JP2009083497A - Foamed filling member - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a foamed filling member which can be manufactured with high working efficiency and at a low cost with its simple structure, and can fill the space of a structure without leaving even a single gap, while reducing the consumption of a foamed base material. <P>SOLUTION: This foamed filling member is of such a construction that a plurality of nipping pieces 5 are arranged at a specified interval to each other, in the peripheral direction of a support plate 4, at the peripheral edge part of the support plate 4 of a holder member 2 made of a non-foaming material. In addition, the foaming base material 3 made of a foaming material is formed like a sheet, then this sheet is arranged along the outer peripheral surface of the support plate 4 and secured to the nipping pieces 5. This foamed filling member 1 can dispense with an injection-molding device or a molding die for making the support plate 4 brace the foaming base material 3, and thus, the member 1 can be manufactured with high working efficiency and at a low cost. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

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

DESCRIPTION OF RELATED ART Conventionally, the foam filling member for filling a hollow structure, such as a pillar of a motor vehicle, with a foaming material is known.
Such a foam filling member is usually provided with a holder member made of a non-foam material and a foam base material made of a foam material supported by the holder member.
For example, in a hollow structure comprising: a holder attached to a hollow chamber of a hollow structure; and a foamable base material that is held in the holder and foams by external heating to form a foam to block the hollow chamber A hollow chamber shut-off device, wherein the holder is integrally provided with a holder main body orthogonal to the longitudinal direction of the hollow chamber and a holding portion formed at the peripheral edge of the holder main body. A holding groove for holding the material is formed, and both side wall portions of the holding groove are parallel to the holder main body and project toward the inner peripheral wall surface of the hollow chamber, and at the same time, the foamable base material is injection-molded. Based on the injection molding, there has been proposed one in which a foamable base material is filled in a holding groove and is provided integrally with a holder (for example, see Patent Document 1). According to this hollow chamber breaker, it is possible to reduce the cost by reducing the step of assembling the foamable base material to the holder.

In addition, for example, it is composed of a foam having heat foamability and a base material that supports the foam on the periphery, and a protrusion is formed on the periphery of the base, and foaming is performed so as to cover at least a part of the protrusion. A sealing material for a body panel of an automobile in which the body is supported has been proposed (for example, see Patent Document 2). According to the sealing material for a body panel of an automobile, a small amount of foam can be held near the interface with the body panel that requires sealing, and the heat receiving efficiency can be improved.
Japanese Patent Laid-Open No. 10-71628 JP 2001-341492 A

However, as for the foam filling member described in patent document 1 and patent document 2, as for all, the holding groove | channel or the protruding item | line for supporting a foaming base material is continuously formed in the peripheral part of the holder member. .
Therefore, in the hollow chamber breaker described in Patent Document 1, after setting the holder in the mold, the foaming material is injected and filled into the cavity formed by the holding groove of the holder and the mold surface of the mold. It is necessary to form a foamable substrate.

Moreover, in the sealing material for automobile body panels described in Patent Document 2, a base material having ridges formed on the periphery is set in an injection mold, and the cavity formed by the mold surface of the substrate and the mold is formed. On the other hand, it is necessary to inject and fill a foam raw material having foaming direction anisotropy from the gate in a direction parallel to the ridges to form a foam having heat foamability on the periphery of the ridges of the substrate.
However, when the foamed base material is formed on the peripheral edge portion of the holder member by injection filling in this way, an injection molding apparatus or a molding die for that purpose is required, which causes an increase in cost.

  The object of the present invention is a foaming that can be manufactured efficiently and at low cost with a simple structure, and can fill the space of the structure without gaps while reducing the amount of the foamed base material used. It is to provide a filling member.

  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 includes a support plate and a plurality of engaging portions arranged at predetermined intervals along a circumferential direction of the support plate at a peripheral end portion of the support plate, It is formed in a sheet shape extending along the outer peripheral surface of the support plate, is supported on the outer peripheral surface of the support plate, and is locked to the locking portion.

