JP2005319843A - Foaming filling member - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a foaming filling member allowing for filling foaming material without any clearance in the entire space of a structure including a dead space. <P>SOLUTION: A flexible part 5 which is deflected in an advancing/retracting direction to/from a one-side short surface 10 is formed on the one-side short surface 10 of a supporting plate 4. In this foaming filling member 1, the flexible part 5 is inserted in a dead space 39 and arranged by deflecting and inserting the flexible part 5 corresponding to the dead space 39 expanding outwardly in the width direction of an opening having the opening width W of an opening 38 in an advancing manner to the one-side short surface 10 when the flexible part is inserted in the internal space 35 via the opening 38 on an outer panel 37 side. By foaming the foaming base material 3, the foaming material 43 can be filled without any clearance in the entire space 35 including the dead space 39. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a foam filling member for filling a space of a structure by foaming.

  2. Description of the Related Art Conventionally, a foam filling member for filling a hollow structure such as an automobile pillar with a foam material is known.

  Such a foam filling member includes, for example, a foamable base material made of a material that foams by external heating, and a support member having a support plate that supports one side of the foamable base material. A foam filling device is proposed which is formed in a substantially annular shape with a size corresponding to the support plate, and an annular crest wall protruding from one side surface of the support plate to support the inner peripheral surface of the foamable substrate. (For example, refer to Patent Document 1).

  In this foam filler, when placed in a hollow chamber such as a pillar and heated from the outside, foaming of the foamable base material is suppressed in the longitudinal direction of the hollow chamber by the support plate, and the hollow is substantially perpendicular to the longitudinal direction. The foam is promoted in the direction toward the inner peripheral wall surface of the chamber. Moreover, it can prevent that a foamable base material foams toward the center part of the opening hole by the cyclic | annular crest wall of a support plate. Therefore, the hollow chamber is efficiently and satisfactorily blocked by the foam based on the heat foaming of the extremely small amount of the foamable substrate.

  However, in such a foam filling member, the width in the direction substantially perpendicular to the insertion direction into the internal space of the hollow structure is regulated to the width in the same direction of the opening that receives the foam filling member in the hollow structure, It is substantially limited to this width or less.

  For this reason, even if there is a region (hereinafter referred to as “dead space”) that extends outward in the width direction rather than the width of the opening in the space inside the opening of the hollow structure, it is described in Patent Document 1. In the foam filling member, the dead space cannot be filled with the foam material without a gap.

  Therefore, in order to fill the foam with a portion where the gap with the foamable base material is maximized, such as the corner of the inner peripheral wall surface of the hollow structure, the foam is placed on the support plate in the direction of the portion where the gap is maximized. A hollow chamber breaker provided with a guiding foam guide has been proposed (see, for example, Patent Document 2).

  In this hollow chamber breaker, when placed in the hollow chamber of the hollow structure and heated from the outside, the foam guide concentrates foaming of the foamable base material on the portion where the gap between the foamable base material is maximum. be able to. Therefore, by using this foam guide, foaming of the foamable base material can be guided to fill the dead space with no gap.

In addition, for example, it is also known that the foam material is filled in the dead space without any gap by partially increasing the amount of the foam base material and increasing the foam amount at the location corresponding to the dead space of the foam filling member. It has been.
JP 2003-146243 A Japanese Patent Laid-Open No. 2001-114037

  However, in the foam filling member described above, the width in the direction substantially perpendicular to the insertion direction of the hollow structure into the internal space is limited to be equal to or less than the width of the opening in the hollow structure that receives the foam filling member. Therefore, the support plate cannot be inserted into the dead space. For this reason, even if a foam guide is provided or the amount of the foam base is increased, foaming of the foam base cannot be suppressed in the dead space in the longitudinal direction of the hollow chamber. As a result, the foamed base material that has become fluidized may hang down downward in the longitudinal direction of the hollow chamber. As a result, there is a problem in that the foam material cannot be filled in the dead space without a gap.

  The objective of this invention is providing the foam filling member which can be filled with the foaming material without the clearance gap to the whole space of the structure containing a dead space.

  In order to achieve the above object, the present invention is a foam filling member for filling a space of a structure by foaming, and includes a holder member made of a non-foam material and a foam base material made of a foam material. The holder member supports the foam base material, supports the foam base material, is provided on the outer peripheral edge of the support plate, and bends in a direction approaching and separating from the outer peripheral edge of the support plate. And a flexible part.

