a state
in
which the thin plate blank undergoes a bending; FIG. 17 is a vertical
sectional
view of the thick plate blank and the thin plate blank after the bending; FIG.
18 is a vertical sectional view of a laser welding portion of the dashboard
lower panel connected with a front side frame to an outer surface thereof and
an insulator panel for sound insulation to an inner surface thereof; FIG. 19
is a
view similar to FIG. 18, showing a modified example in which a portion in the
front side frame which corresponds to the laser welding portion has a
different
shape from the one in FIG. 18; FIG. 20 is a vertical sectional view of a thick
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plate blank and a thin plate blank of an embodiment in which outer surfaces
of the thick plate blank and the thin plate blank which are made flush or
almost flush with each other face the opposite side from a laser device, which
is different from FIG. 14, and FIG. 21 is a vertical sectional view of the
thick
plate blank and the thin plate blank after the laser welding as in FIG. 20.
Best Mode for Carrying out the Invention
Preferred embodiments will be described with reference to the
attached drawings in order to explain the present invention in detail.
The embodiment described below is for a dashboard panel of a car
body of an automobile which is formed with tailored articles, especially for a
dashboard lower panel. FIG. 1 shows a part of the car body of the
automobile, in which the part of the car body is formed by joining a
dashboard upper panel B, a front lower panel C and a front pillar inner lower
panel D to a dashboard lower panel A.
FIG. 2 to FIG. 13 show the embodiment in which a dashboard lower
panel is manufactured by a mash-seam welding. As shown in FIG. 2,
materials of the dashboard lower panel are a thick plate blank 11 and a thin
plate blank 12 both of which are made of a steel plate, and end portions 11A
and 12A of the blanks 11 and 12 overlap each other when joined by the mash-
seam welding as shown in FIG. 3. As shown in FIG. 4, they are overlapped
with the thick plate blank 11 at the lower side and the thin plate blank 12 at
the upper side. Thereby, when the dashboard lower panel is formed of the
thick plate blank 11 and the thin plate blank 12, an inner surface 12C of the
thin plate blank 12 which is an inner side of a car room to be cut off from
the
outside air is overlaid on an outer surface 11B of the thick plate blank 11
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which is an engine room side to be exposed to the outside air. The thick
plate blank 11 and the thin plate blank 12 are clamped together under this
condition.
A mash-seam welding device 13 for joining the end portions 11A and
12A of the blanks 11 and 12 has upper and lower electrode rollers 13A and
13B for pressurizing and mashing the end portions 11A and 12A. The
electrode rollers 13A and 13B move by rolling along the end portions 11A
and 12A while being applied with an electric current between these electrode
rollers 13A and 13B. Thereby, as shown in FIG. 5, the end portion 11A and
the end portion 12A are mashed and joined with a formation of a nugget 14
between the end portions 11A and 12A, whereby a mash-seam welding
portion 15 which has less thickness than the thick plate blank 11 and the thin
plate blank 12 in total is formed at positions of the end portions 11A and
12A.
This mash-seam welding allows the outer surface 11B of the thick plate blank
11 and an outer surface 12B of the thin plate blank 12, which make the
surface of the engine room side of the dashboard lower panel, to be made
uninterrupted or almost interrupted.
It should be mentioned that an edge portion 12D which is an end of
the outer surface 12B of the thin plate blank 12 on the thick plate blank 11
side may have a slight difference in level to the outer surface 11B of the
thick
plate blank 11, but if the difference is significant, a coating film is hard
to be
formed on the surface of the edge portion 12D when an electrodeposition
coating which is described later is performed, which results in a formation of
rust from the edge portion 12D. Therefore, a pressure volume which is
applied to the blanks 11 and 12 by the electrode rollers 13A and 13B in the
mash-seam welding and other conditions are set up so as to prevent the edge
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portion 12D from having the significant difference in level.
Subsequently, the thick plate blank 11 and the thin plate blank 12 are
sent to a press process to undergo a transfer pressing. The thick plate blank
11 and the thin plate blank 12 are subjected to various processings such as a
5 drawing, a piercing and a trimming in due order, whereby the blanks 11 and
12 are processed to predetermined shapes, and a dashboard lower panel 16 is
manufactured as shown in FIG. 6. FIG. 6 is a perspective view of the
dashboard lower panel 16 seen from the inside of the car room.
As one operation of the transfer pressing for manufacturing the
10 dashboard lower panel 16, a bending of the thin plate blank 12 is performed
as shown in FIG. 7. The bending is performed by using an upper die 17 and
a lower die 18, in which an upper surface 18A of the lower die 18 is an even
surface, whereas a protrusion 19 which protrudes downwardly is provided at a
lower surface 17A of the upper die 17 in a position which is slightly
displaced
15 from the mash-seam welding portion 15 to the thin plate blank 12 side.
