JP4472583B2 - Foaming tools - Google Patents

Description

  The present invention relates to a foaming tool used by being supported on a supported portion in various structural members and the like.

Conventionally, a structural member typified by a vehicle pillar or the like sometimes generates abnormal noise due to vibration of the structural member. Therefore, in order to suppress the occurrence of such abnormal noise, it has been proposed to attach a foam to the structural member (see, for example, Patent Document 1). That is, since the vibration of the structural member is reduced by the foam, abnormal noise generated from the structural member is suppressed.
JP-A-1-170683

  By the way, in a structural member, in addition to generation | occurrence | production of the abnormal noise resulting from transmission of a vibration, malfunctions, such as a deformation | transformation resulting from a load being added, may arise. In the conventional foaming tool, for example, although a certain suppression effect can be obtained with respect to the occurrence of abnormal noise, it is difficult to obtain a certain suppression effect with respect to deformation. In other words, the conventional foaming tool has a certain suppression effect for one defect, but it is difficult to obtain a certain suppression effect for other defects.

  The present invention has been made in view of such conventional circumstances, and an object thereof is to provide a foaming tool that can easily suppress various problems.

In order to achieve the above-mentioned object, the invention according to claim 1 is a flat plate-like member in which a foam member formed of a foam material that is foamed by external heating and a structural member that is formed in a hollow shape are supported by the foam member . A foaming tool comprising a support member, wherein the foaming member is a first foaming member formed from a first foaming material and a second foaming member formed from a second foaming material having a composition different from that of the first foaming material. The first foam member and the second foam member are laminated in the thickness direction of the support member, and at least one of the first foam member and the second foam member is provided on the support member. and summary to become supported by the same supporting member by the engagement protrusions.

  According to this configuration, since the first foam material and the second foam material have different compositions, foams having different physical properties are formed by foaming the first foam member and the second foam member by external heating. Will come to be. That is, each foam formed from the first foam member and the second foam member can exhibit different functions.

According to a second aspect of the present invention, in the foaming tool according to the first aspect, the first foaming member and the second foaming member are supported by the support member by an engagement protrusion provided on the support member. Thus, the first foaming member and the second foaming member are characterized in that the engagement protrusion is penetrated and supported.
Thus, for example, the arrangement mode described in claim 2 can be adopted as the arrangement mode of the foaming member in the foaming tool.
According to a third aspect of the present invention, in the foaming tool according to the first or second aspect , the support member includes an engaging portion that is engaged with the hollow structural member. Is the gist.

According to this structure, a foaming tool can be supported now using the engagement of the engaging part with respect to the structural member formed in a hollow shape .
The invention of claim 4, wherein, in the foaming tool according to any one of claims 1 to 3, at least one of the first foam member and the second foam member from adhesive material having a self-adhesive The gist is that it is arranged on the support member via an adhesive member to be formed.

Thus, for example, the support mode of claim 4 can be adopted as a support mode to be supported by the support member of the foam member.

  According to the present invention, it is possible to provide a foaming tool that can easily suppress various problems.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments embodying the present invention will be described in detail with reference to FIGS.
As shown in FIG. 1, the foaming tool 11 includes a foaming member 12 formed from a foaming material, and a support member 13 that supports the foaming member 12 on a supported portion. The foam material forming the foam member 12 is a material that foams by external heating, and the foam member 12 is a member that forms a foam by foaming by the external heating. The foam member 12 includes a first foam member 14 formed from a first foam material and a second foam member 15 formed from a second foam material having a composition different from that of the first foam material. Since the 1st foaming member 14 and the 2nd foaming member 15 are formed from each foaming material of such a different composition, the 1st foam obtained by the 1st foaming member 14 foaming, and the 2nd foaming member 15 The second foam obtained by foaming has different physical properties. That is, the composition of each foam material is appropriately set according to the physical properties required for the first foam and the second foam. Note that the different compositions in the first foam material and the second foam material are not only different in each component of the foamed material, but also the same component in each foam material, It includes that the amount of the component is different for each foamed material.

  If it explains in full detail, the composition of each foaming material can be set according to the function requested | required with respect to each foam, for example. That is, the first foam member 14 and the second foam member 15 can provide, for example, a first foam that exhibits a reinforcing function and a second foam that exhibits a damping function. Moreover, even if each foam obtained from the first foaming member 14 and the second foaming member 15 exhibits the same function, the degree of the function can be changed. In addition, functions required for each foam include a function for increasing rigidity, a sound insulation function, a sound absorption function, an impact absorption function, and the like in addition to a reinforcement function and a vibration suppression function.