  In this foam filling member, when inserted into the space of the structure through the opening of the structure, the flexible portion of the holder member is bent in a direction close to the outer peripheral edge of the support plate, After the insertion, if the flexible part is bent in a direction away from the outer peripheral edge of the support plate, the flexible part can be inserted and disposed in the dead space. Therefore, particularly in a hollow structure or the like, the foaming base material is directed from the dead space in the longitudinal direction, or the foamed base material in a fluid state is drooping downward from the dead space in the longitudinal direction. It can prevent by the flexible part arrange | positioned in. As a result, the entire space of the structure including the dead space can be filled with the foam material without a gap.

  Further, in this foam filling member, the flexible portion may be disposed in a direction in which the foam filling member is inserted into the structure space when the foam filling member is disposed in the structure space. It is preferable to be provided so as to bend in the crossing direction.

  When the flexible part is provided in this way, when the foam filling member is inserted into the space of the structure through the opening of the structure, the flexible part is brought into contact with the edge of the opening. Thus, it is possible to bend in the crossing direction with respect to the insertion direction. Therefore, it is possible to facilitate the insertion work.

  Further, in this foam filling member, the flexible portion is connected to a connecting portion that is continuous to the outer peripheral edge of the support plate, and is connected to the connecting portion and spaced from the outer peripheral edge of the support plate by a predetermined interval. It is preferable to include a flexure portion that is disposed to face the other.

  When the flexible portion includes the connecting portion and the bending portion, the connecting portion is deformed when the flexible portion is bent in a direction approaching and separating from the outer peripheral edge of the support plate. Therefore, if the flexible part is formed in a flat plate shape having a planar shape corresponding to the cross-sectional shape of the dead space, and the foamed base material having the same planar shape is supported by the flexible part, by foaming, the dead space, The foam material can be filled without gaps.

  In the foam filling member, it is preferable that the foam base is formed in a sheet shape.

  If the foamed base material is a sheet, the foamed base material can be produced by continuous molding at high production efficiency and at low cost.

  In the foam filling member, it is preferable that the flexible portion includes a fixing portion for fixing the foam base material supported by the flexible portion.

  If the fixing portion is provided, even if the flexible portion is bent in the direction approaching or separating from the outer peripheral edge of the support plate, the foamed base material supported by the flexible portion follows the bending. Can be bent. Therefore, it is possible to insert the foam base material together with the flexible portion into the dead space and arrange it. As a result, the foaming material can be filled in the dead space without any gaps due to foaming of the foamed base material.

  In the foam filling member of the present invention, when inserted into the space of the structure, the flexible portion is bent in a direction approaching the outer peripheral edge of the support plate, and after passing through the opening of the structure, If the flexible portion is bent in a direction away from the outer peripheral edge of the support plate, the flexible portion can be inserted and disposed in the dead space of the structure. As a result, the entire space of the structure including the dead space can be filled with the foam material without a gap.

  FIG. 1 is an exploded perspective view showing an embodiment of the foam filling member of the present invention, and FIG. 2 is a plan view of the foam filling member shown in FIG.

  In FIG. 1, this foam filling member 1 is used for filling a foam material into an internal space of a hollow structure such as a pillar of an automobile, and a holder member 2 made of a non-foam material and a foam base material made of a foam material. 3 is provided.

  The material forming the holder member 2 supports the foam base material 3 at the time of heating and foaming described below (for example, around 120 to 210 ° C.), and the foam base material 3 hangs down due to its own weight or hangs down. Although it will not be restrict | limited especially if it can prevent, For example, metals, such as iron, stainless steel, aluminum, etc., such as resin, such as nylon and polyester, are used.

  The holder member 2 integrally includes a support plate 4, a flexible portion 5, an auxiliary protruding portion 6, an annular wall 7, an engaging portion 8, and a mounting portion 9.

  The support plate 4 and the auxiliary protrusion 6 are slightly smaller than the shape (see FIGS. 6 and 7) of the inner space 35 of the pillar 34, which will be described later, excluding the dead space 39 in the outer panel 37. The supporting plate 4 is formed in a rectangular flat plate shape that supports the foam base material 3, for example.

  Further, the auxiliary protruding portion 6 is formed on one side from one corner portion of the short side surface 10 on the one side in the opening width direction along the opening width W of the outer panel 37 described later, on the outer peripheral edge of the support plate 4 having a rectangular flat plate shape. It protrudes outward in a direction (opening width direction) substantially orthogonal to the short side face 10. The auxiliary protruding portion 6 has a rectangular flat plate shape, and its free end portion side is formed in a spire shape. In addition, on the one side surface of the auxiliary protruding portion 6, a flat plate-like fixing portion 14 for fixing an auxiliary protruding piece 26, which will be described later, of the foam base material 3 extends in the substantially central portion. It is erected in the direction orthogonal to

  The flexible portion 5 has a slightly smaller similar shape to the shape of the dead space 39, and on the one side short side surface 10 of the support plate 4, the connecting portion 11 that is continuous with the other corner, and the connecting portion 11 is continuous. The bending part 12 to be provided is integrally provided.

