JP2012020649A - Foam filling member - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a technique for improving followability with respect to a spatial shape to be arranged in a hollow structure in a foam filling member for filling the space of the hollow structure.SOLUTION: The foam filling member for filling the space of the hollow structure 110 by foaming includes: a foaming substrate 101 having first and second surfaces 101a, 101b in parallel with each other; and a recessed groove 103 which is set at least on a the first surface 101a so as to bend the foaming substrate 101. The recessed groove 103 has the predetermined width a. Thus, the foamed substrate 101 is allowed to bend both on the first surface 101a side and the second surface 101b side with the recessed groove 103 as a bending start point.

Description

  The present invention relates to a foam filling member that fills a space of a hollow structure by foaming.

  Conventionally, for example, in a cylindrical hollow structure such as a pillar portion, a roof rail portion, and a rocker portion of an automobile, the flow of air is blocked to prevent resonance noise, or for the purpose of sound insulation of the hollow structure, The foam filling member may be disposed in the space of the structure, and the foam filling member may be heated to a predetermined temperature to be solidified by foaming to fill the space of the hollow structure. A foam filling member that fills the space of such a hollow structure is disclosed in, for example, Japanese Patent Application Laid-Open No. 2005-319845 (Patent Document 1).

The foam filling member described in the publication forms a cut in the sheet surface so as to follow (follow) the cross-sectional shape of the space when the sheet-shaped foam filling member is disposed in the space of the hollow structure. It is possible to bend the surface side not having a cut from the cut.
However, the above-described configuration is a configuration in which the bending direction is limited to the surface side that does not have a cut and is restricted to the opposite side (the cut setting side). For this reason, the space when arranged in the space of the hollow structure The followability to the shape is poor, and there is still room for improvement in this respect.

JP-A-2005-319845

  SUMMARY OF THE INVENTION In view of the above problems, the present invention provides a technique that contributes to improvement in followability to a space shape when a foam filling member that fills the space of a hollow structure is disposed in the space of the hollow structure. And

  In order to achieve the above object, a preferred embodiment of the foam filling member according to the present invention includes a foamable base material having first and second surfaces parallel to each other, and at least a first shape to enable bending of the foamable base material. And a concave groove set on one surface. And the ditch | groove has the width | variety of a predetermined | prescribed magnitude | size, and, thereby, a foamable base material is bend | folded in any of the 1st surface side and the 2nd surface side from a ditch | groove as a bending origin. Is allowed. In addition, the “foamable substrate” in the present invention, in a state before being arranged in the space of the hollow structure, is formed in a sheet shape (band shape), an annular shape (tubular shape), etc. Both are included suitably. In addition, the cross-sectional shape of the “concave groove” in the present invention widely includes a quadrangle, a U-shape, a V-shape, a trapezoid, and the like.

  According to the present invention, since the foam filling member can be bent to either the first surface side or the second surface side with the concave groove as a bending starting point, the foam filling member is disposed in the space of the hollow structure. The followability with respect to the space shape at the time is improved, and a rational arrangement can be realized.

  Moreover, according to the further form of this invention, the ditch | groove is set to the width of 20% or more and the depth of 30% or more with respect to the thickness of a foamable base material. By setting in this way, bending to the 1st surface side and the 2nd surface side was rationally realizable by making the concave groove into a bending origin.

  Moreover, according to the further form of this invention, the foamable base material is formed in the sheet form. By making the foamable substrate into a sheet shape, it can be arranged in a narrow space.

  Moreover, according to the further form of this invention, the foamable base material is formed cyclically | annularly. By making the foamable base material into an annular shape, it is possible to foam and fill the entire inner surface of the hollow structure, thereby preventing uneven filling.

  Moreover, according to this invention, the motor vehicle by which the foam filling member is arrange | positioned in the internal space of the vehicle body structural member which comprises a vehicle body is comprised. According to the present invention, it is possible to bend the foamable base material to either the first surface side or the second surface side with the concave groove as a bending starting point, and when placing it in the space of the hollow structure An automobile provided with a foam filling member with improved followability to the space shape is provided. The “internal space of the vehicle body constituent member” in the present invention typically corresponds to the space of the rocker portion, the space of the pillar portion, and the space of the roof rail portion in the vehicle body.

  ADVANTAGE OF THE INVENTION According to this invention, in the foam filling member which fills the space of a hollow structure, the technique which contributes to the improvement of the followable | trackability with respect to the said space shape at the time of arrange | positioning in the space of a hollow structure was provided.

