JP2012241860A - Washer, foam molded article, as well as manufacturing method and mounting structure for foam molded article - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a washer, with which a protrusion height of a protrusion for mounting a foam molded article to be disposed on a member can be relatively decreased and bonding strength between the washer and a foam molded article can be sufficiently increased in a simple configuration, and to provide a foam molded article having the washer, a manufacturing method for the foam molded article, and a mounting structure for the foam molded article to a member.SOLUTION: A washer 1 is embedded in a foam molded article 10 comprising a foamed synthetic resin and is used for mounting the foam molded article 10 on a member 20. The washer 1 is planar as a whole. The washer 1 has a protrusion insertion hole 3 for inserting a protrusion 21 provided on the member 20. The protrusion insertion hole 3 penetrates the washer 1 in a thickness direction. The washer 1 is embedded in the foam molded article 10 in such a manner that an outer circumferential side of the peripheral edge of the protrusion insertion hole 3 is embedded in the foamed synthetic resin. A height increased part 4 is formed on an outer circumferential side of the washer 1, wherein in the height increased part, a height Ht from the back face of the washer 1 to the front face is larger than the thickness in the peripheral edge of the protrusion insertion hole 3 of the washer 1.

Description

  The present invention relates to a washer embedded in a foam molded body and used to attach the foam molded body to a member, a foam molded body provided with the washer, a method for producing the foam molded body, and a method for producing the foam molded body. It is related with the attachment structure to a member.

  In addition, in this invention, the front surface of the member to which a foaming molding is attached means the surface facing this foaming molding, and a back surface means the surface on the opposite side to this foaming molding. Further, the front surface of the foamed molded product and the washer means a surface opposite to the member in a state where the foamed molded product is attached to the member, and the back surface is a surface on the member side.

  An automobile door trim may be abbreviated as an EA material (hereinafter referred to as an EA material) made of foamed synthetic resin such as rigid urethane foam for energy absorption (EA) at the time of side collision (side collision). .) Is attached. As a method of attaching the foamed synthetic resin EA material to the door trim, Patent Document 1 (Japanese Patent Laid-Open No. 2011-51162) describes the structure shown in FIGS. 9 is a perspective view of the EA material described in FIG. 6 of Patent Document 1, and FIG. 10 is a cross-sectional view of the EA material mounting structure described in FIG.

  In this conventional example, a washer 110 is provided integrally with a foamed synthetic resin EA material 100. As shown in FIGS. 9 and 10, the washer 110 includes a cylindrical tube portion 111 having an inner hole 111a, and flange portions 112 and 112 provided on both ends of the tube portion 111 in the direction of the center axis of the tube. It has. The EA material 100 includes a main body portion 101 and an attachment portion 102 in which a washer 110 is disposed. The attachment portion 102 extends sideways from the side surface of the main body portion 101 along the back surface (surface on the door trim 120 side) of the main body portion 101, or an extension portion having a smaller thickness than the main body portion 101, or It consists of a recess or the like that is recessed from the front surface (surface opposite to the door trim 120) of the main body 101 to the back surface side.

  At the time of foam molding of the EA material 100, a washer 110 is attached in a molding die (not shown), and the foamed synthetic resin stock solution is foamed in the mold, so that the washer 110 is embedded in the foamed synthetic resin. And integrated with the EA material 100.

  As shown in FIG. 10, a projection 121 made of a thermoplastic resin such as polyethylene or polypropylene protrudes from the door trim 120. When attaching the EA material 100 to the door trim 120, the protrusion 121 is inserted into the inner hole 111a of the cylindrical portion 111 of the washer 110, and the tip of the protrusion 121 is protruded from the inner hole 111a. Next, a welding jig (not shown) is pressed against the tip of the projection 121, and the tip of the projection 121 is enlarged (crimped) as shown in FIG. 10 to form a flange-shaped enlarged portion 121a. Thereby, the protrusion 121 cannot be removed from the inner hole 111 a, and the EA material 100 is fixed to the door trim 120.

  Patent Document 2 (Japanese Patent Application Laid-Open No. 2005-207524) describes that a flat washer (referred to as a reinforcing piece in Patent Document 2) is provided on the attachment portion of the EA material. In Patent Document 2, a mounting hole through which the projection of the door trim is inserted is provided in the mounting portion of the EA material. The flat washer is also provided with a protrusion insertion hole (protrusion insertion hole). This protrusion insertion hole penetrates the flat washer in the thickness direction. The flat washer is embedded in the attachment portion of the EA material so that the protrusion insertion hole overlaps the attachment hole coaxially. In Patent Document 2, the flat washer extends from the inside of the attachment portion of the EA material to the inside of the main body portion.