  The bending portion 12 has a substantially fan-shaped flat plate shape that is narrow on the connecting portion 11 side and wide on the free end portion side, and is inclined so that the free end portion side faces the auxiliary protruding portion 6 from the other corner of the short side surface 10 on one side. Is formed to protrude. The bending portion 12 is disposed so as to face the short side surface 10 on one side, with a substantially fan-shaped gap 15 narrow on the connecting portion 11 side and wide on the free end side. Further, the auxiliary protrusion 6 and the free end thereof are arranged to face each other with a predetermined interval.

  In addition, a flat plate-like fixing portion 13 for fixing a later-described bending piece 25 of the foam base 3 is orthogonal to the direction in which the one-side surface extends on the one-side surface of the bending portion 12 at a substantially central portion. Standing in the direction.

  Moreover, the connection part 11 is provided so that the one side short side surface 10 and the bending part 12 may be connected. The connecting portion 11 is formed in a narrow shape capable of elastic deformation so that the bending portion 12 can be bent.

  When an external force is applied from the side surface opposite to the side surface facing the one side short side surface 10 toward the one side short side surface 10, the flexible portion 5 is bent due to the elastic deformation of the narrow coupling portion 11. The portion 12 is bent from the position shown in FIG. 7 in the direction approaching the short side surface 10 on the one side of the support plate 4 with the connecting portion 11 as a fulcrum, as indicated by the solid arrow in FIG. And move to the position shown in FIG. Further, when the applied external force is removed, due to the elasticity of the connecting portion 11, the bending portion 12 moves from the position shown in FIG. 6 to the one side short side surface 10 of the support plate 4 with the connecting portion 11 as a fulcrum. Returning to the position shown in FIG. 7 by bending in the separating direction.

  Moreover, the support plate 4, the flexible part 5 (the connection part 11, the bending part 12), and the auxiliary | assistant protrusion part 6 are formed in the flat form where the both-sides surface continues, The thickness is 0.8, for example It is -3.0mm, Preferably, it is 1.0-2.0mm. Further, the holder member 2 is wider in the opening width direction in a state where the flexible portion 5 is separated from the one side short side surface 10 of the support plate 4 with respect to an opening 38 on the outer panel 37 side described later. In the state where they are close to each other, they are formed so as to have substantially the same width.

  The annular wall 7 has a substantially rectangular annular shape that is substantially similar to the outer shape of the support plate 4, and is erected on the one side surface of the support plate 4 in a direction orthogonal to the direction in which the one side surface extends. The annular wall 7 is circumferentially provided on one surface of the support plate 4 with a certain width in which an outer peripheral edge of the support plate 4 and an annular foamed portion 24 described later of the foam base material 3 are disposed. . The height A of the annular wall 7 (that is, the length from the one side surface of the support plate 4 to the free end portion of the annular wall 7) A is larger than the thickness D of the foam base 3 as shown in FIG. For example, it is set to 2.0 to 10.0 mm, preferably 3.0 to 7.0 mm. By forming the annular wall 7, a predetermined inner space surrounded by the annular wall 7 in the support plate 4 is used as an inner closed portion 16, and the outside of the annular wall 7, that is, the outer peripheral edge of the support plate 4 and the annular wall 7. The outer peripheral part between the two is the outer support part 17.

  The engaging portion 8 includes an opening 18 and a claw portion 19 and is provided on the annular wall 7.

  As shown in FIG. 1, a plurality (two) of openings 18 are formed facing each other at a predetermined interval in the circumferential direction in which the annular wall 7 extends. Each opening 18 is formed by partially opening in a slit shape along the circumferential direction of the annular wall 7. As a result, the opening 18 is formed in a substantially rectangular shape between the annular walls 7 in a side view, as shown in FIG. 3, so that the inner blocking portion 16 and the outer support portion 17 communicate with each other. . In addition, the opening width B along the circumferential direction of the annular wall 7 in each opening 18 is, for example, 3.0 to 30.0 mm, preferably 5.0 to 15.0 mm.

