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JP5655558B2 - The hollow structure and a manufacturing method thereof foaming reinforcing member is disposed - Google Patents

The hollow structure and a manufacturing method thereof foaming reinforcing member is disposed

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JP5655558B2
JP5655558B2 JP2010290664A JP2010290664A JP5655558B2 JP 5655558 B2 JP5655558 B2 JP 5655558B2 JP 2010290664 A JP2010290664 A JP 2010290664A JP 2010290664 A JP2010290664 A JP 2010290664A JP 5655558 B2 JP5655558 B2 JP 5655558B2
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JP2012136175A (en )
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之典 中島
之典 中島
金子 満晴
満晴 金子
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マツダ株式会社
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本発明は、発泡補強部材が中空本体の内部に配設された中空構造物及びその製造方法に関し、特に、中空本体の内壁面に前記発泡補強部材の板枠状の周壁部が接着結合された中空構造物及びその製造方法に関する。 The present invention is a hollow structural foam reinforcing member is disposed within the hollow body and to a manufacturing method thereof, in particular, plate-frame-like peripheral wall of the foaming reinforcing member to the inner wall surface of the hollow body is adhesively bonded the hollow structure and a manufacturing method thereof.

自動車等の車両における車体の一部を構成するサイドシルやピラーなどの車体構成部材は一般に、金属製の板状素材を中空状に形成した中空構造物として構成されている。 Generally the vehicle body constituent member such as a side sill or a pillar forming part of the vehicle body in a vehicle such as an automobile, and is configured as a hollow structure forming a metal plate material in a hollow shape. また、車体構成部材として、その中空本体の内部に金属製または樹脂製の補強部材を発泡接着剤によって取り付けたものも知られている。 Further, as the vehicle body structure member, it is also known that attached by foaming adhesive reinforcing member made of metal or resin in the interior of the hollow body.

例えば特許文献1には、ピラーなどの金属製の中空本体の内部に樹脂製の補強部材を配設し、該補強部材に予め取り付けた発泡接着剤を焼付け塗装時の熱により発泡させて膨張させることによって、該発泡接着剤を介して補強部材を中空本体に結合させるようにした構成が開示されている。 For example, Patent Document 1, is disposed inside the resin reinforcing member made of metal hollow body, such as pillars, to inflate the premounted foaming adhesive reinforcing member is foamed by heat at the time of baking finish by the structure which is adapted to couple the reinforcing member to the hollow body through the blowing adhesive is disclosed. このように、補強部材を樹脂製とすれば、金属製の補強部材を用いる場合に比べて重量の増加を抑制することができる。 Thus, the reinforcing member if made of resin, it is possible to suppress the increase in weight as compared with the case of using a metal reinforcing member.

しかしながら、近年ますます高まる燃費向上の要請に応える観点から、補強部材により中空構造物を補強する場合、該補強部材の重量を一層低減して、車体全体の重量低減を図ることが求められる。 However, from the viewpoint of recent meet the demand for ever increasing fuel efficiency, to reinforce the hollow structure by the reinforcing member, and further reduce the weight of the reinforcing member, is required to achieve a weight reduction of the whole vehicle body.

そこで、少なくとも一部が発泡成形された樹脂からなる発泡補強部材を用いることで、補強効果を良好に維持しつつ、重量の低減を図ることが考えられる。 Therefore, by using the foamed reinforcing member made of a resin at least part of which is foam molded, while maintaining a good reinforcing effect, it is conceivable to reduce the weight.

図8は、所謂コアバック法(例えば特許文献2参照)により、発泡補強部材の板枠状の周壁部を発泡成形する成形型の一例として考えられる成形型120を示している。 Figure 8 is a so-called core back method (for example, see Patent Document 2) shows a mold 120 which is considered as an example of a mold for foam molding a plate-frame-like peripheral wall of the foaming reinforcing member.

図8に示す成形型120は、発泡補強部材110の周壁部116を外側から成形する複数の可動コア121〜124と、各可動コア121〜124を挟むようにして設けられた複数の固定コア125〜128と、前記周壁部116を内側から成形する内側コア169とを有する。 Mold 8 120 includes a plurality of movable cores 121 to 124 forming the peripheral wall portion 116 of the foam reinforcing member 110 from the outside, a plurality of fixed core provided so as to sandwich the respective movable core 121 to 124 125 to 128 If, and an inner core 169 for molding the peripheral wall portion 116 from the inside. 成形の際は、先ず、この成形型120のキャビティS1に発泡性樹脂材料P1を射出して充填した後に、前記可動コア121〜124をそれぞれキャビティS1の容積を拡大するように成形型120の外側に向かって移動(コアバック)させる。 During molding, first, after the foamable resin material P1 filled by injection into the cavity S1 of the mold 120, the outer mold 120 so as to enlarge the volume of the movable core 121-124 respectively cavities S1 causes movement (core back) toward the. これにより、キャビティS1内の樹脂は、コアバックにより発泡が促進されながら成形される。 Accordingly, the resin in the cavity S1 is foamed is molded while being accelerated by the core-back.

図9に示すように、上記の成形型120により発泡成形された発泡補強部材110は、発泡接着剤105を介して例えばサイドシル等の中空構造物100の中空本体107に接着結合される。 As shown in FIG. 9, the foamed reinforcing member 110 which is foamed molded by the mold 120 described above is adhesively bonded to the hollow body 107 of the hollow structure 100 of the side sill or the like for example via the foamed adhesive 105. 具体的には、先ず、発泡補強部材110の外周面に発泡接着剤105を二色成形または塗布等により層状に設けた後、この発泡補強部材110を中空本体107の内部に配設する。 More specifically, first, after providing a layer by a foaming adhesive 105 to the outer peripheral surface of the foamed reinforcing member 110 two-color molding or coating or the like, disposing the foamed reinforcing member 110 into the hollow body 107. この時点において、中空構造物100の内周面と発泡接着剤105との間には隙間が生じた状態となるが、その後に行う塗装乾燥時の熱により、発泡接着剤105が発泡しながら膨張し、これにより、中空本体107の内周面と発泡補強部材110の外周面との間に発泡接着剤105が充填されて、この発泡接着剤105を介して、補強部材110が中空本体107に接着結合される。 At this point, although a state where a gap occurs between the inner peripheral surface and foamed adhesive 105 of the hollow structure 100, by heat during coating drying thereafter to carry out, while foamed adhesive 105 is foamed and expanded and, by this, foaming adhesive 105 between the inner peripheral surface and the outer peripheral surface of the foamed reinforcing member 110 of the hollow body 107 is filled, through the foamed adhesive 105, the reinforcing member 110 is hollow body 107 It is adhesively bonded.