  In Patent Document 2, a through hole that penetrates the flat plate washer in the thickness direction is provided in a portion of the flat plate washer that is buried in the foamed synthetic resin of the EA material, and at the time of integral molding with the EA material. It is described that the synthetic property of the flat plate washer and the EA material is improved by inserting a foamed synthetic resin into the through hole.

JP 2011-51162 A JP 2005-207524 A

  In Patent Document 1, the washer 110 has a cylindrical portion 111 and has a large thickness. Therefore, the protrusion 121 of the door trim 120 inserted through the inner hole 111a of the cylindrical portion 111 needs to have a protruding height that is the same as the length of the cylindrical portion 111 in the cylindrical axis direction. However, as the protrusion height of the protrusion 121 increases, there is a higher possibility that the door trim 120 will sink on the back side of the protrusion 121 when the door trim 120 is formed.

  In Patent Document 2, since the washer has a flat plate shape and a small thickness, the protrusion height of the protrusion of the door trim inserted into the protrusion insertion hole of the flat plate washer can be made relatively small. . Thereby, when molding the door trim, it is possible to prevent or suppress the occurrence of sink marks on the door trim on the back side of the projection.

  However, since the flat washer tends to have a small contact area with the EA material in the thickness direction, it may be difficult to improve the bonding strength with the EA material.

  The present invention solves such problems, makes it possible to relatively reduce the protruding height of the protrusion for mounting the foam molded body provided on the member, and simplifies the bonding strength with the foam molded body. It is an object of the present invention to provide a washer that can be made sufficiently high with a simple structure. Another object of the present invention is to provide a foamed molded product provided with the washer, a method for producing the foamed molded product, and a structure for attaching the foamed molded product to a member.

  The washer of the present invention (Claim 1) is a washer embedded in a foam molded body made of a synthetic foamed resin, and is attached to a member. The washer is plate-like as a whole. The washer has a protrusion insertion hole through which a protrusion provided on the member is inserted, and the protrusion insertion hole penetrates the washer in the thickness direction, and the protrusion of the washer In the washer embedded in the foamed molded product so that the outer peripheral side of the peripheral portion of the insertion hole is buried in the foamed synthetic resin, the height from the back side of the washer to the front side is on the outer peripheral side of the washer. A height increasing portion that is larger than the thickness at the peripheral edge portion of the protrusion insertion hole of the washer is provided.

  The washer according to claim 2 is the washer according to claim 1, wherein a height from the back surface side to the front surface side of the washer in the height increasing portion is a thickness of the peripheral portion of the protrusion insertion hole of the washer +2 to 30 mm. It is characterized by this.

  A washer according to claim 3 is the washer according to claim 1 or 2, wherein an overhanging portion projecting from the plate surface of the washer is provided on the outer peripheral side of the washer so as to increase the height from the back surface side to the front surface side of the washer. It is provided, The said height increase part is formed by this overhang | projection part, It is characterized by the above-mentioned.

  The washer according to claim 4 is the washer according to any one of claims 1 to 3, wherein a non-height increasing portion in which the height increasing portion is partially absent is provided on an outer peripheral side of the washer. It is characterized by being.

  The washer according to claim 5 is the washer according to claim 4, wherein the portion that is the non-height-enhancing portion of the outer peripheral edge of the washer is closer to the center of the washer than the portion that is the height-enhancing portion. It is characterized in that it is a concave portion that is recessed.

  The foamed molded product of claim 6 comprises a molded product body made of a foamed synthetic resin, and the washer according to any one of claims 1 to 5 embedded in the molded product body. .

  According to a seventh aspect of the present invention, there is provided a foam molded article according to the sixth aspect, wherein the foam molded article is an impact absorbing material.

  The method for producing a foam molded article according to claim 8 is a method for producing the foam molded article according to claim 6 or 7 using a foam molding die, wherein the washer is attached to an inner surface of the foam molding die. A washer mounting step and a foam molding step of foaming a foamed synthetic resin in the foam molding die and molding the molded body main body after the washer mounting step.

  The foam molded body mounting structure according to claim 9 is a structure in which the foam molded body according to claim 6 or 7 is mounted to a member, and a protrusion provided on the member is inserted into a protrusion insertion hole of the washer. The foam molded body is attached to the member via the washer by forming an enlarged portion having a diameter larger than that of the protrusion insertion hole on the tip end side of the protrusion.

  According to a tenth aspect of the present invention, there is provided the foam molded body mounting structure according to the ninth aspect, wherein the enlarged portion is formed by caulking the tip of the protrusion.

  The washer of the present invention (Claim 1) is plate-like as a whole and can be made thinner than the washer 110 of Patent Document 1. Therefore, when the washer is embedded in a foamed molded product. The distance from the back surface of the foam molded body to the front surface of the washer can be made relatively small. Thereby, when attaching a foaming molding to a member, the protrusion height from the said member of the protrusion inserted in the protrusion insertion hole of this washer can also be made comparatively small. As a result, when forming the member, it is possible to prevent or suppress the occurrence of sink marks on the member on the back side of the protrusion.