  The claw portions 19 are formed as a pair in each opening 18. In other words, the claw portions 19 are formed so as to protrude from the upper side end portions of the respective annular walls 7 facing each other across the opening 18 so as to be close to each other in the inner direction of the opening 18 along the circumferential direction of the annular wall 7. Has been. The pair of claws 19 have a triangular trapezoidal shape in which the upper end edge is inclined downward inward and the lower end edge is substantially parallel to the support plate 4, and the circumferential direction of the annular wall 7 Are opposed to each other at a predetermined interval. In addition, each claw portion 19 is set so that the distance between the lower edge of the claw portion 19 and the one surface of the support plate 4 is substantially the same as the thickness of the foam base material 3. Moreover, each nail | claw part 19 is formed so that elastic deformation is possible, and the protrusion length C from the annular wall 7 of the lower end edge is 0.1-5.0 mm, for example, Preferably, it is 0.5-1.5 mm It is.

  As shown in FIG. 5, the mounting portion 9 has a substantially T shape in plan view, and is formed to protrude outward from the outer peripheral edge of the support plate 4 along the direction in which the support plate 4 extends. The mounting portion 9 is integrally provided with a base 20, an inner locking portion 21 and an outer locking portion 22 provided on the base 20, and an embedded portion 23 in which the foamed base material 3 is embedded.

  The base portion 20 is formed from the end of one side long side surface 44 (see FIG. 1) that is substantially orthogonal across the corner portion of the outer peripheral edge of the support plate 4 on the side where the auxiliary protruding portion 6 of the one side short side surface 10 is provided. , And projecting in a direction substantially perpendicular to the one side long side surface 44.

  The inner locking portion 21 is made of a flexible piece, and is outward in the protruding direction of the base portion 20 from the base end portion of the base portion 20 outward in the width direction of the base portion 20 (the direction along the one side long side surface 44). The projection is formed so as to be inclined. The outer locking portion 22 is formed to protrude outward from the free end portion of the base portion 20 in the protruding direction of the base portion 20. The outer locking portion 22 is formed of a flexible arcuate piece that can be elastically deformed along the width direction of the base portion 20.

  The embedded portion 23 is formed in a groove shape along the direction orthogonal to the protruding direction of the base portion 20 at the base end portion of the base portion 20.

  For example, when the holder member 2 is formed from the above-described resin, the support plate 4, the flexible portion 5, the auxiliary protruding portion 6, the annular wall 7, the engaging portion 8, It can be obtained by integrally molding the mounting part 9, the fixing part 13 and the fixing part 14.

  The foam base material 3 is formed of a foam material that foams by heating (for example, around 120 to 210 ° C.).

  The foam material is not particularly limited, and a known foamable polymer is used. Although it does not restrict | limit especially as a foamable polymer, For example, resin, such as styrene-butadiene rubber (SBR), such as ethylene-vinyl acetate copolymer, polyethylene, polypropylene, polyester, polyvinyl butyral, polyvinyl chloride, polyamide, polyketone ) And rubber such as polybutadiene rubber (BR). Preferably, an ethylene / vinyl acetate copolymer is used. By using an ethylene / vinyl acetate copolymer, the expansion ratio can be increased. These foamable polymers can be used by appropriately selecting one kind or two or more kinds.

  In addition, in order to foam and cure the foamable polymer, for example, a crosslinking agent, a foaming agent, and a foaming aid as necessary are blended in the foamed material as appropriate.

  Although it does not restrict | limit especially as a crosslinking agent, For example, the well-known radical generator which decomposes | disassembles by heating and generate | occur | produces a free radical and forms a crosslinking bond between molecules or in a molecule | numerator is used. More specifically, for example, dicumyl peroxide, 1,1-ditertiarybutylperoxy-3,3,5-trimethylcyclohexane, 2,5-dimethyl-2,5-ditertiarybutylperoxyhexane, 2 , 5-Dimethyl-2,5-ditertiarybutylperoxyhexyne, 1,3-bis (tert-butylperoxyisopropyl) benzene, tertiarybutylperoxyketone, tertiarybutylperoxybenzoate A peroxide etc. are mentioned.

  When the foamable polymer can be vulcanized, a known vulcanizing agent can be used as a crosslinking agent. Such a vulcanizing agent is not particularly limited. For example, sulfur, sulfur compounds, selenium, magnesium oxide, lead monoxide, zinc oxide, polyamines, oximes, nitroso compounds, resins, ammonium salts, etc. Is mentioned.

  These crosslinking agents can be used by appropriately selecting one kind or two or more kinds. The blending ratio of the crosslinking agent is not particularly limited, but is, for example, 0.1 to 10 parts by weight, preferably 0.5 to 7 parts by weight with respect to the foamable polymer.

  When a vulcanizing agent is used, a vulcanization accelerator can be used in combination. Examples of the vulcanization accelerator include known vulcanization accelerators such as dithiocarbamic acids, thiazoles, guanidines, sulfenamides, thiurams, xanthogenic acids, aldehyde ammonias, aldehyde amines, and thioureas. . Such a vulcanization accelerator can be used by appropriately selecting one or more kinds, and the blending ratio thereof is 0.1 to 5 parts by weight with respect to the foamable polymer.