特開2001−191949号公報 JP 2001-191949 JP 特開2009−241537号公報 JP 2009-241537 JP

しかしながら、例えば図8に示す成形型120を用いて全体的に発泡成形した周壁部116は、同じ厚みを有する非発泡の周壁部に比べて、強度的に不利になる。 However, the peripheral wall portion 116, for example the overall foam molding using a mold 120 shown in FIG. 8, as compared with the peripheral wall portion of the non-foamed with the same thickness, the strength disadvantageous.

また、図8に示す成形型120を用いる場合、図10に示すように、各可動コア121〜124のコアバックに対して該可動コア121〜124の成形面の縁部に対向する樹脂部分が追従し難く形状ダレFが生じやすいという理由に加えて、そもそも成形型120の構造上の制約により発泡補強部材100の稜線部141〜144の外側に固定コア125〜128を設けざるを得ないという理由により、発泡補強部材110の稜線部141〜144については、板厚を拡大するように発泡成形できず、板厚の拡大による強度向上を図れない。 Moreover, if, as shown in FIG. 10, facing the resin portion to the edge portion of the molding surface of the movable core 121 to 124 to the core back of the movable core 121 to 124 using the mold 120 shown in FIG. 8 in addition to the reason that follow hardly shape sagging F is likely to occur, the first place that inevitably provided stationary core 125 to 128 to the outside of the ridge portion 141 to 144 of the foam the reinforcing member 100 by structural constraints of the mold 120 the reason for the ridge 141 to 144 of the foamed reinforcing member 110 can not foam molding to enlarge the plate thickness, can not be achieved the strength improvement by expanding the plate thickness. そのため、この場合、補強に関して特に重要な中空本体107の稜線部151〜154を発泡補強部材110により効果的に補強することができない。 Therefore, in this case, it is impossible to effectively reinforce the particularly important ridge 151 to 154 of the hollow body 107 by foaming reinforcing member 110 with respect to the reinforcement. なお、図示された二点鎖線L2は、キャビティS1に充填された後であって発泡成形される前の状態における周壁部116の外周面を示す。 Incidentally, the two-dot chain line L2 illustrated shows an outer peripheral surface of the peripheral wall portion 116 in a state before being foam-molded even after filling the cavity S1.

さらに、この場合、図11(a)に示すように、発泡補強部材110の前記稜線部141〜144と中空本体107の稜線部151〜154との隙間が他の隙間部分に比べて著しく大きくなってしまう。 Furthermore, in this case, as shown in FIG. 11 (a), considerably larger than the gap of other gap portion between ridge portions 151 to 154 of the ridge 141 to 144 and the hollow body 107 of the foamed reinforcing member 110 and will. よって、発泡補強部材110の外周面に一定の厚みで形成された各接着剤部分105a,105b,105cを発泡させたとき、図11(b)に示すように、発泡補強部材110の稜線部141〜144以外の部分を覆う接着剤部分105a',105c'は均一な厚みを維持しながら適切な倍率で発泡するのに対して、稜線部141〜144を覆う接着剤部分105b'は他の部分に比べて厚みを拡大しながら過剰に高い倍率で発泡してしまう。 Therefore, the adhesive portion 105a formed at a constant thickness on the outer peripheral surface of the foamed reinforcing member 110, 105b, when foamed to 105c, as shown in FIG. 11 (b), the edge line portion 141 of the foam reinforcing member 110 adhesive portions 105a for covering the portions other than to 144 ', 105c' whereas foams with appropriate magnification while maintaining a uniform thickness, adhesive portions 105b that covers the ridge portion 141 to 144 'are other portions resulting in foamed excessively high magnification while expanding the thickness compared to. そのため、中空本体107の稜線部151〜154に対する発泡補強部材110の接着強度が弱くなり、中空本体107の稜線部151〜154を効果的に補強することができないという問題もある。 Therefore, the adhesive strength of the foamed reinforcing member 110 against ridge 151 to 154 of the hollow body 107 is weakened, there is also a problem that it is impossible to reinforce the ridge 151 to 154 of the hollow body 107 effectively.

そこで、本発明は、中空本体の内部に配設される補強部材として発泡補強部材を用いることで中空構造物の軽量化を図りつつ、この発泡補強部材により中空本体の特に稜線部を効果的に補強することを課題とする。 Accordingly, the present invention is to reduce the weight of it in the hollow structure using foaming reinforcing member as a reinforcing member disposed in the interior of the hollow body, in particular the ridge portion effectively the hollow body by the foamed reinforcing member it is an object of the present invention to reinforce.

前記課題を解決するため、本発明に係る発泡補強部材が配設された中空構造物及びその製造方法は、次のように構成したことを特徴とする。 To solve the above problems, the hollow structure and a manufacturing method thereof foaming reinforcing member is disposed according to the present invention is characterized by being configured as follows.

まず、本願の請求項1に記載の発明に係る発泡補強部材が配設された中空構造物は、 First, a hollow structure foaming reinforcing member is disposed according to the invention of claim 1 of the present application,
中空本体の内部に発泡補強部材が配設された中空構造物であって、 A hollow structure foaming reinforcing member is disposed within the hollow body,
前記発泡補強部材は、全周に亘って略一定の厚みを有し且つ少なくとも一部が発泡成形された板枠状の周壁部を備え、 The foam reinforcing member includes a peripheral wall portion of the entire periphery over a substantially constant thickness and at least a part of which is foam-molded plate frame shape,
該周壁部は、前記中空本体の内壁面に接着剤を介して接着結合され、 The peripheral wall portion is adhesively bonded via an adhesive to the inner wall surface of the hollow body,
前記周壁部における前記中空本体の稜線部への接着部分は、前記周壁部における残りの部分に比べて発泡倍率が低い樹脂部分からなることを特徴とする。 Bonding portions of the ridge portion of the hollow body in the circumferential wall, characterized by comprising the expansion ratio is lower resin portion as compared with the remaining portion of the peripheral wall.