Therefore, the thin plate blank 12 is subjected to the bending by the
protrusion
19.
As a result, as shown in FIG. 8, an inner surface 11C of the thick plate
blank 11 and the inner surface 12C of the thin plate blank 12 are made flush
or almost flush with each other. At a position of the thick plate blank 11 as
shown in FIG. 8, since the inner surface 11C of the thick plate blank 11 is a
flat surface, the thin plate blank 12 is subjected to the bending to a
position
which corresponds or almost corresponds to an extension of a straight line
from the inner surface 11C, and the inner surface 12C of the thin plate blank
12 is also made to be a flat surface. Meanwhile, at a position where the
inner surface 11C of the thick plate blank 11 is a curved surface, the thin
plate
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blank 12 is subjected to the bending to a position which corresponds or almost
corresponds to an extension of a curved line from the inner surface 11C of the
thick plate blank 11, and the inner surface 12C of the thin plate blank 12 is
made to be a curved surface which has continuity with the inner surface 11C
of the thick plate blank 11, except for the mash-seam welding portion 15.
Incidentally, a bulge portion 15A of the mash-seam welding portion
15, which expands from the inner surface 11C may be extinguished by
applying pressure thereto, when the pressing is performed by the upper die 17
and the lower die 18.
Thus, after the dashboard lower panel 16 in which the inner surface
11C of the thick plate blank 11 and the inner surface 12C of the thin plate
blank 12 are made flush or almost flush with each other is manufactured, a
front side frame 20 as a connection part connected over the mash-seam
welding portion 15 is joined to an outer surface 16A of the dashboard lower
panel 16 which comprises the outer surface 11B of the thick plate blank 11
and the outer surface 12B of the thin plate blank 12 by a spot welding, as in
FIG. 9 showing the dashboard lower panel 16 seen from the engine room side.
Moreover, an insulator panel 21 for sound insulation as a connection part
connected over the mash-seam welding portion 15 is joined to an inner
surface 16B of the dashboard lower panel 16 which comprises the inner
surface 11C of the thick plate blank 11 and the inner surface 12C of the thin
plate blank 12, which are made flush or almost flush with each other by the
spot welding, as shown in FIG. 10.
As shown in FIG. 11, a portion 20A in the front side frame 20, which
corresponds to the mash-seam welding portion 15 is spaced from the mash-
seam welding portion 15 since it is curved slightly in an outward direction
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from the dashboard lower panel 16. Further, a portion 21A in the insulator
panel 21, which corresponds to the mash-seam welding portion 15, is also
spaced from the mash=seam welding portion 15 since it is curved slightly in
an outward direction from the dashboard lower panel 16.
As described above, the front side frame 20 and the insulator panel 21
are attached to the dashboard lower panel 16, further, the dashboard lower
panel, the dashboard upper panel, the front lower panel, the front pillar
inner
lower panel and so on which comprise the car body are joined together to
complete the car body, and thereafter, the car body is immersed into a tank of
an electrodeposition coating device to be subjected to the electrodeposition
coating. In this electrodeposition coating, even if the mash-seam welding
portion 15 of the dashboard lower panel 16 is partially covered with the front
side frame 20 and the insulator panel 21, an electrodeposition coating
solution
certainly enters and adheres to the mash-seam welding portion 15 because the
portion 20A in the front side frame 20 which corresponds to the mash-seam
welding portion 15 and the portion 21A in the insulator panel 21 which
corresponds to the mash-seam welding portion 15 do not contact closely with
the mash-seam welding portion 15 and are spaced from the welding portion
15. Thereby, a coating film 22 is securely formed on the surface of the
mash-seam welding portion 15 by the electrodeposition coating. Further, the
outer surface 16A which is not covered with the front side frame 20 and the
inner surface 16B which is not covered with the insulator panel 21 in the
dashboard lower panel 16 are coated with the coating film 22.
According to the above embodiment, the dashboard lower panel 16 as
a partition article for partitioning the inside and the outside of the
automobile,
that is, the car room and the engine room, is manufactured by joining the end
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portions 11A and 12A of the thick plate blank 11 and the thin plate blank 12
together by the mash-seam welding, and then pressing the thick plate blank 11
and the thin plate blank 12, which makes it unnecessary to prepare a press die
each for the thick plate blank 11 and the thin plate blank 12, in contrast to
the
case where the dashboard lower panel is manufactured by joining the thick
plate blank and the thin plate blank by the spot welding after the pressing.