  In contrast to the vulcanization accelerator, for the purpose of adjusting moldability, for example, a known vulcanization retarder such as an organic acid or an amine can be appropriately blended.

  The foaming agent is not particularly limited, and for example, a known inorganic foaming agent or organic foaming agent is used. Examples of the inorganic foaming agent include ammonium carbonate, ammonium hydrogen carbonate, sodium hydrogen carbonate, ammonium nitrite, sodium borohydride, azides and the like.

  Examples of the organic foaming agent include azo compounds such as azodicarbonamide, barium azodicarboxylate, azobisisobutyronitrile, azodicarboxylic acid amide, such as N, N′-dinitrosopentamethylenetetramine. , N, N′-dimethyl-N, N′-dinitrosotephthalamide, trinitrotrimethyltriamine, and other nitroso compounds such as 4,4′-oxybis (benzenesulfonylhydrazide), paratoluenesulfonylhydrazide, diphenylsulfone- Hydrazide compounds such as 3,3′-disulfonylhydrazide and allylbis (sulfonylhydrazide), for example, semicarbazide compounds such as p-toluylenesulfonyl semicarbazide and 4,4′-oxybis (benzenesulfonyl semicarbazide) , For example, trichloromonofluoromethane, fluoride alkanes such dichloro monofluoromethane, for example, triazole compounds such as 5-morpholyl-1,2,3,4-thiatriazole and the like.

  Among these foaming agents, those that decompose and generate a gas at a temperature higher than the softening temperature of the foamable polymer and that hardly foam when the foaming material 43 described later is formed are appropriately selected depending on the composition. The Preferably, those that foam at around 120 to 210 ° C. are used.

  These foaming agents can be used by appropriately selecting one kind or two or more kinds. The blending ratio of the foaming agent is not particularly limited, but is, for example, 5 to 50 parts by weight, preferably 10 to 30 parts by weight with respect to 100 parts by weight of the foamable polymer.

  In addition, the blending amount of the foaming agent is a range in which the foaming ratio of the foaming base material 3 is about 5 to 25 times, preferably about 10 to 20 times, and substantially closed cells are generated. Is preferred. If the blending amount of the foaming agent is too small, the foam base material 3 will not foam sufficiently. On the other hand, if the blending amount of the foaming agent is too large, voids will be generated due to the dripping of the foamed material obtained by foaming. Sexuality falls.

  Although it does not restrict | limit especially as a foaming adjuvant, For example, according to the kind of foaming agent, a well-known foaming adjuvant can be selected suitably, For example, the urea type compound which has urea as a main component, for example Examples thereof include metal oxides such as zinc oxide and lead oxide, higher fatty acids such as salicylic acid and stearic acid, and metal salts thereof. Preferably, higher fatty acid metal salts are used.

  These foaming auxiliaries can be used by appropriately selecting one kind or two or more kinds. The blending ratio of the foaming aid is not particularly limited, but is, for example, 1 to 20 parts by weight, preferably 5 to 10 parts by weight with respect to 100 parts by weight of the foamable polymer.

  Furthermore, the foamed material may be, for example, a stabilizer, a reinforcing material, a filler, a softener, or, if necessary, for example, within a range that does not affect the physical properties of the obtained foamed material depending on its purpose and application. Well-known additives such as plasticizers, antioxidants, antioxidants, pigments, colorants, fungicides, and flame retardants can be appropriately blended.

  As shown in FIG. 1, the foam base 3 is integrally formed with an annular foam part 24, a flexure piece 25, an auxiliary protruding piece 26, and an engaged part 27, and is formed in a sheet shape. In addition, thickness D (refer FIG. 3) of this foaming base material 3 is 0.5-6.0 mm, for example, Preferably, it is 1.5-3.5 mm.

  By forming the foam base material 3 into a sheet shape, the foam base material 3 can be produced efficiently and at low cost by continuous molding.

  The annular foaming portion 24 has a substantially rectangular annular shape corresponding to the outer support portion 17 of the support plate 4 and is formed in a flat plate shape.

  The bending piece 25 has a substantially fan shape corresponding to the bending portion 12 of the flexible portion 5, and is connected to the annular foaming portion 24 via a connecting piece 28 corresponding to the connecting portion 11 of the flexible portion 5. Further, the bending piece 25 has a substantially rectangular shape slightly smaller than the cross-sectional shape of the fixing portion 13 of the bending portion 12 in the direction in which the one side surface of the support plate 4 extends, and the fixing portion 13 is press-fitted into the bending piece. A press-fit hole 29 for fixing 25 to the bending portion 12 is formed.