It is a figure which shows the structure of the foam filling member which concerns on embodiment of this invention. It is a figure which expands and shows the A section of FIG. It is a figure which shows the state which has arrange | positioned the foam filling member in the space of a hollow structure. It is a figure which shows the modification of a foam filling member, and shows the state which bent the foam filling member to the ditch | groove setting surface side in which the ditch | groove was set. It is a figure which shows the modification of a foam filling member, and shows the state which bent the foam filling member to the non-concave groove setting surface side in which the concave groove is not set. It is a figure which shows the other modification of a foam filling member, and shows the state which bent the foam filling member to the ditch | groove setting surface side in which the ditch | groove was set. It is a figure which shows the other modification of a foam filling member, and shows the state which bent the foam filling member to the non-concave groove setting surface side in which the concave groove is not set. It is a figure which shows the further another modification by which the foam filling member was formed in cyclic | annular form, and shows the case where a ditch | groove is set in the cyclic | annular inner peripheral surface of a foam filling member. It is a figure which shows the further another modification by which the foam filling member was formed cyclically | annularly, and shows the case where a ditch | groove is set in the cyclic | annular outer surface of a foam filling member.

  Hereinafter, a foam filling member according to an embodiment of the present invention will be described with reference to FIGS. As shown in FIG. 1, a foam filling member 100 according to the present embodiment includes a foamable base material 101 formed in a sheet shape, and a plurality of base material surfaces formed to bend the foamable base material 101. (In this embodiment, three grooves are shown). The foamable substrate 101 is formed by blending a thermoplastic resin, an inorganic filler, a foaming agent, and the like. The foamable base material 101 is formed in a substantially square shape in a plan view by, for example, extrusion molding, and a concave groove 103 is formed on the surface of the foamable base material 101 when the foamable base material 101 is extruded. Thus, when the foamable base material 101 is formed by extrusion molding, the concave groove 103 can be formed at the same time, so that productivity is improved. However, the molding of the foamable substrate 101 is not limited to extrusion molding, and may be molded by injection molding, for example. The foamable substrate 101 corresponds to the “foamable substrate” in the present invention, and the concave groove 103 corresponds to the “concave groove” in the present invention.

  The concave groove 103 is provided only on one surface 101 a of the foamable substrate 101. The plurality of concave grooves 103 extend in a straight line from one end surface (side surface) to the other end surface (side surface) of the foamable substrate 101 in parallel with each other so as to cross one surface 101a of the foamable substrate 101. Be present. Each concave groove 103 is provided to allow the foamable base material 101 to be bent to either the one surface 101a or the other surface 101b, and has a predetermined size (wide) as shown in FIG. A) width a and depth b. One surface 101a corresponds to the “first surface” in the present invention, and the other surface 101b corresponds to the “second surface” in the present invention.

  In the present embodiment, since three concave grooves 103 are provided, the foamable base material 101 has four partitioned areas 105A to 105D partitioned by the recessed grooves 103, and each partitioned area 105A to 105D unit. It can be bent at

  As described above, when the concave groove 103 having the predetermined lateral width a is provided, the foamable base material 101 is bent, for example, toward the other surface 101b side with the groove bottom portion 103a of the concave groove 103 as a bending start point. Since the lateral width a of the concave groove 103 is expanded (expands), the bending is not regulated at all. When bent to the one surface 101a side, the width a of the concave groove 103 is narrowed (reduced) to allow the bending. That is, the one surface 101a side can be bent until the opposing walls of the concave groove 103 interfere with each other (the groove is crushed). Thus, according to this embodiment, in the foam filling member 100, the concave groove 103 having a predetermined width a is provided in the foamable base material 101, so that the foamable base material 101 is bent. Regulations can be lifted.

  When the present inventor determines the ratio of the groove width a and the depth b of the groove 103 to the plate thickness t of the foamable base material 101, the foamable base material 101 is placed on one surface 101a. An experiment was conducted as to whether or not each of the first and second surfaces 101b can be bent with a bending angle exceeding 15 degrees. As a result, it was confirmed that when the groove width a was 20% or more and the depth b was 30% or more with respect to the plate thickness t, both were bent over 15 degrees. Here, the bending angle refers to an angle on the side opposite to the bending direction among the angles formed by the surface before the foamable substrate 101 is bent and the surface after the bending. In addition, as a sample, when the plate | board width of the foamable base material 101 which consists of a thermoplastic resin, an inorganic filler, a foaming agent etc. is 10 mm, and plate | board thickness is 2 mm, 3 mm, 4 mm, 6 mm, and 8 mm, respectively, it uses. It was.