  Although the component which comprises each foaming material is not specifically limited, Specifically, a filler, a plasticizer, etc. other than a base material, a foaming agent, and a crosslinking agent are mentioned. Examples of the base material include synthetic resins, elastomers, and rubbers. Synthetic resins are classified into thermosetting resins and thermoplastic resins. Examples of thermosetting resins include epoxy resins, phenol resins, urethane resins, and acrylic resins. Thermoplastic resins include polyolefins, EVA (ethylene / ethylene / ethylene resins). Vinyl acetate copolymer). Examples of the elastomer include SBS (styrene / butadiene / styrene block copolymer), and examples of the rubber include NR (natural rubber), ENR (epoxidized natural rubber), and EPM (ethylene / propylene rubber). Examples of the foaming agent include azodicarbonamide and dinitropentamethylenetetramine, examples of the crosslinking agent include well-known dimethylurea and dicyandiamide, and examples of the filler include calcium carbonate, barium sulfate, ferrite, and silica.

  The first foam member 14 and the second foam member 15 have a square plate shape, and the foam member 12 is formed by laminating the first foam member 14 and the second foam member 15. One surface of the first foam member 14 is an attachment surface 14a, and the support member 13 is attached to the attachment surface 14a. In the foam member 12, the second foam member 15 is configured to be stacked in a substantially vertical direction with respect to the mounting surface 14 a of the first foam member 14.

  The material of the support member 13 may be any material that exhibits a support function as the support member 13 even when the foam member 12 is foamed by external heating to form a foam. That is, for example, the support member 13 may be formed by selecting a material having a predetermined softening temperature according to the foaming temperature at which the foaming member 12 is foamed or the curing temperature at which the foamed material is cured. In particular, when the support member 13 is formed from a synthetic resin, the volume expansion coefficient of the synthetic resin is preferably set to be smaller than the volume expansion coefficient of the foam material constituting the foam member 12. Specific examples of the material of the support member 13 include synthetic resins such as polyamide, various metal materials, and the like.

  The support member 13 of the present embodiment includes a support plate 13a on which the foamed member 12 is supported and an engagement portion 13b connected to the support plate 13a. The support plate 13a has a flat plate shape, and a plurality of engagement protrusions 13c are projected from one surface of the support plate 13a (the upper surface of the support plate 13a in FIG. 1). On the other hand, the first foam member 14 and the second foam member 15 have engagement holes 14b and 15a penetratingly corresponding to the engagement protrusions 13c. As shown in FIGS. 1 and 2, these engaging projections 13 c are sequentially inserted into the engaging holes 14 b and 15 a, and the distal end portion of the engaging projection 13 c is locked to the upper surface of the second foaming member 15. Has been. Due to the relationship between the engagement protrusion 13c and the engagement holes 14b and 15a, the first foam member 14 and the second foam member 15 are integrated, and the foam member 12 is supported by the support plate 13a. When the foamed member 12 (each foamed material) has fluidity due to external heating, the engagement protrusions 13c penetrating the engagement holes 14b and 15a are formed in the first foamed member 14 and the second foamed member 15 ( It also functions as the flow resistance of each foam material.

  As shown in FIGS. 1 and 2, a plurality of connection protrusions 14 c are provided on the upper surface of the first foam member 14. On the other hand, the second foaming member 15 is provided with a connecting hole 15b corresponding to the connecting protrusion 14c. And the 1st foaming member 14 and the 2nd foaming member 15 are connected by inserting the connection protrusion 14c in such a connection hole 15b. When the foamed member 12 (each foamed material) has fluidity due to external heating, the relationship between the connection protrusion 14c and the connection hole 15b is the flow resistance of the second foamed member 15 (second foamed material). Also works.

  The first foam member 14 and the second foam member 15 are molded by, for example, extrusion molding or injection molding. And the foaming tool 11 is manufactured by making the support member 13 shape | molded by injection molding etc. support these 1st foam members 14 and the 2nd foam members 15. FIG.

  As shown in FIG. 3A, the foaming tool 11 is attached to a predetermined part of the structural member 31. More specifically, the structural member 31 of the present embodiment is a member that constitutes a vehicle pillar, for example, and is formed in a hollow shape from a steel plate. An attachment hole 31b is provided through the supported portion 31a of the structural member 31, and the engagement portion 13b is engaged with the attachment hole 31b. Thus, in the foaming tool 11 attached to the structural member 31, the foaming member 12 is supported by the supported portion 31a via the support member 13.