なお、本明細書において、上記の「前記周壁部における残りの部分に比べて発泡倍率が低い」状態には、全く発泡していない状態も含まれるものとする。 In the present specification, the "remaining lower expansion ratio than the portion in the peripheral wall" state described above, also intended to be included state not at all foaming.

次に、請求項2に記載の発明は、前記請求項1に記載の発明において、 Next, the invention of claim 2 is the invention according to claim 1,
前記周壁部は、発泡接着剤を介して前記中空本体の内壁面に接着結合され、 The peripheral wall portion is adhesively bonded to the inner wall surface of the hollow body through the foamed adhesive,
前記周壁部と前記中空本体の内壁面との間隔は全周に亘って略一定であることを特徴とする。 Spacing between the inner wall surface of the hollow body and the peripheral wall portion is characterized by a substantially constant over the entire circumference.

さらに、請求項3に記載の発明は、前記請求項1または請求項2に記載の発明において、 The present invention as described in claim 3 is the invention according to claim 1 or claim 2,
前記中空構造物は、車体の一部を構成する車体構成部材であることを特徴とする。 It said hollow structure, characterized in that it is a vehicle body component member that constitutes a part of the vehicle body.

また、請求項4に記載の発明に係る発泡補強部材が配設された中空構造物の製造方法は、 A method of manufacturing a hollow structure foaming reinforcing member is disposed according to the invention of claim 4,
中空本体の内部に発泡補強部材が配設された中空構造物の製造方法であって、 Internal foaming reinforcing member of the hollow body is a method for producing disposed hollow structure,
全周に亘って略一定の厚みを有する周壁部を備え、且つ、発泡性樹脂材料が成形型のキャビティ内に充填された後に該成形型の少なくとも一部がキャビティの容積を拡大する方向にコアバックされることで前記周壁部における前記中空本体の稜線部の内壁面に対する接着部分が残りの部分に比べて発泡倍率が低くなるように発泡成形された発泡補強部材を準備する準備工程と、 Includes a peripheral wall portion having a substantially constant thickness over the entire circumference, and the core in a direction in which at least a portion of the forming die after the foaming resin material is filled into the mold cavity to expand the volume of the cavity a preparation step of preparing a foam reinforcing member bonded portion is expansion ratio as compared with the remaining portion being foam-molded so as to be lower with respect to the inner wall surface of the ridge portion of the hollow body in the peripheral wall by being back,
該準備工程の後、前記発泡補強部材の前記周壁部において前記発泡倍率が低い部分を、前記中空本体の内壁面に接着剤を介して接着結合する接着工程と、を有することを特徴とする。 After said preparing step, the said expansion ratio is lower portions in the peripheral wall of the foaming reinforcing member, characterized by having a a bonding step of bonding bonded via an adhesive to the inner wall surface of the hollow body.

さらに、請求項5に記載の発明は、前記請求項4に記載の発明において、 The present invention as described in claim 5 is the invention according to claim 4,
前記準備工程の前に、前記発泡補強部材を成形する成形工程を有し、 Prior to said preparing step includes a molding step of molding the foamed reinforcing member,
該成形工程では、前記稜線部の内壁面に対する前記発泡補強部材の前記周壁部の接着部分を成形する複数の固定型と、隣り合う該固定型間に挟まれて配設されるとともに前記周壁部の残りの部分を成形する複数の可動型とを備えた成形型を用いて、該成形型のキャビティに発泡性樹脂材料を充填した後、前記キャビティの容積を拡大する方向に前記可動型をコアバックすることで前記残りの部分を発泡させながら、前記発泡補強部材を成形することを特徴とする。 The molding step, the peripheral wall portion and a plurality of fixed molding the adhered portion of the peripheral wall of the foaming reinforcing member against the inner wall surface of the ridge portion, while being sandwiched between adjacent solid fixed arranged core using a mold and a plurality of movable molds for molding the rest, after filling a foaming resin material into the molding mold cavity, said movable mold in the direction of expanding the volume of the cavity while blowing the remaining portion by the back, characterized by molding the foamed reinforcing member.

さらにまた、請求項6に記載の発明は、前記請求項4または請求項5に記載の発明において、 Furthermore, the invention of claim 6 is the invention according to claim 4 or claim 5,
前記接着工程では、前記発泡補強部材の周壁部を、前記中空本体の内壁面に対して全周に亘って略一定の間隔を空けて対向配置し、前記周壁部と前記中空本体の内壁面との間に発泡接着剤を配設した後、該発泡接着剤を発泡させ、該発泡接着剤を介して前記周壁部を前記中空本体に接着結合することを特徴とする。 In the bonding step, the peripheral wall of the foaming reinforcing member, opposed spaced a substantially constant distance along the entire circumference against the inner wall surface of the hollow body, the inner wall surface of the hollow body and the peripheral wall portion after disposing the foaming adhesive between, by foaming the foam adhesive, characterized in that through the blowing adhesive adhesively bonding said peripheral wall to the hollow body.

加えて、請求項7に記載の発明は、前記請求項4から請求項6のいずれか1項に記載の発明において、 In addition, the invention of claim 7 is the invention according to any one of claims 6 to claim 4,
前記中空構造物は、車体の一部を構成する車体構成部材であり、 It said hollow structure is a vehicle body component member that constitutes a part of the vehicle body,
前記接着工程では、車体の塗装乾燥時の熱によって前記発泡接着剤を発泡させることを特徴とする。 Wherein in the bonding step, and wherein the foaming the foamed adhesive by heat during coating drying of the vehicle body.

請求項1に記載の発明に係る発泡補強部材が配設された中空構造物では、発泡補強部材の周壁部における中空本体の稜線部への接着部分が、前記周壁部における残りの部分に比べて発泡倍率が低い樹脂部分からなるため、この発泡倍率の低さにより高強度が維持された部分を中空本体の稜線部に接着結合することにより、この稜線部を効果的に補強することができるとともに、前記周壁部における残りの部分を比較的高い発泡倍率で発泡成形することで、発泡補強部材の重量を低減することができ、中空構造物全体の軽量化に貢献することができる。 The hollow structure foaming reinforcing member is disposed according to the invention of claim 1, the adhesive portion of the ridge line portion of the hollow body at the peripheral wall of the foaming reinforcing member, compared to the rest of the peripheral wall portion since the expansion ratio is made a low resin portion, by adhesively bonding strength by low is maintained portion of the expansion ratio in the ridge portion of the hollow body, it is possible to reinforce the edge line effectively , by foam molding at a relatively high expansion ratio to the remaining portions of the peripheral wall portion, it is possible to reduce the weight of the foamed reinforcing member, it can contribute to a reduction in the weight of the whole hollow structure.