  In this washer, the height from the back surface side to the front surface side of the washer is larger than the thickness at the peripheral edge portion of the projection insertion hole of the washer on the outer peripheral side of the washer embedded in the foam molded body. Since the height increasing portion is formed, the contact area with the foamed synthetic resin in the thickness direction of the washer can be increased as compared with the washer of Patent Document 2. Thereby, it is possible to improve the joint strength of a washer and a foaming molding with a simple structure.

  The washer and the foamed molded article can be obtained by setting the height from the back surface side to the front surface side of the washer at the height increasing portion to the thickness of the peripheral edge portion of the protrusion insertion hole of the washer +2 to 30 mm. The bond strength with can be sufficiently improved.

  As described in claim 3, by providing an overhanging portion that projects from the plate surface of the washer so as to increase the height from the back surface side to the front surface side of the washer on the outer peripheral side of the washer, It can be formed easily. In addition, by providing the overhanging portion that projects from the plate surface of the washer in this way, it is possible to effectively prevent the washer from moving in the direction of the plate surface of the washer.

  As described in claim 4, by providing the non-height increase portion where the height increase portion is partially absent on the outer peripheral side of the washer, the foamed synthetic resin is not in the non-height form during the foam molding of the foam molded body. It is possible to enter the center side of the washer through the height increasing portion rather than the height increasing portion. Thereby, it is possible to effectively prevent the occurrence of molding defects such as a lack of thickness on the center side of the washer with respect to the height increasing portion.

  In this non-height increasing portion, the foamed synthetic resin is formed at the time of foam molding of the foam molded body by forming a recess by recessing the outer peripheral edge of the washer toward the center of the washer. Since it can enter the center side of the washer through the concave portion rather than the height increasing portion, it can more effectively prevent the occurrence of molding defects such as lacking in the center side of the washer than the height increasing portion. Can do. Moreover, it is possible to effectively prevent the washer from trying to rotate around the axial center line of the protrusion insertion hole by the foamed synthetic resin entering the recess.

  The foamed molded product of the present invention (Claim 6) is formed by embedding the washer of the present invention in the molded product main body. In the foamed molded product of the present invention, the bonding strength between the molded product main body and the washer can be improved with a simple configuration.

  As described in claim 7, the foamed molded article of the present invention is suitable for an impact absorbing material.

  According to the method for producing a foamed molded product of the present invention (invention 8), a foamed molded product with improved bonding strength between the molded product main body and the washer can be produced with a simple configuration.

  According to the foam molded body mounting structure of the present invention (Claim 9), the height of the protrusion of the member inserted into the protrusion insertion hole of the washer can be made relatively small. It is possible to prevent or suppress the occurrence of sink marks on the member on the back side of the protrusion.

  As described in claim 10, in order to form an enlarged portion at the tip of the protrusion, it is convenient and preferable to crimp the tip of the protrusion.

It is a top view and a sectional view of a washer concerning an embodiment. It is sectional drawing which shows the manufacturing process of the foaming molding provided with the washer of FIG. It is sectional drawing which shows the attachment structure to the member of the foaming molding provided with the washer of FIG. It is a top view and a sectional view of a washer concerning an embodiment. It is a top view and a sectional view of a washer concerning an embodiment. It is a top view and a sectional view of a washer concerning an embodiment. It is a top view and a sectional view of a washer concerning an embodiment. It is the perspective view and sectional drawing of a washer concerning an embodiment. It is a perspective view of the impact-absorbing material provided with the washer which concerns on a prior art example. It is sectional drawing which shows the attachment structure to the door trim of the shock absorber of FIG.

  Hereinafter, embodiments will be described with reference to the drawings. In the following embodiments, an impact absorbing material (hereinafter sometimes abbreviated as EA material) attached to a vehicle door trim is exemplified as the foam molded body. However, the present invention is not limited to this. The present invention is also applicable to a molded body, a manufacturing method thereof, and a structure for mounting a foam molded body to a member other than a door trim.

[First Embodiment]
1 (a) is a plan view of the washer according to the first embodiment, FIG. 1 (b) is a cross-sectional view taken along line BB of FIG. 1 (a), and FIG. It is sectional drawing which follows the CC line of Fig.1 (a). FIGS. 2 (a) and 2 (b) are longitudinal sectional views of a mold for foam molding showing a method for producing an EA material as a foam molded body provided with this washer, and FIG. 2 (a) is a foam. A state before foaming of the synthetic resin stock solution is shown, and FIG. 2 (b) shows a state where foaming is completed. FIG. 3 (a) is a longitudinal sectional view showing a mounting structure in which this EA material is attached to a door trim as a member, and FIG. 3 (b) is a sectional view taken along line BB in FIG. 3 (a). FIG. In the following description, the front surface of the EA material and the washer refers to a surface opposite to the door trim in a state where the EA material is attached to the door trim, and the rear surface refers to a surface on the door trim side.