  The auxiliary protruding piece 26 has a substantially rectangular shape corresponding to the auxiliary protruding portion 6 and has a free end portion in the shape of a spire, and is formed in a flat plate shape. The auxiliary protruding piece 26 has a substantially rectangular shape slightly smaller than the cross-sectional shape of the fixing portion 14 of the auxiliary protruding portion 6 in the direction in which the one surface of the support plate 4 extends, and the fixing portion 14 is press-fitted into the auxiliary protruding portion 26. A press-fit hole 30 for fixing the piece 26 to the auxiliary protrusion 6 is formed.

  As shown in FIG. 4, the engaged portion 27 is formed in a substantially T shape in plan view, which integrally includes a protruding portion 31 and a bulging portion 32.

  A plurality (two) of protrusions 31 are provided corresponding to the openings 18 of the annular wall 7 in a state where the foam base 3 is supported by the holder member 2. Each protrusion 31 has a substantially rectangular shape slightly narrower than the opening width B of the opening 18, and is formed to protrude from the annular foaming portion 24 in an inner direction substantially orthogonal to the circumferential direction of the annular foaming portion 24. ing.

  The bulging portion 32 is formed to bulge toward both sides in the circumferential direction of the annular foaming portion 24 at the free end portion of the protruding portion 31. The bulging portion 32 is provided so as to face the annular foaming portion 24 across the thickness of the annular wall 7.

  Further, as shown in FIG. 1, the annular foaming portion 24 of the foam base 3 is annularly foamed in the embedded portion 23 at a position corresponding to the base portion 20 disposed on the opposite side to the protruding direction with respect to the embedded portion 23. A cut 33 for embedding the portion 24 is formed along the longitudinal direction of the embedded portion 23.

  For example, the foam base 3 is prepared by first blending each component in the above-described foamed material in the above-described blending ratio, and then kneading using, for example, a mixing roll or a pressure kneader, and then pressing or calendering. Continuously formed into a sheet using a roll or the like, or foamed material is continuously formed into a sheet using, for example, an extrusion molding machine, and then an annular foamed portion 24, a flexible piece 25, an auxiliary protruding piece 26, It can be obtained by punching so that the engaged portion 27, the connecting piece 28, the press-fit hole 29, the press-fit hole 30 and the notch 33 are formed.

  And the foaming base material 3 obtained in this way, as shown in FIGS. 1 and 2, the annular foaming portion 24 is supported by the outer support portion 17 on the outer periphery of the support plate 4, and at the same time, each protruding portion. 31 is fitted into each opening 18 while elastically deforming the pair of claws 19 from above each opening 18, and at the same time, the base 20 is inserted into the notch 33 and embedded in the embedded portion 23. The annular foamed portion 24 is fitted, and the fixing portion 13 is press-fitted into the press-fitted hole 29, and the fixed portion 14 is press-fitted into the press-fitted hole 30.

  As a result, each protrusion 31 of the foam base 3 extends from the annular foam portion 24 disposed outside the annular wall 7 to the inner closing portion 16 inside the annular wall 7 via each opening 18. And each of the openings 18 is sandwiched between the pair of claws 19 and the support plate 4. Thereby, the vertical movement of the protrusion 31 is restricted.

  Further, a bulging portion 32 formed at the free end portion of each projecting portion 31 is arranged along the circumferential direction of the annular wall 7, and each side end portion of the annular wall 7 (the opening 18 is arranged around the annular wall 7). Each side end portion of the annular wall 7 facing in the direction is sandwiched between the bulging portion 32 and the annular foaming portion 24. As a result, the extraction of the protrusion 31 from the opening 18 is restricted. By such engagement of the engaged portion 27 of the foam base material 3 with the engagement portion 8 of the holder member 2, the foam base material 3 is simply and reliably fixed to the holder member 2.

  In addition, since the free end portion and the bulging portion 32 disposed in the inner closing portion 16 of the annular wall 7 in the protruding portion 31 are expanded by foaming, more reliable engagement can be achieved during foaming.

  Further, the bending piece 25 of the foam base 3 is fixed to the bending portion 12 of the holder member 2 by press-fitting the fixing portion 13 into the press-fit hole 29. As a result, even if the bending portion 12 is bent in the direction approaching or separating from the short side surface 10 on one side, the bending piece 25 supported by the bending portion 12 can be bent following the bending. . Therefore, as will be described later, the bending piece 25 can be bent and deformed together with the bending portion 12 and inserted into the dead space 39 in the outer panel 37 to be arranged. And by bending the arrange | positioned bending piece 25, the bending piece 25 expand | swells and the dead space 39 can be filled with the foaming material 43 without a clearance gap.