  The structural member 31 to which the foaming tool 11 is applied constitutes a part of the vehicle body, and the vehicle body is subjected to coating such as electrodeposition coating and baking coating. The foaming tool 11 is heated at a predetermined temperature for a predetermined time when the vehicle body is heated in the drying furnace in the manufacturing process of the vehicle. Subsequently, when a predetermined amount of heat moves from the outside to the foam member 12, foaming (expansion) of the foam member 12 is started. Then, the foamed foam member 12 is cured, whereby a foam 21 is formed as shown in FIG. That is, the first foam 22 is formed from the first foam member 14, and the second foam 23 is formed from the second foam member 15. In addition, since the foaming member 12 of this embodiment employ | adopted the structure which the 1st foaming member 14 and the 2nd foaming member 15 laminated | stacked, the foam in which the 1st foam 22 and the 2nd foam 23 make a layer structure 21 will be obtained. A predetermined part of the structural member 31 is filled with the foam 21 thus formed. At this time, since the 1st foam 22 and the 2nd foam 23 are foams formed from each foam material of a different composition, it has a respectively different physical property. For this reason, the foam 21 can be made to exhibit different functions, or even to have the same function, the degree of the function can be changed. For example, the first foam 22 can exhibit the function of reinforcing the structural member 31, while the second foam 23 can exhibit the function of damping the structural member 31. In this case, the structural member 31 to which the foaming tool 11 is applied can be reinforced and the vibration damping performance of the structural member 31 can be enhanced.

  Moreover, in the formation process of such a foam 21, the flow of the first foam material and the second foam material is suppressed by the engagement protrusions 13c penetrating the engagement holes 14b and 15a shown in FIG. For this reason, the phenomenon that each foam material hangs down under the influence of its own weight is suppressed. That is, foaming (expansion) of the foamed material is performed while suppressing the displacement of the foamed material with respect to the supported portion 31a. Further, in the process of forming the foam body 21, the flow of the second foam material is also suppressed by the relationship between the connection protrusion 14c and the connection hole 15b. Therefore, the position of the foamed material is also determined by the connection protrusion 14c and the connection hole 15b. Deviation is suppressed. As described above, since the positional deviation of the foam material is suppressed, the foam 21 is easily placed (filled) at a predetermined position, and as a result, the function of the foam 21 is sufficiently exhibited.

The effects exhibited by this embodiment will be described below.
(1) The foam member 12 includes a first foam member 14 and a second foam member 15, a first foam material that forms the first foam member 14, and a second foam that forms the second foam member 15. The material has a different composition. Therefore, the first foam member 22 and the second foam member 23 having different physical properties are formed by foaming the first foam member 14 and the second foam member 15 by external heating. That is, the first foam 22 and the second foam 23 formed from the first foam member 14 and the second foam member 15 can exhibit different functions. Therefore, it is easy to suppress various problems in the structural member 31 due to different functions of the foam 21 in the structural member 31. Moreover, in the foam 21, even if it is the same function, since the degree of the function can be changed, an appropriate function can be expressed according to the state of the malfunction in the structural member 31. Become.

  (2) Since the support member 13 includes the engagement portion 13b, it is easy to support the foaming tool 11 on the supported portion 31a by using the engagement of the engagement portion 13b with the supported portion 31a. It becomes.

  (3) The support plate 13a is provided with an engagement protrusion 13c. By engaging the engagement protrusion 13c with the first foam member 14 and the second foam member 15, the foam member 12 is supported by the support plate 13a. Has been. In this case, the foam member 12 can be stably supported by the support plate 13a.

The embodiment may be modified as follows.
Below, the foaming tool demonstrated based on FIGS. 4-11 is a foaming tool as a reference example.
The first foam member 14 and the second foam member 15 may be arranged on the same plane without being stacked. For example, as shown in FIGS. 4 and 5, the foaming member 12 includes a first foaming member 14 having a frame shape and a second foaming member 15 having a size that fits inside the first foaming member 14. . The first foam member 14 is disposed on the upper surface of the support plate 13a, and the second foam member 15 is disposed on the inner surface of the first foam member 14 on the upper surface of the support plate 13a. The first foam member 14 and the second foam member 15 are arranged with the upper surface of the support plate 13a as the same plane. As shown in FIG. 6A, the foaming tool 11 is supported by the supported portion 31 a of the structural member 31 via the support member 13. When the structural member 31 is heated from the outside, a predetermined portion of the structural member 31 is filled with the foam 21 as shown in FIG. The foam 21 is formed with a second foam 23 inside the first foam 22.