  In this embodiment, the washer 1 is provided integrally with the EA material 10 as a foamed molded body. The EA material 10 is made of a foamed synthetic resin such as rigid urethane foam. The EA material 10 is attached to the door trim 20 of the vehicle. From the EA material mounting surface of the door trim 20, a protrusion 21 for fixing the EA material 10 is provided. In this embodiment, the protrusion 21 is made of a thermoplastic resin such as polyethylene or polypropylene. In this embodiment, the protrusion 21 is integrally formed of the same material as the door trim 20. The configuration of the door trim 20 is not limited to this. For example, the protrusion 21 may be made of a material suitable for caulking, and a portion other than the protrusion 21 of the door trim 20 may be made of a material different from the protrusion 21.

  As shown in FIGS. 1 (a) to (c), the washer 1 is plate-shaped as a whole. In this embodiment, the washer 1 has a flat main plate portion 2 having a relatively small thickness as a whole, and a protrusion insertion hole through which the protrusion 21 of the door trim 20 passes through the main plate portion 2 in the thickness direction. 3 and on the outer peripheral side of the main plate portion 2, the main plate portion 2 protrudes from the front surface and the back surface so as to increase the height Ht (FIG. 1 (b)) from the back surface side to the front surface side of the washer 1. A plurality of overhang portions 4 are provided. That is, in this embodiment, the overhanging portion 4 forms a height increasing portion on the outer peripheral side of the washer 1. In addition, the formation method of the height increase part on the outer peripheral side of the washer 1 is not limited to this.

  As shown in FIG. 1A, in this embodiment, a plurality of the overhang portions 4 are provided at intervals in the extending direction of the outer peripheral edge of the main plate portion 2. That is, in this embodiment, a non-height increase portion where there is no height increase portion between the protruding portions 4 adjacent to each other in the extending direction of the outer peripheral edge of the main plate portion 2 is a non-height increase portion. Yes. In this embodiment, the protrusion insertion hole 3 is disposed at the center of the main plate portion 2, and each overhanging portion 4 is disposed at substantially the same distance from the center of the protrusion insertion hole 3. The portion of the main plate portion 2 between each overhanging portion 4 and the protrusion insertion hole 3 has a substantially constant thickness Tm.

  The same number (eight in this embodiment) of overhang portions 4 are provided on the front side and the back side of the main plate portion 2. As shown in FIGS. 1 (b) and 1 (c), the overhang portions 4 on the front surface side and the back surface side of the main plate portion 2 are arranged so as to be positioned on the same phase around the axial center line of the protrusion insertion hole 3. Has been. In this embodiment, each overhanging portion 4 has a wall shape extending along the outer peripheral edge of the main plate portion 2, and the wall-like overhanging portions 4 are the axes of the protrusion insertion holes 3. It is curved in a concentric arc around the core.

  Note that the shape, number and arrangement of the overhang portions 4 are not limited to this. For example, 7 or less or 9 or more overhang portions 4 may be provided on the front side and the back side of the main plate portion 2, respectively. In addition, it is preferable that three or more overhang portions 4 are provided on the front side and the back side of the main plate portion 2, respectively. With this configuration, it is possible to more effectively prevent the washer 1 embedded in the EA material 10 from shifting in the direction of the plate surface by the overhang portions 4. The overhanging portion 4 on the front surface side and the overhanging portion 4 on the back surface side of the main plate portion 2 may be arranged with a phase shift around the axial center line of the protrusion insertion hole 3. The number of the overhang portions 4 may be different between the front side and the back side of the main plate portion 2. Since the washer 1 has a symmetrical shape, for example, when the washer 1 is installed in the EA material molding die 30 as described later, the washer 1 can be installed regardless of the front and back. The manufacturing work of the EA material 10 is facilitated.

  In this embodiment, as shown in FIG. 1 (a), the envelope E enveloping the outer peripheral surfaces of the overhang portions 4 is substantially circular. Hereinafter, the shape of the envelope E is referred to as a schematic plan view shape of the washer 1. The rough plan view shape of the washer 1 is easy to mold and can be installed regardless of the orientation when the washer 1 is installed in the mold 30, as in this embodiment. Although it is preferable that it is circular, it is not limited to this.