In this foam filling member, the foam base material is disposed along the outer peripheral surface of the support plate, and is engaged with a plurality of engagement portions disposed at predetermined intervals along the circumferential direction of the support plate. Thus, it can be manufactured with a simple configuration. Therefore, an injection molding device or a molding die for supporting the foamed base material on the support plate is not necessary, and it can be manufactured efficiently and at low cost.
Further, in this foam filling member, since the foam base material is provided on the outer peripheral surface of the support plate, if the foam base material is foamed by placing it in the space of the structure, the space between the support plate and the structure can be reduced. Is filled with the foam material, and the space of the structure can be filled with the support plate and the foam material. Therefore, it is possible to fill the space of the structure without a gap while reducing the amount of the foam base material used.

Further, in this foam filling member, it is preferable that the locking portion includes a sandwiching piece for sandwiching the foam base material supported on the outer peripheral surface of the support plate from both sides in the thickness direction of the support plate. It is.
If the foam base material is sandwiched from both sides in the thickness direction of the support plate by the sandwiching piece, the foam base material can be locked without providing a locked portion for locking the foam base material with the lock portion. Can do. Therefore, the foamed base material can be locked along the outer peripheral surface of the support plate with a simple configuration.

Further, in this case, the sandwiching piece is provided such that the sandwiching piece on one side and the sandwiching piece on the other side sandwiching the foam base material are provided at different positions along the circumferential direction of the support plate. Is preferred.
If the one-side holding piece and the other-side holding piece are provided at different positions along the circumferential direction of the support plate, the foam base material can be easily locked with the holding piece. Therefore, the work efficiency at the time of manufacture can be further improved.

Further, in this foam filling member, the foam base has a plurality of through-holes penetrating in the thickness direction and spaced apart from each other in the longitudinal direction, and the locking portion is the support plate It is also preferable to have an insertion protrusion that is inserted through the through hole of the foam base material supported on the outer peripheral surface of the foam base material.
If the insertion protrusion is inserted into the through hole of the foam base material, the foam base material can be easily locked along the outer peripheral surface of the support plate with a simple configuration. Therefore, the work efficiency at the time of manufacture can be further improved.

In this case, the insertion protrusion is inserted into the foam base material, and a free end portion of the insertion protrusion projects from the foam base material, and a bulge that bulges at the free end portion of the insertion portion. It is suitable to provide a part.
If the insertion protrusion is inserted into the through hole of the foam base material, the insertion portion is inserted in the thickness direction of the foam base material, and the bulging portion sandwiches the foam base material with the outer peripheral surface of the support plate. Therefore, the foamed base material can be reliably locked along the outer peripheral surface of the support plate.

Further, in this foam filling member, the support plate includes a bent portion where the outer peripheral surface is bent, and the foam base material has a cut portion cut into the middle in the thickness direction corresponding to the bent portion. It is suitable that it is formed.
If the cut portion is formed, the foamed base material can be easily refracted with the cut portion as a boundary. Therefore, even in the bent portion of the support plate, it can be supported while following the foam base material on the outer peripheral surface of the support plate.

In this foam filling member, it is preferable that the foam base material is supported on the outer peripheral surface of the support plate in a state of being divided into a plurality of parts.
If the foam base material is supported on the outer peripheral surface of the support plate in a state of being divided into a plurality of parts, if the two foam base materials are arranged at a predetermined angle in the bent portion of the support plate, the foam base material is not bent. Can be arranged. Further, if the free end portion of the disposed foam base is projected in a direction away from the outer peripheral surface of the support plate, the free end portion is disposed in the dead space of the structure space, and the dead space is a gap. It can be filled without.

  The foam filling member of the present invention can be manufactured efficiently and at low cost without the need for an injection molding device or a molding die for supporting the foam base material on the support plate. Moreover, the space of a structure can be filled without gap, reducing the usage-amount of a foaming base material.