  The location where the first foam member 14 and the second foam member 15 are arranged is not limited to the upper surface of the support plate 13a. For example, as shown in FIGS. 7A and 7B, the first foam member 14 is disposed on the outer peripheral edge of the support plate 13 a, and the second foam member is disposed on the outer peripheral surface of the first foam member 14. 15 may be stacked and arranged.

  For example, the arrangement | positioning aspect of the foaming member 12 as shown to Fig.8 (a)-FIG.8 (d) is mentioned. In FIG. 8A, the support plate 13a of the above embodiment is used as a support member main body 13d, and the support member 13 is used in which a support plate 13e is erected on the outer periphery of the support member main body 13d. The first foam member 14 is disposed on the outer surface of the support plate 13e, and the second foam member 15 is laminated on the first foam member 14. In FIG.8 (b), the 1st foam member 14 is arrange | positioned surrounding the support plate 13e.

  In FIG. 8C, the support plate 13a of the above embodiment is a support member main body 13d, and a support member 13 is employed in which a pair of upper and lower support plates 13e are erected on the inner periphery of the support member main body 13d. Then, a pair of upper and lower first foam members 14 are arranged on the outer surface of the support plate 13e, and the second foam members 15 are laminated on the first foam members 14, respectively. In FIG.8 (d), the 1st foam member 14 and the 2nd foam member 15 are arrange | positioned at the outer surface of a pair of support plate 13e, respectively.

-You may abbreviate | omit the said engaging part 13b. For example, only the support plate 13a can be used as the support member 13, and the support member 13 can be attached to the supported portion 31a with an adhesive member.
-The shape of the support member 13 is not particularly limited. That is, the support member 13 may be changed to a block shape or the like.

  The engagement protrusion 13c may be omitted. In this case, the first foam member 14 may be provided integrally with the support plate 13a, for example, by injection molding. Examples of the injection molding include insert molding in which the support member 13 is inserted into a mold. Further, for example, the first foam member 14 may be adhered to the support plate 13a with an adhesive, or the first foam member 14 may be interposed via the adhesive member 26 as shown in FIGS. 9 (a) and 9 (b). You may make it support by sticking to the support plate 13a. The adhesive member 26 is formed from an adhesive material having self-adhesiveness. The adhesive material is a material based on a synthetic resin, an elastomer, rubber or the like, and specifically includes a rubber adhesive material, an acrylic adhesive material, a urethane adhesive material, a silicone adhesive material, or the like. For example, examples of the base material of the rubber-based adhesive material include BR (butadiene rubber), IIR (isobutylene / isoprene copolymer rubber), SBR (styrene / butadiene rubber) and the like. The volume expansion coefficient of the adhesive material is set to be smaller than the volume expansion coefficient of the foam material, so that the first foam member 14 is suitably held when the first foam member 14 is foamed by external heating. It is configured. Further, for example, the first foam member 14 may be adhered to the support plate 13a by employing a self-adhesive foam material as the first foam material.

The engaging protrusion 13c may be configured to engage only the first foaming member 14 without engaging the second foaming member 15.
-You may abbreviate | omit the said connection protrusion 14c and the connection hole 15b. In this case, the second foamed member 15 can be laminated on the first foamed member 14 by bonding using an adhesive or bonding using injection molding. Further, by adopting a foam material having self-adhesiveness as at least one of the first foam material and the second foam material, the second foam member 15 may be adhered to the first foam member 14 and laminated. .

  A regulating member that regulates the direction in which the foaming member foams (expands) can be provided on the support member. For example, the support member 25 shown in FIGS. 9A to 9C includes a support plate 25a, a restriction plate 25b as a restriction member standing from both sides of the support plate 25a, and an engaging portion (illustrated). (Omitted). As described above, according to the support member 25 including the restriction plate 25b, the foaming member 12 is easily filled into the predetermined portion by restricting the foaming direction of the foaming member 12 by the restriction plate 25b. FIG. 9A shows an example in which the first foaming member 14 and the second foaming member 15 are arranged on the support plate 25a in a stacked state. FIG. 9B shows an example in which the first foam member 14 and the second foam member 15 are laminated adjacent to each other, and the first foam member 14 and the second foam member 15 are arranged on the same plane. Show. Further, FIG. 9C shows an example in which the second foam member 15 is laminated inside the first foam member 14, and the first foam member 14 and the second foam member 15 are arranged on the same plane. .