また、請求項2に記載の発明によれば、発泡補強部材の周壁部と中空本体の内壁面との間隔が全周に亘って略一定であるため、この隙間に一定の厚みで層状に設けた発泡接着剤を発泡、膨張させる際、この発泡接着剤の発泡倍率を全周に亘って均一にすることができる。 Further, according to the invention described in claim 2, since the interval between the inner wall surface of the peripheral wall portion and the hollow body of foam reinforcement member is substantially constant over the entire circumference, provided in a layer with a constant thickness in the gap and the foamed adhesive foam, when inflating, can be made uniform over the expansion ratio of the foamed adhesive on the entire circumference. そのため、中空本体の稜線部の内壁面に対する発泡補強部材の接着部分において、適切な倍率で発泡した発泡接着剤により高い接着強度が得られるため、この稜線部を一層効果的に補強することができる。 Therefore, in the bonded portion of the foamed reinforcing member against the inner wall surface of the ridge portion of the hollow body, since high adhesive strength by foaming adhesive foam with appropriate magnification is obtained, it is possible to reinforce the edge line portion more effectively .

さらに、請求項3に記載の発明によれば、中空構造物は、車体の一部を構成する車体構成部材であることにより、車体の重量を抑制しつつ車体の剛性を向上させることができ、前記効果を具体的に実現することができる。 Further, according to the invention described in claim 3, the hollow structure by a vehicle body component member that constitutes a part of the vehicle body, it is possible to improve the vehicle body rigidity while suppressing the vehicle body weight, it can be realized specifically the effect.

また、請求項4に記載の発明に係る発泡補強部材が配設された中空構造物の製造方法によれば、前記発泡補強部材の周壁部における中空本体の稜線部への接着部分が、前記周壁部における残りの部分に比べて発泡倍率が低い樹脂部分からなるため、前記周壁部において発泡倍率が比較的低く高強度が維持された部分を中空本体の稜線部に接着結合することにより、この稜線部を効果的に補強することができるとともに、前記周壁部における残りの部分が比較的高い発泡倍率で発泡成形されていることで、発泡補強部材の重量を低減することができ、中空構造物全体の軽量化に貢献することができる。 According to the manufacturing method of hollow structural foamed reinforcing member according to the invention described in claim 4 is disposed, the bonded portion of the ridge line portion of the hollow body at the peripheral wall of the foaming reinforcing member, the peripheral wall since the expansion ratio as compared to the rest consisting of lower resin portion in part, by adhesively bonding portion strength expansion ratio is relatively low is maintained in the peripheral wall portion in the ridge line portion of the hollow body, the ridge part it is possible to effectively reinforce the, by the remaining portion being foam molded at a relatively high expansion ratio in the peripheral wall portion, it is possible to reduce the weight of the foamed reinforcing member, the whole hollow structure it can contribute to a reduction in the weight of the.

また、請求項5に記載の発明によれば、発泡補強部材を成形する際、該発泡補強部材の周壁部における中空本体の稜線部の内壁面への接着部分以外の部分について、可動型のコアバックにより発泡成形することで発泡補強部材を軽量化することができる。 Also, according to the invention described in claim 5, when forming a foamed reinforcement member, the portion other than the bonding portion of the inner wall surface of the ridge portion of the hollow body in the circumferential wall of the foam reinforcing member, the movable die core it is possible to reduce the weight of the foam reinforcing member by expansion molding by the back. また、前記周壁部における中空本体の稜線部の内壁面に対する接着部分については、固定型により確実に所望の形状および板厚となるように成形されるため、当該接着部分の支持強度を高めて、中空本体の稜線部を一層効果的に補強することができる。 Also, the adhesive portion to the inner wall surface of the ridge portion of the hollow body in the circumferential wall, because it is shaped so as to ensure that the desired shape and thickness by fixed, to enhance the support strength of the adhesive portion, the ridge portion of the hollow body can be further effectively reinforced.

さらに、請求項6に記載の発明によれば、発泡補強部材の周壁部を、全周に亘って略一定の厚みとなるように中空本体の内壁面に対向配置するため、この隙間に一定の厚みで層状に設けた発泡接着剤を発泡、膨張させる際、この発泡接着剤の発泡倍率を全周に亘って均一にすることができる。 Further, according to the invention described in claim 6, the peripheral wall of the foaming reinforcing member, for facing the inner wall surface of the hollow body to be substantially constant thickness over the entire periphery, the constant in the gap when the foamed adhesive provided on the layered foam, inflated with thickness, it can be made uniform over the expansion ratio of the foamed adhesive on the entire circumference. そのため、中空本体の稜線部の内壁面に対する発泡補強部材の接着部分において、適切な倍率で発泡した発泡接着剤により高い接着強度が得られるため、この稜線部を一層効果的に補強することができる。 Therefore, in the bonded portion of the foamed reinforcing member against the inner wall surface of the ridge portion of the hollow body, since high adhesive strength by foaming adhesive foam with appropriate magnification is obtained, it is possible to reinforce the edge line portion more effectively .

さらにまた、請求項7に記載の発明によれば、前記中空構造物は、車体の一部を構成する車体構成部材であり、発泡接着剤の発泡を、車体の塗装乾燥時の熱によって行うことによって、発泡接着剤を発泡させるための工程を別途設ける必要がなく、車体の製造時に一般に施される塗装乾燥時に発泡接着剤を発泡させることができるので、既存の製造工程を利用することができ、前記効果をより有効に奏することができる。 Furthermore, according to the invention described in claim 7, wherein the hollow structure is a vehicle body component member that constitutes a part of the vehicle body, the expansion of the expandable adhesive, be carried out by heat at the time of painting Drying of the vehicle body Accordingly, there is no need to separately provide a process for foaming a foaming adhesive, it is possible to foam a foamed adhesive during coating drying to be applied generally when the vehicle manufacturing, it is possible to utilize the existing manufacturing process it can exhibit the effect more effective.