  In this embodiment, on the outer peripheral edge of the main plate portion 2, the portion (non-height increasing portion) between the overhanging portions 4 adjacent to each other in the extending direction is the center side of the main plate portion 2. A recessed portion 5 having a notch shape is formed. Each concave portion 5 is recessed to the center side of the main plate portion 2 from each overhang portion 4. As shown in FIG. 1 (a), each recess 5 has a substantially C-shaped plan view shape in which the width (width in the direction perpendicular to the radial direction of the envelope E. The same applies hereinafter) becomes narrower toward the inlet side. . In addition, the shape of the recessed part 5 is not limited to this.

  It is preferable that the thickness Tm of the main plate portion 2 between the protrusion insertion hole 3 and each overhang portion 4 and the recess portion 5 is 0.5 to 3 mm, particularly 1 to 2 mm. The inner diameter of the protrusion insertion hole 3 is preferably 4 to 10 mm, particularly 6 to 8 mm. The outer diameter of the envelope E is preferably 8 to 40 mm, particularly 15 to 25 mm. The protruding height Hp (FIG. 1 (b)) of each protruding portion 4 from the front surface and the back surface of the main plate portion 2 is preferably 1 to 15 mm, particularly 3 to 5 mm. That is, the height Ht from the back surface side to the front surface side of the washer 1 at the height increasing portion of the washer 1 is the thickness Tm + 2 to 30 mm of the main plate portion 2 at the peripheral edge portion of the protrusion insertion hole 3, especially the thickness of the main plate portion 2. Tm + 6 to 10 mm is preferable. In this embodiment, since the overhang portions 4 are provided on the front surface and the back surface of the washer 1, respectively, the height Ht from the back surface side to the front surface side of the washer 1 in the height increasing portion is the front surface. This is the total value of the height Hp of the overhanging portion 4 on the side, the height Hp of the overhanging portion 4 on the back surface side, and the thickness Tm of the main plate portion 2. If the overhanging portion 4 is provided only on one plate surface of the washer 1, the height Ht is the height Hp of the overhanging portion 4 of this one plate surface and the height of the main plate portion 2. The total value with the thickness Tm.

The thickness T _P (FIG. 1 (b)) of each overhang portion 4 in the radial direction of the envelope E is preferably 0.5 to 3 mm, particularly preferably 1 to 2 mm. It is preferable that the space | interval S (FIG. 1 (a)) of the overhang | projection parts 4 adjacent to the extension direction of the outer periphery of the main-plate part 2 is 3-20 mm, especially 5-10 mm. The maximum width W (FIG. 1 (a)) of each recess 5 is preferably 5 to 25 mm, particularly 8 to 15 mm. The distance D (FIG. 1 (a)) from the envelope E to the innermost part of each recess 5 is preferably 2 to 15 mm, particularly 3 to 10 mm.

  The material constituting the washer 1 is preferably polypropylene, polyethylene, nylon, urethane, or the like, but is not limited thereto. As a method for manufacturing the washer 1, injection molding using these resins is suitable, but is not limited thereto. In this embodiment, the main plate portion 2 and each overhang portion 4 are integrally formed of a common material, but are not limited thereto.

  As shown in FIGS. 3A and 3B, the EA material 10 in which the washer 1 is integrally provided has a main body portion 11 and an attachment portion 12 on which the washer 1 is disposed. The attachment portion 12 is provided with an attachment hole 13 through which the protrusion 21 of the door trim 20 is inserted. In this embodiment, the attachment portion 12 is formed of an extension portion that extends laterally from the side surface of the main body portion 11 along the back surface of the main body portion 11 and has a smaller thickness than the main body portion 11. The washer 1 has a plate surface (front surface and back surface) of the main plate portion 2 in a direction substantially parallel to the back surface of the mounting portion 12, and the projection insertion hole 3 is substantially coaxial with the mounting hole 13. It is buried in the middle. The inner diameter of the mounting hole 13 is larger than the inner diameter of the protrusion insertion hole 3 of the washer 1 and smaller than the distance from the protrusion insertion hole 3 to the innermost part of each recess 5. As a result, the washer 1 is exposed in the mounting hole 13 at the peripheral edge of the protrusion insertion hole 3 of the main plate 2 (the portion closer to the protrusion insertion hole 3 than the innermost part of each recess 5). The sides (the overhang portions 4 and the recesses 5) are buried in the attachment portion 12.

  The configuration of the EA material 10 is not limited to this. For example, the attachment portion 12 may be formed by a recess or the like that is recessed from the front surface to the back surface side of the main body portion 11.

  In this EA material 10, the distance K (FIG. 3 (a)) from the back surface of the attachment portion 12 to the front surface of the main plate portion 2 of the washer 1 embedded in the attachment portion 12 is 5 to 20 mm, particularly 5 to 5 mm. 10 mm is preferable. The thickness of the mounting portion 12 is preferably the distance K + 10 to 100 mm, particularly the distance K + 10 to 50 mm.