1 is an exploded perspective view showing an embodiment of the foam filling member of the present invention, FIG. 2 is a plan view of the foam filling member shown in FIG. 1, and FIG. 3 is a longitudinal sectional view of the foam filling member shown in FIG. It is.
In FIG. 1, a 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 is not particularly limited as long as it supports the foamed base material 3 and does not deform at the time of heating and foaming (for example, around 120 to 210 ° C.) to be described later. Resins such as polyester, for example, metals such as iron, stainless steel, and aluminum are used.
The holder member 2 is integrally provided with a support plate 4, a clamping piece 5 as a locking portion, and a mounting portion 15.

The support plate 4 has a slightly small similar shape with respect to the space of the structure to be filled. For example, the support plate 4 has a substantially fan-shaped flat plate shape having two bent portions 13 formed on the outer peripheral surface at a substantially right angle or a substantially acute angle. None, the thickness is smaller than the width of the foamed substrate 3 (width in the direction perpendicular to the longitudinal direction), for example, 0.5 to 6.0 mm, preferably 1.5 to 3.5 mm. Yes.
A plurality of sandwiching pieces 5 are provided at a peripheral end portion of the support plate 4 along the circumferential direction of the support plate 4 at a predetermined interval from each other. As shown in FIG. 3, each clamping piece 5 includes a support piece portion 6 erected from the surface of the peripheral end portion of the support plate 4 in a direction substantially orthogonal to the direction in which the surface extends, and the support piece portion 6. A substantially L-shaped cross section integrally including a holding piece portion 7 extending from the free end portion of the support plate 4 in a direction substantially orthogonal to the circumferential direction of the support plate 4 and extending outward from the peripheral end portion of the support plate 4. It is formed into a shape.

  Such sandwiching pieces 5 are provided on both sides in the thickness direction of the support plate 4, that is, on the support plate so that the foam base 3 supported on the outer peripheral surface of the support plate 4 can be sandwiched at the peripheral end of the support plate 4. 4 is provided with one side clamping piece 8 provided on one side surface of the support plate 4 and the other side clamping piece 9 provided on the other side surface of the support plate 4. As shown in FIG. 2, the one side clamping piece 8 and the other side clamping piece 9 are arranged in the circumferential direction of the support plate 4 so as not to face each other with the foam base material 3 supported on the outer peripheral surface of the support plate 4 interposed therebetween. Are alternately arranged at positions different from each other.

If the one-side holding piece 8 and the other-side holding piece 9 are arranged at different positions along the circumferential direction of the support plate 4, the foam base material 3 can be easily locked by the holding pieces 5. That is, the foam base material 3 can be fitted and locked in turn alternately on the one-side sandwiching piece 8 and the other-side sandwiching piece 9. Therefore, it is possible to improve the working efficiency during manufacturing.
Further, the holding piece portion 7 of the one-side holding piece 8 and the holding piece portion 7 of the other-side holding piece 9 are spaced from each other at a base end where each holding piece portion 7 is continuous with each supporting piece portion 6. The base end portion is equal to or larger than the width of the foam base material 3 at the portion, and is slightly smaller than the width of the foam base material 3 at the free end portion on the opposite side of the base end portion. Are formed so as to be inclined inward in the thickness direction of the support plate 4 toward the free end portion.

Further, the holding piece portion 7 of the one-side holding piece 8 and the holding piece portion 7 of the other-side holding piece 9 have a length from the base end portion to the free end portion, which is larger than the thickness of the foam base 3. For example, it is set to 2.0 to 10.0 mm, preferably 4.0 to 5.0 mm.
If the foam base material 3 is sandwiched from the both sides in the thickness direction of the support plate 4 on the outer peripheral surface of the support plate 4 by the sandwiching piece 5 with the one side sandwiching piece 8 and the other side sandwiching piece 9, The material 3 can be locked without providing a locked portion for locking to the support plate 4, that is, as described later, only by forming the foam base 3 into an elongated sheet shape. Therefore, the foam base material 3 can be locked along the outer peripheral surface of the support plate 4 with a simple configuration.