本発明の実施形態に係る発泡補強部材が配設された中空構造物を適用したサイドシルを示す斜視図である。 The side sill foam reinforcing member has applied a hollow structure arranged according to the embodiment of the present invention is a perspective view showing. 本発明の実施形態に係る発泡補強部材を示す斜視図である。 The foam reinforcing member according to an embodiment of the present invention is a perspective view showing. 図1におけるY3a−Y3a線に沿ったサイドシルの断面図である。 It is a cross-sectional view of the side sill along Y3a-Y3a line in FIG. 図1におけるY3b−Y3b線に沿ったサイドシルの断面図である。 It is a cross-sectional view of the side sill along Y3b-Y3b line in FIG. 発泡補強部材の外周面に設けられた発泡接着剤が発泡する前の状態におけるサイドシルのY3a−Y3a線断面図である。 A Y3a-Y3a line cross-sectional view of a side sill in a state before provided on the outer peripheral surface of the foamed reinforcing member foamed adhesive foams. 図2に示す発泡補強部材を成形する成形型のコアバック前の状態を示す断面図である。 It is a sectional view showing a state before the core back of the mold for molding the foamed reinforcing member shown in FIG. 図6に示す成形型のコアバック後の状態を示す断面図である。 It is a sectional view showing a state after the mold core back shown in FIG. 発泡補強部材の板枠状の周壁部を発泡成形する成形型の従来例を示す断面図である。 It is a sectional view showing a conventional example of a mold for foam molding a plate-frame-like peripheral wall of the foaming reinforcing member. 図8に示す成形型で成形された発泡補強部材が発泡接着剤を介して中空本体の内壁面に接着結合された中空構造物を示す断面図である。 Foam reinforcing member molded in the mold shown in FIG. 8 is a sectional view showing a hollow structure that is adhesively bonded to the inner wall surface of the hollow body via a foamed adhesive. 図8のA部に関するコアバック後の状態を示す拡大図である。 Is an enlarged view showing a state after the core back on A portion of FIG. 図9のB部に関する発泡接着剤の発泡前後の状態を示す拡大図である。 Is an enlarged view showing the foam before and after the state of the foamed adhesive regarding part B of FIG.

以下、本発明の実施形態について添付図面を参照しながら説明する。 It will be described below with reference to the accompanying drawings embodiments of the present invention. なお、以下の説明では、「上」、「下」、「右」、「左」及びそれらの用語を含む別の用語など特定の方向を意味する用語を使用するが、それらの使用は図面を参照した発明の理解を容易にするためであって、それらの用語の意味によって本発明の技術的範囲が限定されるものではない。 In the following description, "upper", "lower", "right", but uses the terms indicating specific directions such as another terminology, including "left" and these terms, their use to the drawings a in order to facilitate understanding of the referenced invention, but the technical scope of the present invention by means of those terms is limited.

図1は、本発明の実施形態に係る発泡補強部材が配設された中空構造物を適用したサイドシルを示す斜視図であり、図1では、センタピラーとの結合部を含むサイドシルを示している。 Figure 1 is a perspective view showing a side sill of foam reinforcement member has applied a hollow structure arranged according to the embodiment of the present invention, FIG. 1 shows a side sill including a connecting portion between the center pillar . なお、図1では、サイドシルの内部に配設された補強部材を明瞭に図示するために、サイドシルを構成するサイドシルインナ及びサイドシルアウタと、センタピラーを構成するセンタピラーインナ及びセンタピラーアウタとを二点鎖線で示し、これを透過状態で示している。 In FIG. 1, to illustrate a reinforcement member disposed within the side sill clearly, the side sill inner and a side sill outer which constitute the side sill, a center pillar inner and a center pillar outer constitutes a center pillar two shown in dash-dotted, shows this in a transparent state.

図1に示すように、本発明の実施形態に係る発泡補強部材が配設された中空構造物を適用したサイドシル10は、車体の一部を構成する車体構成部材であり、車体下部において車体前後方向に延びるように配設された中空本体17を備え、該中空本体17に車体上下方向に延びるセンタピラー20が結合されている。 As shown in FIG. 1, a side sill 10 to foam the reinforcing member according to an embodiment of the present invention has applied a hollow structure is arranged is a vehicle body component member that constitutes a part of the vehicle body, the vehicle back and forth in the vehicle body bottom comprises a hollow body 17 which is disposed so as to extend in a direction, the center pillar 20 extending in the vertical direction of the vehicle body is coupled to the hollow body 17. また、中空本体17の内部には、センタピラー20との結合部25の近傍において該結合部25の車体前方側及び車体後方側にそれぞれサイドシル10を補強するための補強部材30及び40が配設されている。 Inside the hollow body 17, the reinforcing member 30 and 40 for reinforcing the front side of the vehicle body and each side sill 10 to the vehicle body rear side of the coupling portion 25 in the vicinity of the coupling portion 25 of the center pillar 20 is arranged It is.

中空本体17は、車体の内面の一部を構成して車体前後方向に延びるサイドシルインナ11と、車体の外面の一部を構成して車体前後方向に延びるサイドシルアウタ12とによって中空状に形成されている。 The hollow body 17 includes a side sill inner 11 which extends in the longitudinal direction of the vehicle body constitutes a part of the body of the inner surface, formed in a hollow shape by a side sill outer 12 which extends in the longitudinal direction of the vehicle body constitutes a part of the body of the outer surface ing.

具体的には、サイドシルインナ11は、略水平方向に延びる上面部11aと、上面部11aに対向して上面部11aの下方に位置し、略水平方向に延びる下面部11bと、下面部11bから上面部11aまで略垂直方向に延びる側面部11cとを備え、車幅方向内方側(図1では左側である車内側)に側面部11cが膨出するようにして配設されている。 Specifically, the side sill inner 11, and the upper surface portion 11a extending in a substantially horizontal direction, located below the upper surface portion 11a to face the upper surface portion 11a, and the lower surface portion 11b extending substantially horizontally from the lower surface portion 11b and a side surface portion 11c extending substantially perpendicular to the upper surface portion 11a, side surface portions 11c in the vehicle width direction inner side (vehicle inner side is a left side in FIG. 1) is disposed so as to bulge.

サイドシルインナ11にはまた、上面部11aの車幅方向外方端部に上面部11aから上方へ延びる上フランジ部が形成されるとともに、下面部11bの車幅方向外方端部に下面部11bから下方へ延びる下フランジ部が形成され、サイドシルインナ11は、断面略ハット状に形成されている。 Also the side sill inner 11, with the upper flange portion is formed extending from the upper surface portion 11a in the vehicle width direction outer end portion of the upper surface portion 11a upwardly, the lower surface portion 11b in the vehicle width direction outer end portion of the lower surface portion 11b lower flange portion is formed extending downward from the side sill inner 11 is formed in a substantially hat shape.