Next, the mold 30 for foam-molding the EA material 10 will be described. As shown in FIGS. 2 (a) and 2 (b), in this embodiment, the mold 30 has a lower mold 31 and an upper mold 32. In this embodiment, the EA material 10 is molded in the mold 30 with the front face facing downward. That is, the front surface side of the EA material 10 is molded by the lower mold 31, and the rear surface side of the EA material 10 is molded by the upper mold 32. In the mold 30, a first cavity space R ₁ for molding the main body portion 11 of the EA material 10 and a second cavity space R ₂ for molding the attachment portion 12 are provided. A cavity R ₁ of the first second and the cavity space R _2, along the cavity ceiling surface of the upper mold 32 is continuous, the second depth of the cavity R ₂ in the lower mold 31, It is shallower than the first cavity space R _1.

From the cavity ceiling surface of the cavity bottom surface and the upper mold 32 of the lower die 31 facing the second cavity R _2, respectively, the mounting hole-forming convex part for forming a mounting hole 13 in the mounting portion 12 of the EA material 10 33 and 34 project. These mounting holes forming convex part 33 protrudes into the second cavity space R within ₂ coaxially with each other. In the mold 30, the main plate portion 2 of the washer 1 is interposed between the front end surfaces in the protruding direction of the mounting hole forming convex portions 33 and 34 in a state where the lower die 31 and the upper die 32 are clamped. The gap is configured to be open. From the tip surface of the mounting hole forming convex portion 33 on the lower mold 31 side, a protruding portion 35 that engages with the protruding insertion hole 3 of the washer 1 protrudes. The protrusion 35 is arranged coaxially with the mounting hole forming convex portion 33.

  When the EA material 10 is molded using this mold 30, first, the lower mold 31 and the upper mold 32 are opened, and the washer 1 is placed on the mounting hole forming convex portion 33 on the lower mold 31 side. The protrusion 35 is engaged with the protrusion insertion hole 3 of the washer 1. Then, the foamed synthetic resin stock solution is injected into the lower mold 31 and the lower mold 31 and the upper mold 32 are clamped. Thereby, the washer 10 is hold | maintained between the convex parts 33 and 34 for attachment hole formation as FIG. 2 (a). Thereafter, the foamed synthetic resin stock solution is heated and foamed.

The foamed synthetic resin, the first cavity space R ₁ flows second into the cavity R _2, continue to fill the periphery of the washer 1 and the mounting hole-forming convex part 33 and 34. Thereby, the outer peripheral side (each overhang | projection part 4 and the recessed part 5) is embedded in the foamed synthetic resin rather than the peripheral part of the protrusion insertion hole 3 of the main plate part 2 in the washer 1, and the washer 1 is integrated with the EA material 10. Is done. At this time, part of the foamed synthetic resin wraps around between the protruding portions 4 of the washer 1 and between the protruding portions 4 and the mounting hole forming convex portions 33 and 34 through the concave portions 5. Thereby, each overhang | projection part 4 and the convex parts 33 and 34 for attachment hole formation are fully filled with foaming synthetic resin.

  After the foamed synthetic resin is cured, the mold is opened to remove the EA material 10. Then, the EA material 10 is completed by performing the finishing process of the surface of the EA material 10 as needed.

  When attaching the EA material 10 with the washer 1 to the door trim 20, as shown in FIGS. 3A and 3B, the projection 21 of the door trim 20 is inserted through the attachment hole 13 of the attachment portion 12 of the EA material 10. The projection 21 is inserted into the projection insertion hole 3 of the washer 1, and the tip of the projection 21 is projected to the front side of the washer 1. Next, a welding jig (not shown) is pressed against the tip of the projection 21 to enlarge (crimp) the tip of the projection 21, and the flange-like enlarged portion 22 having a diameter larger than that of the projection insertion hole 3. Form. Thereby, the protrusion 21 cannot be removed from the protrusion insertion hole 3, and the EA material 10 is fixed to the door trim 20.

  US caulking is preferred as a method of caulking the tip of the protrusion 21 to form the enlarged portion 22, but is not limited thereto.

  The effects achieved by this washer 1 are as follows.

  The washer 1 is plate-like as a whole, and can be made thinner than the washer 110 of Patent Document 1. Therefore, when the washer 1 is embedded in the mounting portion 12 of the EA material 10, The distance K from the back surface of the mounting portion 12 to the front surface of the main plate portion 2 of the washer 1 can be made relatively small. Thereby, when attaching the EA material 10 to the door trim 20, the protrusion height from the door trim 20 of the protrusion 21 inserted into the protrusion insertion hole 3 of the washer 1 can also be made relatively small. As a result, it is possible to prevent or suppress the occurrence of sink marks in the door trim 20 on the back side of the protrusion 21 when the door trim 20 is molded.