As shown in FIG. 2, the mounting portion 15 is formed to project outward from the outer peripheral surface of the support plate 4 along a direction substantially orthogonal to the circumferential direction of the support plate 4. The mounting portion 15 is integrally provided with a base 10 and an inner locking portion 11 and an outer locking portion 12 provided on the base 10.
The base 10 is provided on the outer peripheral surface of the support plate 4 and is formed to bulge from the outer peripheral surface.
The inner locking portion 11 is made of a portable piece, and protrudes from the base end portion of the base portion 10 toward the outside in the width direction of the base portion 13 (the direction along the circumferential direction of the support plate 4). A protrusion is formed so as to incline outward. The outer locking portion 12 is made of a flexible piece, and is formed to project from the free end portion of the base portion 10 in an arc shape along the width direction of the base portion 10.

Such a holder member 2 can be obtained, for example, by integrally molding the support plate 4, the sandwiching piece 5 and the mounting portion 15 by injection molding or the like when formed from the above-described resin.
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 ethylene-vinyl acetate copolymer, polyethylene, polypropylene, polyester, polyvinyl butyral, polyvinyl chloride, polyamide, polyketone, for example, styrene-butadiene rubber (SBR) ) 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, Organic peroxidation such as 2,5-dimethyl-2,5-ditertiarybutylperoxyhexyne, 1,3-bis (tertiarybutylperoxyisopropyl) benzene, tertiarybutylperoxyketone, tertiarybutylperoxybenzoate Such as things.

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. Moreover, the mixing 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-3 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 hardly foam when the foamed base material 3 is formed are appropriately selected depending on the composition. . 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. Sex is reduced.

  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 substrate 3 is formed in a sheet shape extending along the outer peripheral surface of the support plate 4. More specifically, the foamed base material 3 has an elongated sheet shape, and is substantially the same length as the circumferential length of the outer peripheral surface of the support plate 4 (excluding the portion where the mounting portion 15 is formed). Thus, the width thereof is substantially equal to or smaller than the interval between the base end portion of the holding piece portion 7 of the one side holding piece 8 and the base end portion of the holding piece portion 7 of the other side holding piece 9. It is formed to 3.0 to 20.0 mm, preferably 5.0 to 15.0 mm. Moreover, the thickness is 0.5-6.0 mm, for example, Preferably, it is set to 1.5-4.0 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.
That is, for example, the foam base 3 is first blended in the above-described foamed material in the above-described blending ratio, and then kneaded using, for example, a mixing roll or a pressure kneader, and then pressed or calendered. It can be obtained by continuously forming into a sheet using a roll or the like, or by continuously forming a foamed material into a sheet using, for example, an extruder.

  Further, in the foamed base material 3, a cut portion 14 that is cut halfway in the thickness direction is formed in two portions corresponding to the bent portion 13 of the support plate 4. Each incision 14 has a depth of 1/3 to 2/3 with respect to the thickness of the foam substrate 3 from the outer surface opposite to the inner surface facing the outer peripheral surface of the support plate 4 in the foam substrate 3. It is formed by cutting along the width direction of the foamed substrate 3 with a cutter or the like.

And the foam filling member 1 arrange | positions the foaming base material 3 along the outer peripheral surface (except the part in which the mounting part 15 is formed) of the support plate 4, as shown in FIG. 1 and FIG. This can be obtained by being fitted and locked so as to be sandwiched between the one-side sandwiching piece 8 and the other-side sandwiching piece 9 and supported on the outer peripheral surface of the support plate 4.
As described above, the holding piece portion 7 of the one-side clamping piece 8 and the holding piece portion 7 of the other-side holding piece 9 are mutually connected to the thickness of the support plate 4 from the base end portion toward the free end portion. Since the foam base material 3 is inclined inward in the direction, the pulling-out of the foam base material 3 is restricted in a state where the foam base material 3 is sandwiched between the base end portions of the holding piece portions 7.

  The foam filling member 1 thus obtained has the foam base material 3 disposed along the outer peripheral surface of the support plate 4 so as to be sandwiched between the one-side sandwiching piece 8 and the other-side sandwiching piece 9. Can be manufactured with a simple configuration. Therefore, an injection molding device or a molding die for supporting the foam base material 3 on the support plate 4 is not required, and it can be manufactured efficiently and at low cost.