  Further, the auxiliary protruding piece 26 of the foam base 3 is fixed to the auxiliary protruding portion 6 of the holder member 2 by press-fitting the fixing portion 14 into the press-fit hole 30.

  And if the foam filling member 1 obtained in this way is arrange | positioned in the space between structures, or the internal space of a hollow structure, and it heats to foaming temperature (for example, about 120-210 degreeC), it will be by foaming. The space can be filled without gaps. Therefore, the foam filling member 1 is not particularly limited, and fills the space of the structure for the purpose of vibration suppression, soundproofing, dustproofing, heat insulation, buffering, watertightness, and the like. It can be used as a foam filling member of various industrial products as a material, a dustproof material, a heat insulating material, a buffer material, a waterstop material, and the like.

  More specifically, by using the foam filling member 1 as a hollow structure, for example, if the interior space of an automobile pillar is filled by foaming, the foaming material formed by foaming causes engine vibration and noise, Alternatively, it is possible to effectively prevent wind noise and the like from being transmitted to the passenger compartment.

  Next, as an example of using the foam filling member 1, a method for filling the interior space of an automobile pillar will be described.

  In this method, first, as shown in FIGS. 6 and 7, the foam filling member 1 formed corresponding to the closed cross-sectional shape and size of the internal space 35 of the pillar 34 to be filled is placed in the pillar 34. Install. The pillar 34 includes an inner panel 36 and an outer panel 37. The inner panel 36 and the outer panel 37 have a substantially sectional concave shape in which an opening 38 is formed on one side, and flange portions are formed at both ends in the opening width direction along the opening width W of the opening 38. And the pillar 34 is provided so that the inner space 35 of a closed cross section may be formed by joining the inner panel 36 and the outer panel 37 with their flange portions facing each other and welding them together. .

  In this pillar 34, in the inner space 35, inward of the opening 38 on the outer panel 37 side, the opening 38 is substantially orthogonal to the insertion direction of the foam filling member 1 (indicated by a white arrow in FIG. 6). A dead space 39 that further expands is formed on the inner side in the insertion direction with respect to the opening width W in the direction in which the opening width W extends outward in the opening width direction.

  The dead space 39 is formed so as to be continuous with one end edge in the opening width direction of the opening width W of the opening 38 on the outer panel 37 side and to be recessed in a substantially V shape outward in the opening width direction.

  And in order to install the foam filling member 1 in the pillar 34, the mounting portion 9 of the foam filling member 1 is locked in the locking hole 41 formed in the inner panel 36 in advance.

  More specifically, the outer locking portion 22 of the mounting portion 9 is inserted into the locking hole 41. Then, the outer locking portion 22 is elastically deformed inward in the width direction while the locking hole 41 is being inserted. However, after passing through the locking hole 41, the outer locking portion 22 is elastically deformed outward in the width direction, and the inner panel. The outer surface of 36 is elastically contacted. Further, in this state, the inner locking portion 21 of the mounting portion 9 is elastically brought into contact with the inner side surface of the inner panel 36. The panel 36 is sandwiched, whereby the foam filling member 1 is fixed to the inner panel 36.

  Next, the foam filling member 1 fixed to the inner panel 36 is inserted into the inner space 35 from the opening 38 on the outer panel 37 side. Then, the free end portion of the bending portion 12 is brought into contact with one end edge of the opening 38, and the connecting portion 11 is deformed by receiving an external force in a direction from the one end edge toward the one side short side surface 10. And as shown in FIG. 6, the direction (opening width W) which the bending part 12 adjoins with respect to the one side short side surface 10 of the support plate 4 with the bending piece 25 of the foaming base material 3 by using the connection part 11 as a fulcrum. And pass through the opening 38.

  After the passage of the opening 38, the bent portion 12 is released from contact with one end edge of the opening 38 on the outer panel 37 side, so that the bent portion 12 and the bent piece 25 are caused by the elasticity of the connecting portion 11. By bending in the direction away from the short side surface 10 on one side of the support plate 4 with the connecting portion 11 as a fulcrum (outward in the opening width direction of the opening width W), as shown in FIG. Return to. Thus, the bending portion 12 of the flexible portion 5 and the bending piece 25 of the foam base material 3 supported by the bending portion 12 are inserted and arranged in the dead space 39 of the outer panel 37 by an easy insertion operation. The In addition, in the internal space 35 other than the dead space 39, the support plate 4 and the auxiliary protrusion 6 and the foam base material 3 supported by the support plate 4 and the auxiliary protrusion 6 are arranged.