Therefore, the number of the dies can be reduced and the cost for the dies can
be reduced. Further, the blanks are joined together without leaving any
space therebetween by the mash-seam welding, which makes it unnecessary
to perform an extra waterproofing onto the manufactured dashboard lower
panel 16 as a post-processing in order to prevent the formation of rust, and
hence the number of working process can be reduced and the productivity can
be increased.
Moreover, the mash-seam welding has higher joining strength than
that of the spot welding so that the thick plate blank 11 and the thin plate
blank 12 can be joined together with higher strength. Further, an overlap
margin of the end portions 11A and 12A of the thick plate blank 11 and the
thin plate blank 12 can be reduced in the mash-seam welding than in the spot
welding so that the weight of the dashboard lower panel 16 can be decreased
by the same weight thereof and material yield can be improved.
Furthermore, the outer.surface 16A and the inner surface 16B of the
dashboard lower panel 16 according to this embodiment, for forming an
engine room and for forming a space inside the car room, respectively, are
coated with the coating film 22 by the electrodeposition coating, which makes
it possible to increase durability of the outer surface 16A and the inner
surface
16B. Especially, since the outer surface 16A is covered with the coating
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film 22, durability of the outer surface 16A to water and rust can be
increased
even if the outer surface 16A which is exposed to the outside air is exposed
to
the waterdrop such as the rainwater.
Moreover, in this embodiment, the thin plate blank 12 is subjected to
the bending in the pressing of the joined thick plate blank 11 and the thin
plate
blank 12 so that the inner surface 12C of the thin plate blank 12 and the
inner
surface 11C of the thick plate blank 11 are made flush or almost flush with
each other, whereby the insulator panel 21 for sound insulation, which is
connected over the mash-seam welding portion 15 can be attached to the inner
surface 16B of the dashboard lower panel 16 comprising the inner surface
11C and the inner surface 12C in a predetermined manner. Further, a
plurality of parts which are attached separately to the inner surface 11C of
the
thick plate blank 11 and the inner surface 12C of the thin plate blank 12 can
be attached with respect to either inner surface because the inner surfaces
11C
and 12C are made flush or almost flush with each other.
Furthermore, when the front side frame 20 is connected to the outer
surface 16A of the dashboard lower panel 16 and the insulator panel 21 is
connected to the inner surface 16B thereof, each of which is connected over
the mash-seam welding portion 15, the coating film 22 can be securely
formed on the surface of the mash-seam welding portion 15 by the
electrodeposition coating and the formation of rust can be prevented, because
the portions 20A and 21A which correspond to the mash-seam welding
portion 15 are spaced from the mash-seam welding portion 15.
Moreover, according to this embodiment, a material of the lower side
of the dashboard lower panel 16 is the thick plate blank 11 so that the
portion
of the thick plate blank 11 can bear a load from the front side frame 20
CA 02595215 2007-08-03
effectively in a collision of the automobiles. Further, a material of the
upper
side of the dashboard lower panel 16 is the thin plate blank 12 so that the
entire weight of the dashboard lower panel 16 can be decreased.
Furthermore, according to this embodiment, the bending as in FIG. 7
5 is performed onto the thin plate blank 12 by making the inner surface 12C of
the thin plate blank 12, which is the surface inside the car room, flush or
almost flush with the inner surface 11C of the thick plate blank 11 so that a
concave portion 23 which arises between the thick plate blank 11 and the thin
plate blank 12 as shown in FIG. 11 is formed in the inner surface 16B of the
10 dashboard lower panel 16, which is inside the car room, not in the outer
surface 16A of the dashboard lower panel 16, which is the engine room side
to be exposed to the air. Thereby, in contrast to the case where the concave
portion 23 is formed in the outer surface 16A of the dashboard lower panel 16,
the problem of the formation of rust from the dashboard lower panel 16 over a
15 long period of time since the waterdrop is collected in the concave portion
23
of the outer surface 16A which is exposed to the outside can be solved.
FIG. 12 is a modified example concerning a shape of a portion in the
front side frame 20, which corresponds to the mash-seam welding portion 15.
In this modified example, a portion 20B has a shape which is sharply spaced
20 from the dashboard lower panel 16, different from the portion 20A in FIG.
11,
having a shape which is gradually spaced from the dashboard lower panel 16.
The shape of the portion in the front side frame 20, which corresponds
to the mash-seam welding portion 15 may be the one in FIG. 11 or the one in
FIG. 12, which can be freely chosen by considering the easiness of its
molding process and the connection strength to the dashboard lower panel 16.