  Further, in the foam filling member 1, since the cut portion 14 is formed in the foam base material 3, the foam base material 3 can be refracted at a substantially right angle or a substantially acute angle with the cut portion 14 as a boundary. Therefore, in the state where the foam base 3 is supported by the support plate 4 as described above, if the cut portion 14 is opposed to the bent portion 13 bent at a substantially right angle or a substantially acute angle in the support plate 4, the bent portion 13. The foamed base material 3 can be refracted corresponding to the bending angle, and the foamed base material 3 can be supported while following the outer peripheral surface of the support plate 4 at the bent portion 13.

  And the foam filling member 1 obtained in this way is placed in the space between the structures or in the internal space of the hollow structure and foamed if heated to the foaming temperature (for example, around 120 to 210 ° C.). Thus, the space can be filled without a gap. 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 foamed material formed by foaming causes vibration and noise of the engine, 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 FIG. 4, the foam filling member 1 including the support plate 4 formed corresponding to the closed cross-sectional shape and size of the internal space of the pillar 31 to be filled is provided in the pillar 31. Install in. In order to install the foam filling member 1 in the pillar 31, the mounting portion 15 of the foam filling member 1 is locked in the locking hole 32 formed in advance in the pillar 31.
More specifically, the outer locking portion 12 of the mounting portion 15 is inserted into the locking hole 32. Then, while the outer locking portion 12 is elastically deformed inward in the width direction while the locking hole 32 is being inserted, the outer locking portion 12 is elastically deformed outward in the width direction after passing through the locking hole 32, and the pillar 31. Elastically abuts against the outer surface of the. Further, in this state, the inner locking portion 11 of the mounting portion 15 is elastically brought into contact with the inner side surface of the pillar 31, so that the outer locking portion 12 and the inner locking portion 11 form the pillar 31. This causes the foam filling member 1 to be fixed to the pillar 31.

  The pillar 31 includes an inner panel 33 and an outer panel 34 that are substantially cut and concave. First, after the foam filling member 1 is installed on the inner panel 33, both ends of the inner panel 33 and the outer panel 34 are brought into contact with each other. Then, a closed cross section is formed by joining by welding. More specifically, such a pillar 31 is used as a front pillar, a side pillar, or a rear pillar of a vehicle body.

Thereafter, as shown in FIG. 5, after appropriate processing such as rust prevention treatment, for example, by heating (for example, around 120 to 210 ° C.) in the drying line process at the time of baking coating, A foam material 35 is formed by foaming and curing the foam base material 3, and the foam material 35 fills the internal space of the pillar 31 without a gap.
The density of the foam material 35 (the weight of the foam material (g) / the volume of the foam material (g / 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.

  And in such a foam filling member 1, since the foaming base material 3 is provided in the outer peripheral surface of the support plate 4 in such foaming, it arrange | positions in the space (internal space of the pillar 31) of a structure. If the foamed base material 3 is foamed, the space between the support plate 4 and the structure (inner side surface of the pillar 31) is filled with the foam material 35, and the space of the structure (by the support plate 4 and the foam material 35) ( The internal space of the pillar 31) can be filled. Therefore, it is possible to fill the space of the structure (the internal space of the pillar 31) without a gap while reducing the amount of the foam base 3 used.

6 is an exploded perspective view showing a foam filling member of an embodiment different from the foam filling member of the embodiment shown in FIGS. 1 to 3, and FIG. 7 is a plan view of the foam filling member shown in FIG. 8 is a longitudinal sectional view of the foam filling member shown in FIG.
6 to 8, the same members as those in the embodiment shown in FIGS. 1 to 3 described above are denoted by the same reference numerals, and the description thereof is omitted.