  Thereafter, the flanges of the inner panel 36 and the outer panel 37 are brought into contact with each other and joined by welding, whereby the pillar 34 is formed as a closed cross section. More specifically, such a pillar 34 is used as a front pillar, a side pillar, or a rear pillar of a vehicle body.

  Thereafter, after appropriate treatment such as rust prevention treatment, for example, by heating (for example, around 120 to 210 ° C.) in the drying line process during subsequent baking coating, as shown in FIG. A foamed material 43 is formed by foaming and curing the foamed base material 3, and the foamed material 43 fills the internal space 35 of the pillar 34 without a gap.

The density of the foam material 43 (weight of foam (g) / volume of foam (cm ³ )) is, for example, 0.04 to 0.2 g / cm ³ , and further 0.05 to 0. 0.1 g / cm ³ is preferable, and the expansion ratio at the time of foaming is preferably 5 to 25 times, and more preferably 10 to 20 times.

  In the foam filling member 1, since the flexible portion 5 can be disposed in the dead space 39 in such foaming, the foaming of the foam base material 3 extends from the dead space 39 in the longitudinal direction of the pillar 34. It is possible to prevent the foamed base material 3 facing or flowing from dropping from the dead space 39 downward in the longitudinal direction of the pillar 34. Therefore, the foam material 43 can be filled in the internal space 35 of the pillar 34 without a gap. In addition, since the support plate 4, the flexible portion 5, and the auxiliary protruding portion 6 of the holder member 2 can suppress the foaming of the foamed base material 3 toward the other side of the holder member 2, the other of the holder member 2 Foaming toward the back side can be regulated. As a result, the foam material 43 can be filled in the internal space 35 of the pillar 34 including the dead space 39 without a gap.

  In the foam filling member of the present invention, in the holder member, the shape of the support plate, the flexible portion, and the like is not limited to the above, and can be appropriately selected according to the space of the structure. Moreover, the number of flexible parts can also be suitably selected corresponding to the space of a structure. For example, when there are dead spaces on both sides of the opening of the outer panel in the opening width direction, flexible portions can be provided on both sides of the support plate.

  Moreover, in said embodiment, although the foaming base material 3 was supported on the one side surface of the support plate 4, as shown in FIG. 9, the foaming base material 3 is supported on both surfaces of the support plate 4, for example. You may let them.

  If the foam base material 3 is supported on both surfaces of the support plate 4, the foam base material 3 can be foamed on both surfaces of the support plate 4, and the foam material 43 can be sufficiently filled.

It is a disassembled perspective view which shows one Embodiment of the foam filling member of this invention. It is a top view of the foam filling member shown in FIG. It is the side view to which some holder members of the foam filling member shown in FIG. 2 were expanded. It is the top view which expanded a part of foam filling member shown in FIG. It is a top view of the mounting part of the holder member of the foam filling member shown in FIG. It is sectional drawing which shows the state which inserts the foam filling member shown in FIG. 1 in the internal space of a pillar. It is sectional drawing which shows the state which completed insertion of the foam filling member from the state shown in FIG. It is sectional drawing which shows the state which made the foam filling member foam from the state shown in FIG. It is a sectional side view which shows other embodiment (The aspect which supports a foaming base material in both surfaces of a support plate) of the foam filling member of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Foam filling member 2 Holder member 3 Foam base material 4 Support plate 5 Flexible part 10 One side short side surface 11 Connection part 12 Deflection part 13 Fixed part 15 Crevice 34 Pillar 35 Internal space

Claims (5)

A foam filling member for filling a space of a structure by foaming,
A holder member made of a non-foam material and a foam base made of a foam material,
The holder member supports the foam base material, supports the foam base material, is provided on the outer peripheral edge of the support plate, and bends in a direction approaching and separating from the outer peripheral edge of the support plate. A foam filling member comprising: a flexible portion. The flexible portion is provided so as to bend in a crossing direction with respect to a direction in which the foam filling member is inserted into the space of the structure when the foam filling member is disposed in the space of the structure. The foam filling member according to claim 1, wherein the foam filling member is provided. The flexible portion includes a connecting portion that is continuous with the outer peripheral edge of the support plate, and a flexible portion that is continuous with the connecting portion and is opposed to the outer peripheral edge of the support plate with a predetermined interval. The foam filling member according to claim 1, wherein the foam filling member is provided. The foam filling member according to claim 1, wherein the foam base is formed in a sheet shape. The foam filling member according to any one of claims 1 to 4, wherein the flexible part is provided with a fixing part for fixing a foam base material supported by the flexible part.

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