一方、サイドシルアウタ12は、略水平方向に延びる上面部12aと、上面部12aに対向して上面部12aの下方に位置し、略水平方向に延びる下面部12bと、下面部12bから上面部12aまで略垂直方向に延びる側面部12cとを備え、車幅方向外方側(図1では右側である車外側)に側面部12cが膨出するようにして配設されている。 On the other hand, side sill outer 12, and the upper surface portion 12a extending in a substantially horizontal direction, located below the upper surface portion 12a to face the upper surface portion 12a, and the lower surface portion 12b extending in a substantially horizontal direction, the upper surface portion 12a from the lower surface portion 12b and a side portion 12c extending in a direction substantially perpendicular to the side surface portion 12c in the vehicle width direction outer side (in FIG. 1 is a right exterior side) are disposed so as to bulge.

サイドシルアウタ12もまた、上面部12aの車幅方向内方端部に上面部12aから上方へ延びる上フランジ部が形成されるとともに、下面部12bの車幅方向内方端部に下方へ延びる下フランジ部が形成され、サイドシルアウタ12は、断面ハット状に形成されている。 Side sill outer 12 is also lower extending from the upper surface portion 12a in the vehicle width direction inner end portion of the upper surface portion 12a together with the flange portion is formed on the upwardly extending, downwardly in the vehicle width direction inner end portion of the lower surface portion 12b flange portion is formed, the side sill outer 12 is formed in a cross-hat.

そして、サイドシルインナ11とサイドシルアウタ12とは、上フランジ部及び下フランジ部同士が接合され、これによって中空状の中空本体17が形成されている。 Then, the side sill inner 11 and the side sill outer 12, is joined upper flange and the lower flange portions, which hollow of the hollow body 17 is formed by. なお、サイドシルインナ11とサイドシルアウタ12とはそれぞれ、鋼板などの金属製の板状素材をプレス加工して形成され、サイドシルインナ11とサイドシルアウタ12とは、例えばスポット溶接などを用いて接合される。 Incidentally, each of the side sill inner 11 and the side sill outer 12, is formed a metal plate material such as steel plate by pressing, and the side sill inner 11 and the side sill outer 12 is joined by using, for example, spot welding .

このようにして形成されるサイドシル10には、サイドシルインナ11の上面部11a及び側面部11cによってそれらの間に稜線部11dが形成され、サイドシルインナ11の下面部11b及び側面部11cによってそれらの間に稜線部11eが形成され、サイドシルアウタ12の上面部12a及び側面部12cによってそれらの間に稜線部12dが形成され、サイドシルアウタ12の下面部12b及び側面部12cによってそれらの間に稜線部12eが形成され、中空本体17は略矩形閉断面状に形成されている。 The side sill 10 is formed in this way, the ridge line portion 11d is formed between them by the upper surface portion 11a and side surface portions 11c of the side sill inner 11, between which the lower surface portion 11b and the side surface portions 11c of the side sill inner 11 the ridge portion 11e is formed, the side sill ridge 12d therebetween by the upper surface portion 12a and side surface portions 12c of the outer 12 is formed, ridge 12e therebetween by the lower surface portion 12b and the side surface portions 12c of the side sill outer 12 There is formed, the hollow body 17 is formed into a substantially rectangular closed cross section shape.

なお、以下では、適宜、サイドシルインナ11の側面部11cを中空本体17の車幅方向内方側の側面部である内側面部11cとして表し、サイドシルアウタ12の側面部12cを中空本体17の車幅方向外方側の側面部である外側面部12cとして表し、サイドシルインナ11の上面部11a、サイドシルアウタ12の上面部12aを中空本体17の上面部11a,12aとして表し、サイドシルインナ11の下面部11b、サイドシルアウタ12下面部12bを中空本体17の下面部11b,12bとして表す。 In the following, as appropriate, represents a side portion 11c of the side sill inner 11 as an inner surface portion 11c is a side portion of the vehicle width direction inner side of the hollow body 17, the vehicle width of the side surface portion 12c of the side sill outer 12 hollow body 17 expressed as an outer surface portion 12c is a side portion of the outward side, represents the upper surface portion 11a of the side sill inner 11, the upper surface portion 12a of the side sill outer 12 upper surface portion 11a of the hollow body 17, as 12a, lower surface portion 11b of the side sill inner 11 represents a side sill outer 12 lower surface portion 12b lower surface portion 11b of the hollow body 17, as 12b.

また、サイドシル10に結合されるセンタピラー20は、車体の内面の一部を構成して車体上下方向に延びるセンタピラーインナ21と、車体の外面の一部を構成して車体上下方向に延びるセンタピラーアウタ22とによって中空状に形成され、サイドシル10との結合部25において、センタピラーインナ21がサイドシルインナ11と一体的に形成されるとともにセンタピラーアウタ22がサイドシルアウタ12と一体的に形成されている。 Further, the center pillar 20 which is coupled to the side sill 10, a center pillar inner 21 extending in the vertical direction of the vehicle body constitutes a part of the body of the inner surface, extending in the vertical direction of the vehicle body constitutes a part of the body of the outer surface center formed in a hollow shape by a pillar outer panel 22, the coupling portion 25 of the side sill 10, the center pillar outer 22 with the center pillar inner 21 is formed integrally with the side sill inner 11 is formed integrally with the side sill outer 12 ing.

図2は、本発明の実施形態に係る発泡補強部材を示す斜視図、図3は、図1におけるY3a−Y3a線に沿ったサイドシルの断面図、図4は、Y3b−Y3b線に沿ったサイドシルの断面図である。 Figure 2 is a side sill perspective view of a foamed reinforcement member according to the embodiment of the present invention, FIG. 3 is a cross-sectional view of the side sill along Y3a-Y3a line in FIG. 1, FIG. 4, along the Y3b-Y3b line it is a cross-sectional view of. なお、図2では、発泡補強部材の周壁部の発泡前の状態を二点鎖線L12で示している。 In FIG. 2 shows a foaming state before the peripheral wall of the foaming reinforcing member by a two-dot chain line L12.