In FIG. 6, in the foam filling member 1, an insertion protrusion 16 is formed on the support plate 4 instead of the sandwiching piece 5, and a through hole 17 is formed on the foam base material 3.
More specifically, the holder member 2 is integrally provided with a support plate 4, an insertion protrusion 16 as a locking portion, and a mounting portion 15.
The support plate 4 has a slightly small similar shape with respect to the space of the structure to be filled. For example, the support plate 4 has a substantially fan-shaped flat plate shape having two bent portions 13 formed on the outer peripheral surface at a substantially right angle or a substantially acute angle. None, a flat plate main body 18 having a plate thickness smaller than the width of the foam base 3, and an outer peripheral edge of the plate main body 18 formed in a direction orthogonal to the direction in which the plate main body 18 extends. It is formed in a substantially H-shaped cross section (see FIG. 8) integrally including a peripheral end plate 19 for supporting. The width of the peripheral end plate 19 (the width in the direction orthogonal to the circumferential direction of the support plate 4) is set to be substantially the same as or larger than the width of the foam base material 3.

  A plurality of insertion protrusions 16 are provided at predetermined intervals along the circumferential direction of the support plate 4 at the peripheral end of the support plate 4. As shown in FIG. 8, each insertion protrusion 16 protrudes outward from the outer peripheral surface of the support plate 4 (the surface of the peripheral end plate 19) along a direction substantially orthogonal to the circumferential direction of the support plate 4. Is formed. The insertion protrusion 16 integrally includes an insertion portion 20 and a bulging portion 21 formed at the free end portion of the insertion portion 20.

The insertion portion 20 is provided on the outer peripheral surface of the support plate 4 and is formed so as to protrude from the outer peripheral surface. The protruding length of the insertion portion 20 is, for example, 3.0 to 15.0 mm, preferably such that the free end portion protrudes from the foaming substrate 3 through a through-hole 17 described later of the foaming substrate 3. Is set to 4.0 to 10.0 mm.
The bulging portion 21 is bulged along the circumferential direction of the support plate 4 at the free end portion of the insertion portion 20 (see FIG. 2).

As shown in FIG. 7, the mounting portion 15 is formed in the same manner as described above, and integrally includes a base portion 10, an inner locking portion 11, and an outer locking portion 12.
When the holder member 2 is also formed from the above-described resin, it can be obtained by integrally molding the support plate 4, the insertion protrusion 16, and the mounting portion 15 by injection molding or the like. .

  The foam base material 3 is formed in a sheet shape extending from the same foam material as described above along the outer peripheral surface of the support plate 4. More specifically, the foamed base material 3 is formed in an elongated sheet shape, and is divided into a plurality (three) in a state of being supported on the outer peripheral surface of the support plate 4. Further, the foamed base material 3 is formed to have a width of 5 to 25 mm, preferably 7 to 15 mm, which is substantially equal to or smaller than the width of the peripheral end plate 19. Moreover, the thickness is 0.5-6.0 mm, for example, Preferably, it is set to 1.5-4.0 mm.

  Moreover, in this foaming base material 3, in each foaming base material 3 divided into three, a plurality of through holes 17 penetrating in the thickness direction of the foaming base material 3 are provided in the longitudinal direction so as to correspond to the respective insertion protrusions 16. Are formed at predetermined intervals. Each through-hole 17 is formed in a shape that is larger than the thickness of the insertion portion 20 of the insertion protrusion 16 and slightly smaller than the thickness of the bulging portion 21.

  In the same manner as described above, for example, the foamed base material 3 is first blended in the above-described foamed material in the above-described blending ratio, and then kneaded using, for example, a mixing roll or a pressure kneader. Thereafter, the sheet is continuously formed into a sheet using a press, a calender roll, or the like, or the foamed material is formed into a sheet using an extrusion molding machine, for example. Next, for example, this can be obtained by forming the through-hole 17 by punching or the like, and cutting out or punching into the above-described width and the length to be divided.

  As shown in FIGS. 6 and 7, the foam filling member 1 excludes a plurality (three) of the foam base materials 3 from the outer peripheral surface of the corresponding support plate 4 (the portion where the mounting portion 15 is formed). ), The through holes 17 of the foam base materials 3 are inserted through the insertion protrusions 16 formed on the outer peripheral surface of the support plate 4 to be locked, and the outer peripheral surface of the support plate 4 It can obtain by making it support.