  As shown in FIG. 3, the foam filling member 100 formed as described above is disposed in the space of the hollow structure, and is heated at a predetermined temperature to be solidified by foaming, thereby filling the space of the hollow structure. Thereby, the flow of air in the hollow structure can be blocked to prevent resonance noise, or the sound insulation of the hollow structure can be improved. FIG. 3 shows a state before foaming. The hollow structure shown in FIG. 3 is a hollow member 110 constituting a part of a vehicle body of an automobile, and is formed into a cylindrical shape by an inner panel 111 and an outer panel 113, and a foam filling member 110 is formed in the hollow member 110. Is placed.

  The foam filling member 100 disposed in the hollow member 110 is attached and fixed to a support member (reinforcement) 115 fixed to the hollow member 110 by a resin clip 117 as an attachment member. When the foam filling member 100 is disposed in the hollow member 110, the foam filling member 100 is bent with the groove bottom portion 103 a of the groove 103 as a bending start point so as to follow (follow) the space shape in the hollow member 110. According to the present embodiment, as described above, it is not restricted in the bending direction of the foamable base material 101, that is, it is allowed to be bent on either the one surface 101a side or the other surface 101b side. . For this reason, when the foam filling member 100 is disposed in the hollow member 110, the cross-sectional shape of the hollow member 110 with respect to the bending direction of the plurality of partition regions 105 </ b> A to 105 </ b> D of the foamable base material 101 partitioned by the plurality of concave grooves 103. Can change in response to changes. That is, the followability of the arrangement of the foamable base material 101 with respect to the change in the cross-sectional shape of the hollow member 110 is improved, and thereby the rational arrangement of the foam filling member 100 with respect to the hollow member 110 becomes possible.

  As shown in FIG. 3, in the present embodiment, two portions of the foam filling member 100 are fixed to the support member 115 by resin clips 117. When the direction orthogonal to the paper surface in FIG. 3 is the direction of the action of gravity, among the plurality of partition regions 105A to 105D of the foamable base material 101, the leftmost partition region 105A in the drawing is arranged substantially horizontally. Since the space between the lower wall of the hollow member 110 is large, it may be softened by heating and drooping downward. In consideration of such circumstances, in the present embodiment, among the partitioned regions 105A to 105D of the foamable base material 101 partitioned by the concave groove 103, the partitioned region 105A that may drop due to the influence of gravity during heating. Is configured to be fixed to the support member 115 by the resin clip 117. Thus, the partition area 105A is maintained at a predetermined arrangement position, and thereafter proper foaming is possible.

  As described above, according to the present embodiment, the foam filling member 100 can be bent on either side of the one surface 101a and the other surface 101b of the foamable base material 101. The followability to the space shape when arranged in the space of the member 110 is improved, and a rational arrangement of the foam filling member 100 with respect to the hollow member 110 becomes possible. In addition, according to the present embodiment, since the concave groove 103 is provided only on one surface 101a of the foamable base material 101, when the foamable base material 101 is produced, the formation of the concave groove 103 is facilitated. Productivity is improved.

Next, modifications of the present embodiment will be described with reference to FIGS.
In the modification shown in FIGS. 4 and 5, two concave grooves 103 are set in the foamable base material 101 of the foam filling member 100, and the partition regions at both ends with respect to the central partition region in the foamable substrate 101 are set. It is configured to be bent and disposed in a substantially U-shape in the space of the hollow member 110 and fixed to the support member 115 by a single resin clip 117. FIG. 4 shows a case where the foamable base material 101 is bent toward the one surface 101a side where the concave groove 103 is set, and FIG. 5 shows the other surface 101b side where the foamable base material 101 is not set as the concave groove 103. Shows the case of bending.

  Thus, according to the modification shown in FIG.4 and FIG.5, the foaming base material 101 is made to have one surface 101a by providing the foaming base material 101 with the concave groove 103 having a predetermined width a. Since it can be bent to any one of the other surfaces 101b, the assembling directionality of the foam filling member 100 when it is arranged in the hollow member 110 is not specified, and the mounting workability is improved.