  In this washer 1, the height Ht from the back surface side to the front surface side of the washer 1 on the outer peripheral side of the main plate portion 2 embedded in the EA material 10 is at the peripheral edge portion of the protrusion insertion hole 3 of the main plate portion 2. Since the height increasing part (in this embodiment, each overhang | projection part 4) which is larger than thickness Tm is formed, compared with the washer of patent document 2, in the thickness direction of this washer 1 The contact area with the foamed synthetic resin can be increased. Thereby, it is possible to improve the joint strength between the washer 1 and the EA material 10 with a simple configuration.

  As described above, the height Ht from the back surface side to the front surface side of the washer 1 in the height increasing portion is set to the thickness Tm + 2 to 30 mm of the main plate portion 2 in the peripheral edge portion of the protrusion insertion hole 3. The bond strength with the EA material 10 can be sufficiently improved.

  As in this embodiment, the overhanging portions 4 projecting from the front and back surfaces of the main plate portion 2 so as to increase the height Ht from the back surface side to the front surface side of the washer 1 on the outer peripheral side of the main plate portion 2. By providing this, the height increasing portion can be easily formed. In addition, by providing the overhang portions 4 that project from the front surface and the back surface of the main plate portion 2 in this way, it is possible to effectively prevent the washer 1 from shifting in the plate surface direction of the main plate portion 2.

  In this embodiment, a plurality of overhang portions 4 are provided at intervals in the extending direction of the outer peripheral edge of the main plate portion 2. That is, between the overhanging parts 4 adjacent to each other in the extending direction of the outer peripheral edge of the main plate part 2, the height increasing part is a non-height increasing part that is not present. Therefore, at the time of foam molding of the EA material 10, the foamed synthetic resin can enter the center side of the main plate portion 2 from each overhang portion 4 through this non-height increased portion. Thereby, it is possible to effectively prevent a molding defect such as a lack of thickness from occurring on the center side of the main plate portion 2 relative to the overhang portions 4.

  In this embodiment, each of the outer peripheral edges of the main plate portion 2 between the protruding portions 4 adjacent to each other in the extending direction of the outer peripheral edge of the main plate portion 2 (non-height increasing portion) A notch-shaped recess 5 is formed which is recessed toward the center side of the main plate 2 from the overhang 4. Thereby, at the time of foam molding of the EA material 10, the foamed synthetic resin can enter the center side of the main plate portion 2 through the recesses 5 rather than the respective overhang portions 4. It is possible to more effectively prevent the occurrence of molding defects such as lack of thickness on the center side of the portion 2. Moreover, it is possible to effectively prevent the washer 1 from rotating about the axial center line of the protrusion insertion hole 3 by the foamed synthetic resin entering each recess 5.

[Other configuration examples of washers]
FIG. 4 (a) is a plan view of the washer according to the second embodiment, and FIG. 4 (b) is a cross-sectional view taken along line BB of FIG. 4 (a). FIG. 5 (a) is a plan view of the washer according to the third embodiment, and FIG. 5 (b) is a cross-sectional view taken along the line BB of FIG. 5 (a). FIG. 6 (a) is a plan view of the washer according to the fourth embodiment, and FIG. 6 (b) is a sectional view taken along line BB in FIG. 6 (a). FIG. 7 (a) is a plan view of the washer according to the fifth embodiment, and FIG. 7 (b) is a cross-sectional view taken along the line BB of FIG. 7 (a). FIG. 8 (a) is a perspective view of the washer according to the sixth embodiment, and FIG. 8 (b) is a sectional view taken along the line BB of FIG. 8 (a).

  In the above embodiment, the overhanging portion 4 has a wall shape extending along the outer peripheral edge of the main plate portion 2, but the shape of the overhanging portion is not limited to this. For example, it may be cylindrical like the overhanging portion 4A in the washer 1A in FIGS. 4 (a) and 4 (b), and the overhanging portion 4B in the washer 1B in FIGS. 5 (a) and 5 (b). A conical shape may be used, and a triangular pyramid shape may be used like the overhanging portion 4C of the washer 1C in FIGS. 6 (a) and 6 (b). Of course, the protruding portion may have a shape other than these.

  Note that in the washer 1C of FIGS. 6 (a) and 6 (b), on the front side and the back side of the washer 1C, the overhang portions 4C are spaced in the extending direction of the outer peripheral edge of the main plate portion 2, respectively. Are provided, and recesses 5 are formed between the protruding portions 4C and 4C adjacent to each other in the extending direction of the outer peripheral edge of the main plate portion 2 (that is, in this embodiment, the recesses are 3 is also provided at intervals in the extending direction of the outer peripheral edge of the main plate portion 2). Thus, if at least three overhang portions are provided on the front side and the back side of the washer, it is possible to effectively prevent the washer embedded in the EA material from moving in the direction of the plate surface. is there.