  More specifically, first, the foam base materials 3 are arranged so as not to be continuous at the bent portions 13 of the support plate 4. More specifically, it is a fan-shaped curved peripheral surface of the support plate 4, and the corresponding foam base 3 is disposed between the two bent portions 13. A foam base material 3 corresponding to one of the bent portions 13 and the mounting portion 15 is disposed between the one bent portion 13 and the mounting portion 15, and the other bent portion in the fan-shaped radial direction of the support plate 4. Corresponding foam base material 3 is arranged between 13 and mounting part 15.

  Thus, if the foam base material 3 is divided into a plurality (three) and supported on the outer peripheral surface of the support plate 3, the two foam base materials 3 are held at a predetermined angle at the bent portion 13 of the support plate 4. In other words, the foam base material 3 can be arranged without being bent at a substantially right angle or a substantially acute angle by arranging the end portions of the foam base materials 3 to face each other at each bent portion 13. can do.

  Next, when the through-hole 17 is inserted into the insertion protrusion 16, the insertion portion 20 is inserted in the thickness direction of the foam base material 3, and the bulging portion 21 protrudes from the foam base material 3 in a bulging shape and is supported. The foam base material 3 is sandwiched between the outer peripheral surface of the plate 4. Therefore, the foam base 3 can be reliably locked along the outer peripheral surface of the support plate 4. As a result, the foamed base material 3 can be easily locked along the outer peripheral surface of the support plate 4 with a simple configuration. Therefore, it is possible to improve the working efficiency during manufacturing.

  In the foam filling member 1 thus obtained, the foam base material 3 is disposed along the outer peripheral surface of the support plate 4 in the same manner as described above, and the through hole 17 is inserted through the insertion protrusion 16 to engage with the foam filling member 1. If it is stopped, it can be manufactured with a simple configuration. Therefore, an injection molding device or a molding die for supporting the foam base material 3 on the support plate 4 is not required, and it can be manufactured efficiently and at low cost.

  And the foam filling member 1 obtained in this way is also disposed in the space between the structures and the internal space of the hollow structure, and is heated to a foaming temperature (for example, around 120 to 210 ° C.). Thus, the space can be filled without a gap. 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.

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 FIG. 9, the foam filling member 1 including the support plate 4 formed corresponding to the closed sectional shape and size of the internal space of the pillar 31 to be filled is the same as described above. Next, the mounting part 15 is installed in the pillar 31 by being locked in the locking hole 32.

Thereafter, as shown in FIG. 10, after appropriate treatment such as rust prevention treatment, for example, by heating (for example, around 120 to 210 ° C.) in the drying line process at the time of baking coating, A foam material 35 is formed by foaming and curing the foam substrate 3, and the foam material 35 fills the internal space of the pillar 31 without any gaps.
Such a foam filling member 1 is also disposed in the space of the structure (the internal space of the pillar 31) because the foam base 3 is provided on the outer peripheral surface of the support plate 4 in such foaming. If the foam base 3 is foamed, the space between the support plate 4 and the structure (the inner surface of the pillar 31) is filled with the foam material 35, and the space of the structure is formed by the support plate 4 and the foam material 35. (The internal space of the pillar 31) can be filled. Therefore, it is possible to fill the space of the structure (the internal space of the pillar 31) without a gap while reducing the amount of the foam base 3 used.

  Furthermore, in this foam filling member 1, since the foam base material 3 is supported on the outer peripheral surface of the support plate 4 in a state of being divided into a plurality of parts, for example, as shown by an imaginary line in FIG. If the free end portion 22 of the foam base 3 is arranged so as to protrude in a direction away from the outer peripheral surface of the support plate 4, the free end portion 22 is disposed in the dead space of the structure space, The dead space can be filled without any gaps.

  In the foam filling member of the present invention, in the holder member, the shape of the support plate is not limited to the above, and can be appropriately selected according to the space of the structure. Further, the number, the formation interval, and the shape of the sandwiching pieces and the insertion protrusions can be appropriately selected according to the space of the structure. Further, the shape of the foam base material is not limited to the above, and can be appropriately selected according to the shape of the support plate. Further, the number and shape of the through holes can be appropriately selected.