サイドシル10において、センタピラー20との結合部25よりも車体前方側に配設される発泡補強部材30と、前記結合部25よりも車体後方側に配設される発泡補強部材40とは同様に構成されているため、以下では、車体前方側の補強部材30についてのみ説明する。 In the side sill 10, the foamed reinforcing member 30 disposed to the front side of the vehicle body than the coupling portion 25 of the center pillar 20, similarly to the foam reinforcing member 40 disposed on the rear side of the vehicle body than the coupling portion 25 because it is composed, in the following description, only the reinforcing member 30 of the vehicle body front side.

図2及び図3に示すように、中空本体17の内部に配設される発泡補強部材30は、中空本体17を横切る方向に延び、中空本体17の内部を車体前後方向に区切る板状の隔壁部35と、該隔壁部35に結合され該隔壁部35の周縁を覆う枠板状の周壁部36とを備えている。 As shown in FIGS. 2 and 3, foam reinforcing member 30 disposed inside the hollow body 17 extends transversely to the hollow body 17, a plate-shaped partition wall that separates the interior of the hollow body 17 in the longitudinal direction of the vehicle body and parts 35, and a frame-shaped peripheral wall 36 for covering the periphery of the partition wall portion 35 is coupled to the partition wall portion 35.

図3に示すように、隔壁部35は、中空本体17の内面形状に対応した外形を有し、中空本体17の長手方向に直角な面に沿って形成されている。 As shown in FIG. 3, the partition wall portion 35 has an outer shape corresponding to the inner shape of the hollow body 17, it is formed along a plane perpendicular to the longitudinal direction of the hollow body 17. ただし、本発明において、発泡補強部材30には必ずしも隔壁部35を設ける必要はない。 However, in the present invention, it is not always necessary to provide the partition wall 35 in the foam reinforcing member 30.

周壁部36もまた、中空本体17の内面形状に対応した外形を有し、中空本体17の上面部11a,12a、下面部11b,12b、内側面部11c及び外側面部12cにそれぞれ発泡接着剤15を介して接着結合される接着面部である上面部31、下面部32、内側面部33及び外側面部34を備え、これら相互に隣接する接着面部間にそれぞれ稜線部41〜44が形成されている。 The peripheral wall portion 36 also has an outer shape corresponding to the inner shape of the hollow body 17, the upper surface portion 11a of the hollow body 17, 12a, lower surface portion 11b, 12b, respectively foamed adhesive 15 to the inner surface 11c and outer face 12c upper surface part 31 is an adhesive surface which is adhesively bonded over the lower surface portion 32, an inner surface 33 and outer surface 34, respectively ridgeline portions 41-44 between the adhesive surface adjacent thereto one another are formed. また、周壁部36は、全周に亘って略一定の厚みを有するように形成されている。 Further, the peripheral wall portion 36 is formed so as to have a substantially constant thickness over the entire circumference.

また、発泡補強部材30は、周壁部36において互いに対向する内壁面同士に跨る複数のリブ37を有する。 Further, the foamed reinforcing member 30 has a plurality of ribs 37 extending over the inner wall faces facing each other in the peripheral wall 36. これらのリブ37は、隔壁部35を中空本体17の長手方向に貫通して設けられている。 These ribs 37 are provided through the partition wall 35 in the longitudinal direction of the hollow body 17.

発泡補強部材30は、図6及び図7に示す成形型60を用いて射出成形されるが、その具体的な成形方法については後述する。 Foam reinforcing member 30 are injection molded by using a mold 60 shown in FIGS. 6 and 7 will be described later The specific molding method.

図3及び図4に示すように、発泡補強部材30の周壁部36は、中空本体17の内壁面に対して略平行に配置された状態、具体的には、周壁部36を構成する上面部31、下面部32及び両側の側面部33,34がそれぞれ中空本体17の上面部11a,12a、下面部11b,12b及び両側の側面部11c,12cに対して所定の間隔を空けて略平行に配置された状態で、中空本体17に接着結合されている。 As shown in FIGS. 3 and 4, the peripheral wall 36 of the foam reinforcing member 30 is disposed substantially parallel to state the inner wall surface of the hollow body 17, specifically, the upper surface portion constituting the peripheral wall portion 36 31, the upper surface portion 11a of the lower surface portion 32 and both side portions 33 and 34 respectively hollow body 17, 12a, lower surface portion 11b, 12b and both side portions 11c, substantially parallel to and spaced a predetermined distance from the 12c the arrangement state, is adhesively bonded to the hollow body 17. すなわち、この結合状態において、発泡補強部材30の周壁部36の各稜線部41〜44は、中空本体17の各稜線部11d,11e,12d,12eの内壁面に対して所定の間隔を空けて対向配置されている。 That is, in this connection state, the ridge line portions 41 to 44 of the peripheral wall portion 36 of the foam reinforcing member 30, the ridge portion 11d of the hollow body 17, 11e, 12d, at a predetermined distance from the inner wall surface of 12e They are oppositely disposed.

続いて、上記のように構成される発泡補強部材30が配設されたサイドシル10を製造する方法について説明する。 Next, a method for fabricating the side sill 10 to foam the reinforcing member 30 configured as described above is disposed.

先ず、別々に所定形状に成形した発泡補強部材30と中空本体17とを準備する。 First, a molded separately predetermined shape and foam the reinforcing member 30 and the hollow body 17. 前述したように、中空本体17は、サイドシルインナ11とサイドシルアウタ12とがそれぞれ、鋼板などの金属製の板状素材をプレス加工して所定形状に成形され、発泡補強部材30は、成形型のキャビティに発泡性樹脂材料を射出して充填した後、該成形型の少なくとも一部をキャビティの容積を拡大する方向に該成形型の外側に向かってコアバックさせることで成形される。 As described above, the hollow body 17, side sill inner 11 and the side sill outer 12 and, respectively, is molded a metal plate material such as steel plate pressing to a predetermined shape, the foam reinforcing member 30, the mold after the foamable resin material is filled by injection into the cavity, it is molded by causing the core back toward the outside of the forming die at least a portion of the forming die in a direction to increase the volume of the cavity. 発泡補強部材30を成形する方法については後に詳細に説明する。 It will be described in detail later how to mold the foamed reinforcing member 30.