  -When providing a control member in a support member, the control member is not limited to the control board 25b shown to Fig.9 (a). That is, for example, as shown in FIG. 10, a restriction projection 13f as a restriction member can be provided on the upper surface of the support plate 13a. The first foam member 14 and the second foam member 15 are arranged on the upper surface of the support plate 13a so as to surround the restricting protrusion 13f. The foaming tool 11 is supported by the structural member 31 as shown in FIG. 11A, and when the structural member 31 is heated from the outside, the foaming member 12 is foamed as shown in FIG. 11B. Is regulated by the regulation protrusion 13f, the foam 21 is easily filled in a predetermined part. In the example shown in FIG. 11A, the foaming member 12 is restricted from foaming toward the center of the support plate 13a by the restricting protrusion 13f. For this reason, as a result of promoting foaming toward the outside of the support plate 13a, the foam 21 can be brought into close contact with the inner peripheral surface of the structural member 31 quickly.

  -The shape of the said 1st foaming member 14 and the 2nd foaming member 15 is not specifically limited. That is, the shape of the foam member 12 is appropriately changed according to the shape of the structural member 31, the performance required for the foam 21, and the like.

  -At least one of the first foam member 14 and the second foam member 15 may be composed of a plurality of members. For example, the foamed member 12 shown in FIG. 9B is an example in which a plurality of second foamed members 15 are provided.

  -In addition to the 1st foaming member 14 and the 2nd foaming member 15, you may comprise the 3rd foaming member formed from the 3rd foaming material, and may comprise the foaming tool 11. FIG. That is, the third foam material has a composition different from both the first foam material and the second foam material.

  -The member to which the foaming tool 11 is fixed is not particularly limited. In addition to structural members such as covers and door panels, hollow structural members such as pillars, rocker panels and doors, various hollow panels in buildings, and air conditioners The panel etc. which comprise an outdoor unit are mentioned.

The disassembled perspective view which shows the foaming tool in embodiment. The perspective view which shows a foaming tool. (A) is sectional drawing which shows the state by which the foaming tool was supported by the structural member, (b) is sectional drawing which shows the structural member with which the foam was filled. The disassembled perspective view which shows the foaming tool as a reference example . The perspective view which shows the foaming tool as a reference example . (A) is sectional drawing which shows the state by which the foaming tool as a reference example was supported by the structural member, (b) is sectional drawing which shows the structural member with which the foam as a reference example was filled. (A) is a perspective view which shows the foaming tool as a reference example , (b) is the AA line end view of (a). (A)-(d) is an end view of the foaming tool as a reference example, respectively. (A)-(c) is an exploded perspective view which shows the foaming tool as a reference example, respectively. The disassembled perspective view which shows the foaming tool as a reference example . (A) is sectional drawing which shows the state by which the foaming tool as a reference example was supported by the structural member, (b) is sectional drawing which shows the structural member with which the foam as a reference example was filled.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 11 ... Foaming tool, 12 ... Foam member, 13, 25 ... Support member, 13a, 13e, 25a ... Support plate, 13b ... Engagement part, 13c ... Engagement protrusion, 13d ... Support member main body, 13f ... Restriction protrusion, DESCRIPTION OF SYMBOLS 14 ... 1st foam member, 14a ... Mounting surface, 14b ... Engagement hole, 14c ... Connection protrusion, 15 ... 2nd foam member, 15a ... Engagement hole, 15b ... Connection hole, 21 ... Foam, 22 ... 1st Foam, 23 ... second foam, 25b ... regulating plate, 26 ... adhesive member, 31 ... structural member, 31a ... supported portion, 31b ... mounting hole.

Claims (4)

In a foaming tool comprising a foaming member formed from a foaming material foamed by external heating, and a flat support member that supports the foaming member on a structural member formed in a hollow shape ,
The foam member includes a first foam member formed from a first foam material and a second foam member formed from a second foam material having a composition different from that of the first foam material. And the second foamed member is laminated in the thickness direction of the support member,
At least one of the first foam member and the second foam member is supported by the support member by an engagement protrusion provided on the support member . The first foam member and the second foam member are supported by the support member by an engagement protrusion provided on the support member, and the first foam member and the second foam member are the engagement protrusion. The foaming tool according to claim 1, wherein is penetrated and supported . The support member, foam device according to claim 1 or claim 2 comprising includes an engaging portion which is engaged to the structural member to be formed in the hollow. Wherein at least one of the first foam member and the second foam member is either one of claims 1 disposed on the support member via an adhesive member formed from an adhesive material having a self-adhesive according to claim 3 one The foaming tool according to Item.

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