  In said embodiment, in the outer peripheral edge of the main plate part 2, each of the parts (non-height increase parts) between the overhanging parts 4 adjacent to each other in the extending direction of the outer peripheral edge of the main plate part 2, Although a notch-like recess 5 that is recessed toward the center of the main plate portion 2 is formed, the recess 5 may be omitted as in the washer 1D of FIGS. 7 (a) and 7 (b).

  In the above-described embodiment, the overhanging portions 4 that protrude from the front surface and the back surface of the main plate portion 2 are provided on the outer peripheral side of the main plate portion 2 so as to increase the height Ht from the back surface side to the front surface side of the washer. Thus, the height increasing portion is formed, but the method of forming the height increasing portion is not limited to this. For example, the washer 1E of FIG. 8 has a main plate portion 2 ′ having a substantially circular shape in plan view, and the main plate portion 2 ′ has a front surface and a back surface that are closer to the center of the main plate portion 2, respectively. It is curved in a bowl shape so as to approach. Thereby, the outer peripheral side of the main plate portion 2 'has a height Ht from the back surface side to the front surface side of the washer 1E larger than the thickness Tm at the peripheral edge portion of the projection insertion hole 3 of the main plate portion 2'. It is an increasing part 6. In addition, the shape of the front surface and the back surface of the main plate portion 2 ′ is not limited to a mortar shape. For example, the thickness increases stepwise from the peripheral edge of the protrusion insertion hole 3 of the main body portion 2 ′ toward the outer peripheral side. The shape which becomes may be sufficient.

  Note that each of the above configurations is an example of the present invention, and the present invention may have a configuration other than the above.

DESCRIPTION OF SYMBOLS 1,1A-1E Washer 2,2 'Main board part 3 Protrusion insertion hole 4,4A-4C Overhang | projection part 5 Concave part 6 Height increase part 10 EA material 11 Main body part 12 Attachment part 13 Attachment hole 20 Door trim 21 Protrusion 22 Expansion part 30 Mold for foam molding 31 Lower mold 32 Upper mold 33, 34 Mounting hole forming convex part 35 Protruding part

Claims (10)

A washer embedded in a foam molded body made of a foamed synthetic resin, for attaching the foam molded body to a member,
The washer is plate-like as a whole,
The washer has a protrusion insertion hole through which a protrusion provided on the member is inserted,
The protrusion insertion hole penetrates the washer in the thickness direction,
In the washer embedded in the foamed molded product so that the outer peripheral side of the washer is inserted into the foamed synthetic resin with respect to the peripheral edge of the projection insertion hole,
A height increasing portion is provided on the outer peripheral side of the washer, wherein the height from the back surface side to the front surface side of the washer is larger than the thickness at the peripheral edge portion of the projection insertion hole of the washer. Characteristic washer.   2. The washer according to claim 1, wherein a height from the back surface side to the front surface side of the washer in the height increasing portion is a thickness of the peripheral portion of the protrusion insertion hole of the washer +2 to 30 mm. In Claim 1 or 2, the overhang part which projects from the plate surface of the washer is provided on the outer peripheral side of the washer so as to increase the height from the back surface side to the front surface side of the washer,
The washer characterized in that the height increasing portion is formed by the overhanging portion.   The washer according to any one of claims 1 to 3, wherein a non-height increasing portion in which the height increasing portion is partially absent is provided on an outer peripheral side of the washer. .   In Claim 4, The part which is the said non-height increase part among the outer periphery parts of the said washer becomes a recessed part dented in the center side of this washer rather than the part which is the said height increase part. A washer characterized by being. A molded body made of foamed synthetic resin;
A foamed molded article comprising the washer according to any one of claims 1 to 5, embedded in the molded article main body.   The foamed molded product according to claim 6, wherein the foamed molded product is an impact absorbing material. A method for producing a foamed molded article according to claim 6 or 7, using a foam molding die,
A washer attachment step of attaching the washer to the inner surface of the foam molding die;
After the washer mounting step, a foam molding step is performed in which a foamed synthetic resin is foamed in the foam molding die to mold the molded body. A structure in which the foam molded article according to claim 6 or 7 is attached to a member,
The protrusion provided on the member is inserted into the protrusion insertion hole of the washer, and an enlarged portion having a larger diameter than the protrusion insertion hole is formed on the tip end side of the protrusion, so that foam molding is performed via the washer. A foam-molded body mounting structure, wherein the body is mounted on a member.   In Claim 9, The said enlarged part is formed by crimping the front-end | tip of the said protrusion, The mounting structure of the foaming molding characterized by the above-mentioned.

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