  6 and 7, the foamable base material 101 is formed in a long sheet shape, that is, a strip shape, and one end in the longitudinal direction of the strip-shaped foamable base material 101 is overlapped on the other end. Thus, the foamable substrate 101 is annular, and the overlapped portion is fixed to the support member 115 in the hollow member 110 by the resin clip 117. 6 shows a case where the foamable base material 101 is bent so that the one surface 101a side where the concave groove 103 is set is inside, and FIG. 7 shows the foamable base material 101 where the concave groove 103 is set. The case where it is not bent to the other surface 101b side is shown.

  As described above, according to the modification shown in FIGS. 6 and 7, the groove 103 having a predetermined lateral width a is formed on the foamable substrate 101 as in the modification shown in FIGS. 4 and 5. Since the foamable base material 101 can be bent to either the one surface 101a or the other surface 101b, the assembling directionality of the foam filling member 100 when it is arranged in the hollow member 110 is specified. This improves the installation workability.

  In the modification shown in FIG. 8 and the modification shown in FIG. 9, the foamable base material 101 of the foam filling member 100 is formed in an annular shape (cylindrical shape) before being placed in the hollow member 110, that is, in a molded state. It is a thing. In the modification shown in FIG. 8, the groove 103 is set on the annular inner surface 101a, and in the modification shown in FIG. 9, the groove 103 is set on the annular outer surface 101a. The annular inner surface 101a in the modification of FIG. 8 and the annular outer surface 101a in the modification of FIG. 9 correspond to the “first surface” in the present invention, and the annular outer surface 101b in the modification of FIG. The annular inner surface 109b in the modification of FIG. 9 corresponds to the “second surface” in the present invention.

  The concave groove 103 set in the foamable base material 101 is set at a location where bending is required according to a change in the spatial shape of the hollow member 110 in which the foam filling member 100 is disposed. As shown in FIG. 4, when the concave grooves 103 are densely set on the surface of the foamable substrate 101 at a predetermined interval (for example, when set at intervals of 2 to 3 mm), the spatial shape of the hollow member 110 is simple. Of course, even in a complicated case, it is possible to easily follow the space shape.

In addition, although the groove 103 shown in FIG. 2 shows the case where it forms in a cross-sectional rectangle, about the cross-sectional shape of the groove 103, it can change suitably, such as V shape or U shape, for example. It is also possible to adjust the bendability by providing a small hole or slit penetrating from one surface 101a to the other surface 101b in the groove bottom 103a of the concave groove 103.
Further, in this embodiment, the concave groove 103 is set only on one surface 101a of the foamable substrate 101, but it may be set not only on one surface 101a but also on the other surface 101b.

In view of the gist of the present invention, the following aspects can be configured.
(Aspect 1)
“A foam filling member according to claim 1,
The foam filling member, wherein the concave groove is formed only on the first surface side. "

(Aspect 2)
“A foam filling member according to claim 3,
The foam member has a plurality of partition regions that are partitioned by a concave groove and bent in different directions, and two of the partition regions are formed into a hollow structure by a mounting member. The foam filling member is fixed, and at least one of the two partition regions is a region that is horizontally disposed with a space between the lower wall of the hollow structure. "

(Aspect 3)
“A foam filling member according to claim 4,
A foam filling member, wherein grooves are formed on the inner surface or outer surface of the foam member at close intervals in the circumferential direction of the foamable substrate. "
In addition, said close space | interval means the space | interval of 2-3 mm or less.

100 Foam filling member 101 Foamable substrate 101a One surface (first surface)
101b The other surface (second surface)
103 groove 103a groove bottom part 105A-105D partition area 110 hollow member (hollow structure)
111 Inner panel 113 Outer panel 115 Support member 117 Resin clip (attachment member)

Claims (5)

A foam filling member for filling a space of a hollow structure by foaming,
A foamable substrate having first and second surfaces parallel to each other;
A concave groove set on at least the first surface to enable bending of the foamable substrate;
Have
The concave groove has a predetermined width, so that the foamable base material can be formed on either the first surface side or the second surface side with the concave groove as a starting point. A foam filling member characterized by being allowed to be bent. The foam filling member according to claim 1,
The foam filling member, wherein the concave groove is set to a width of 20% or more and a depth of 30% or more with respect to the thickness of the foamable substrate. The foam filling member according to claim 1 or 2,
The foamable filling member, wherein the foamable base material is formed in a sheet shape. The foam filling member according to claim 1 or 2,
The foamable filling member, wherein the foamable substrate is formed in an annular shape.   An automobile, wherein the foam filling member according to any one of claims 1 to 4 is disposed in an internal space of a vehicle body constituting member constituting the vehicle body.

Images