For example, in the foam filling member 1 shown in FIG. 1, as shown in FIG. 11, the thickness of the support plate 4 is made thinner than the width of the foam base material 3, and the thickness of the support portion 5 is set to the support plate. It may be formed thicker than the thickness of 4.
Further, for example, in the foam filling member 1 shown in FIG. 1, the support plate 4 may be provided with reinforcing ribs 31 substantially similar to the support plate 4, as shown by phantom lines in FIG. 12. In the foam filling member 1 shown in FIG. 6, as indicated by phantom lines in FIG. 13, reinforcing ribs 31 having substantially similar shapes to the plate body 18 may be provided on the plate body 18 of the support plate 4.

It is a disassembled perspective view which shows one Embodiment (The aspect which forms a clamping piece in a support plate) of the foam filling member of this invention. It is a top view of the foam filling member shown in FIG. It is a longitudinal cross-sectional view of the foam filling member shown in FIG. It is sectional drawing which shows the state which has arrange | positioned the foam filling member shown in FIG. 1 in the internal space of a pillar. It is sectional drawing which shows the state which made the foaming base material foam from the state shown in FIG. It is a disassembled perspective view which shows other embodiment (The aspect which forms an insertion protrusion in a support plate, and forms a through-hole in a foam base material) of the foam filling member of this invention. It is a top view of the foam filling member shown in FIG. It is a longitudinal cross-sectional view of the foam filling member shown in FIG. It is sectional drawing which shows the state which has arrange | positioned the foam filling member shown in FIG. 6 in the internal space of a pillar. It is sectional drawing which shows the state which made the foaming base material foam from the state shown in FIG. It is a longitudinal cross-sectional view which shows other embodiment (The aspect by which the thickness of a support part is formed more thickly than the thickness of a support plate) other than the foam filling member shown in FIG. It is a top view which shows other embodiment (mode in which the reinforcement rib is formed) of the foam filling member shown in FIG. It is a top view which shows other embodiment (a mode in which the reinforcement rib is formed) of the foam filling member shown in FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Foam filling member 2 Holder member 3 Foaming base material 4 Support plate 5 Clamping piece 8 One side clamping piece 9 The other side clamping piece 13 Bending part 14 Cutting part 16 Insertion protrusion 17 Through-hole 20 Insertion part 21 Swelling part 21 Pillar

Claims (7)

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 includes a support plate and a plurality of locking portions arranged at predetermined intervals along the circumferential direction of the support plate at a peripheral end portion of the support plate,
The foam base is formed in a sheet shape extending along the outer peripheral surface of the support plate, is supported on the outer peripheral surface of the support plate, and is locked to the locking portion. Foam filling member. The said latching | locking part is equipped with the clamping piece which clamps the said foaming base material supported in the outer peripheral surface of the said support plate from the thickness direction both sides of the said support plate. Foam filling member. The sandwiching piece is characterized in that the sandwiching piece on one side and the sandwiching piece on the other side sandwiching the foam base material are provided at different positions along the circumferential direction of the support plate. 2. The foam filling member according to 2. In the foam base, a plurality of through holes penetrating in the thickness direction are formed at predetermined intervals in the longitudinal direction,
2. The foam filling member according to claim 1, wherein the locking portion includes an insertion protrusion that is inserted into the through hole of the foam base material supported on the outer peripheral surface of the support plate.   The insertion protrusion includes an insertion portion that is inserted into the foam base material, and a free end portion of the insertion protrusion protrudes from the foam base material, and a bulge portion that bulges at the free end portion of the insertion portion. The foam filling member according to claim 4, wherein: The support plate includes a bent portion where the outer peripheral surface is bent,
The foam filling member according to any one of claims 1 to 5, wherein a cut portion that is cut halfway in the thickness direction is formed in the foam base material in correspondence with the bent portion. The foam filling member according to claim 1, wherein the foam base material is supported on an outer peripheral surface of the support plate in a state of being divided into a plurality of parts.

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