Further, the connection part which is connected to the dashboard
CA 02595215 2007-08-03
21
lower panel 16 over the mash-seam welding portion 15 is not limited to the
front side frame 20 or the insulator panel 21, but may be any parts. As an
example thereof, in FIG. 13, a reinforcing panel 24 is attached to the inner
surface 16B of the dashboard lower panel 16 by the spot welding. A portion
24A in this panel 24, which corresponds to the mash-seam welding portion 15
is also spaced from the mash-seam welding portion 15 so that the
electrodeposition coating solution enters therebetween.
Next, the embodiment in which a dashboard lower panel is
manufactured by using a laser welding will be explained with reference to
FIG. 14 to FIG. 21.
As shown in FIG. 14, both blanks 31 and 32 are clamped while outer
surfaces 31B and 32B of a thick plate blank 31 and a thin plate blank 32 are
made flush or almost flush with each other and respective end portions 31A
and 32A are matched. The end portions 31A and 32A are welded and joined
by a laser light 33C from a laser welding device 33 which has a generator
33A and a condenser lens 33B.
FIG. 15 shows the thick plate blank 31 and the thin plate blank 32
after the laser welding, in which a joining portion of the end portions 31A
and
32A is a laser welding portion 35 and the outer surface 31B of the thick plate
blank 31 and the outer surface 32B of the thin plate blank 32 are made
uninterrupted or almost uninterrupted.
Subsequent working process is the same with that of the aforesaid
mash-seam welding. Namely, the thick plate blank 31 and the thin plate
blank 32 undergo a transfer pressing to manufacture a dashboard lower panel
36 of the blanks 31 and 32, and a bending of the thin plate blank 32 is
performed by an upper die 17 and a lower die 18 in the transfer pressing as
CA 02595215 2007-08-03
22
shown in FIG. 16. Thereby, as shown in FIG. 17, an inner surface 32C of
the thin plate blank 32 and an inner surface 31C of he thick plate blank 31
are
made flush or almost flush with each other. Next, as shown in FIG. 18, a
front side frame 20 is attached to an outer surface 36A of the dashboard lower
panel 36 and an insulator panel 21 for sound insulation is attached to an
inner
surface 36B thereof, respectively by the spot welding. Portions 20A and
21A in the front side frame 20 and the insulator panel 21, each of which
corresponds to the laser welding portion 35, are spaced from the welding
portion 35.
Thereafter, a car body which comprises the dashboard lower panel 36
attached with the front side frame 20 and the like, a dashboard upper panel, a
front lower panel, a front pillar inner lower panel and so on is subjected to
an
electrodeposition coating and the outer surface 36A and the inner surface 36B
of the dashboard lower panel 36, including the laser welding portion 35, are
coated with a coating film 22.
In the laser welding like this, the same effects as those in the aforesaid
mash-seam welding can be obtained, in comparison with the spot welding.
Among these effects, such an effect is included as the formation of rust from
the outer surface 36A which is exposed to the outside can be prevented over a
long period of time because a concave portion 43 between the thick plate
blank 31 and the thin plate blank 32, as shown in FIG. 18, is formed in the
inner surface 36B of the dashboard lower panel 36, which is the inside of the
car room, not in the outer surface 36A which is the engine room side.
Moreover, in the laser welding, it is not necessary to overlap the end
portions 31A and 32A of the thick plate blank 31 and the thin plate blank 32
together so that the weight of the dashboard lower panel can be further
CA 02595215 2007-08-03
23
decreased by the same weight thereof and material yield can be further
improved.
In the laser welding, as shown in FIG. 19, a portion 20B in the front
side frame 20, which corresponds to the laser welding portion 35 may also
have a shape which is sharply spaced from the dashboard lower panel 36.
Further, the connection part which is connected to the dashboard
lower panel 36 over the laser welding portion 35 may be a reinforcing panel
similarly to FIG. 13.
Furthermore, as shown in FIG. 20, when the thick plate blank 31 and
the thin plate blank 32 are joined with the respective end portions 31A and
32A being matched, the outer surfaces 31B and 32B of these blanks 31 and 32,
which are made flush or almost flush with each other, may downwardly face
the opposite side from the laser device 33. Thereby, the thick plate blank 31
and the thin plate blank 32 can be clamped by a clamping device while the
outer surfaces 31B and 32B are placed on the flat working table. An upper
part 35A of thus-welded laser welding portion 35 is dripped as shown in FIG.
21.
Industrial Availability
As described above, the tailored blank article and the manufacturing
method thereof according to the present invention are effectively applied to
the case in manufacturing the article for partitioning the inside and the
outside,
such as the dashboard panel for partitioning the engine room and the inside of
the car room of the car body, with the tailored blank.