次に、発泡補強部材30の周壁部36を中空本体17の内壁面に接着剤を介して接着結合する。 Next, adhesive bonding via an adhesive peripheral wall 36 of the foam reinforcing member 30 on the inner wall surface of the hollow body 17. 具体的には、先ず、発泡補強部材30の周壁部36の外周面に発泡接着剤15を層状に設ける。 Specifically, first, providing a foamed adhesive 15 in layers on the outer peripheral surface of the peripheral wall portion 36 of the foam reinforcing member 30. 本実施形態では、図5に示すように、周壁部36の全周に亘って一定の厚みで発泡接着剤15を設けるようにするが、発泡接着剤15は、周壁部36における中空本体17の稜線部11d,11e,12d,12eへの接着部分、すなわち周壁部36の稜線部41〜44を挟んだ両側近傍部間に亘る連続部分の外周面に連続的に設けるようにすれば、必ずしも全周に亘って設けなくてもよい。 In the present embodiment, as shown in FIG. 5, so as provide a foamed adhesive 15 at a constant thickness over the entire circumference of the peripheral wall 36, foamed adhesive 15, the hollow body 17 in the peripheral wall 36 ridge portions 11d, 11e, 12d, the bonded portion to 12e, i.e. when the outer peripheral surface of the continuous portion over between sides vicinity sandwiching the ridge portion 41 to 44 of the peripheral wall 36 so as to continuously provide necessarily all need not be provided over the circumference.

発泡接着剤15は、発泡補強部材30と同様に射出成形によってシート状に成形することができる。 Foamed adhesive 15 can be formed into a sheet by injection molding in the same manner as the foam reinforcing member 30. 例えば、発泡補強部材30を成形した後に、別の成形装置の成形型に発泡補強部材30をインサートし、発泡補強部材30の外周にシート状の発泡接着剤15を射出成形によって成形することができる。 For example, after forming the foamed reinforcing member 30, insert the foam reinforcing member 30 to the mold of another molding apparatus can be molded by injection molding a sheet-like foamed adhesive 15 to the outer periphery of the foamed reinforcing member 30 . また、発泡補強部材30を成形するための成形型において発泡補強部材30を成形した後に該成形型を所定厚み分だけ開き、これにより生じる隙間に発泡接着剤15を射出充填して成形する、所謂二重成形(二色成形)によって発泡接着剤15をシート状に設けることも可能である。 Also, open the forming die after molding the foamed reinforcing member 30 in the mold for molding a foamed reinforcing member 30 by a predetermined thickness of, thereby forming by injection filled with the foamed adhesive 15 to the gap formed, the so-called by a double molding (two-color molding) can also be provided a foaming adhesive 15 into a sheet.

なお、発泡接着剤としては、エポキシ樹脂やウレタン樹脂などの熱硬化性樹脂を用いることができ、該樹脂にフィラーとして無機系のガラス繊維、炭酸カルシウム、タルク、クレーなど、有機系フィラーのパルプ繊維や木粉などを含有させるようにしてもよい。 As the foaming adhesive, it is possible to use a thermosetting resin such as epoxy resin or urethane resin, glass fiber, calcium carbonate inorganic as filler to the resin, talc and clay, pulp fiber of the organic filler it may be made to contain the like and wood flour. 例えば、発泡接着剤として、商品名:L−5520(エルアンドエル・プロダクツ社製)を用いることができる。 For example, as a foaming adhesive, trade name: L-5520 (manufactured by L & El Products, Inc.) can be used. また、発泡接着剤に用いる発泡剤としては、超臨界状態にした二酸化炭素又は窒素等の不活性ガスを用いることができ、その他の物理発泡剤、炭酸水素ナトリウム等の化学発泡剤、或いは、気化等により膨張可能な膨張剤と該膨張剤を内包する球殻状のシェルとからなる熱膨張性マイクロカプセルを使用することも可能である。 As the blowing agent used for foaming adhesive, it is possible to use an inert gas such as carbon dioxide or nitrogen and the supercritical state, other physical blowing agents, chemical blowing agents such as sodium hydrogen carbonate, or vaporized it is also possible to use a thermally expandable microcapsule comprising a spherical shell of the shell enclosing the inflatable swelling agent and said swelling agent by like.

続いて、この発泡補強部材30を中空本体17の内部の所定位置に配設する。 Then, disposing the foamed reinforcing member 30 at a predetermined position inside the hollow body 17. このとき、発泡補強部材30の周壁部36が中空本体17の内壁面に対して全周に亘って略一定の間隔を空けて対向配置されるように、発泡補強部材30を配設する。 At this time, as opposed to at a substantially constant spacing wall portion 36 of the foam reinforcing member 30 over the entire circumference against the inner wall surface of the hollow body 17, disposing the foamed reinforcing member 30. なお、このとき、このような発泡補強部材30の配置状態を維持するために、図示しないクリップ等を用いて、発泡補強部材30を中空本体17に対して仮止めしておく。 At this time, in order to maintain the arrangement of such a foamed reinforcement member 30, using a clip or the like (not shown) keep temporarily fixed foam reinforcing member 30 relative to the hollow body 17. このようにして発泡補強部材30を中空本体17の内部に配設した状態において、発泡補強部材30の周壁部36と中空本体17の内壁面との間に発泡接着剤15が配設されることとなる。 In the state which is arranged in the interior of the foamed reinforcing member 30 in this way the hollow body 17, the foamed adhesive 15 is disposed between the inner wall surface of the peripheral wall portion 36 and the hollow body 17 of foamed reinforcing member 30 to become.

その後、サイドシル10を備えた車体に防錆処理として電着塗装が施され、サイドシル10では、この車体の電着塗装の乾燥時の熱によって発泡接着剤15が発泡して、この発泡接着剤15が発泡補強部材30の周壁部36と中空本体17の内壁面との隙間を埋めるように膨張し、これにより、発泡補強部材30と中空本体17とが発泡接着剤15を介して接着結合されて、発泡補強部材30が配設されたサイドシル10が得られる。 Then, electrodeposition coating as rust is applied to a vehicle body provided with a side sill 10, the side sill 10, foamed adhesive 15 by heat during drying of the body of the electrodeposition coating is foamed, the foamed adhesive 15 There inflated to fill the gap between the inner wall surface of the peripheral wall portion 36 and the hollow body 17 of foam the reinforcing member 30, thereby, the foam reinforcing member 30 and the hollow body 17 is adhesively bonded via the foaming adhesive 15 , the side sill 10 is obtained foamed reinforcing member 30 is disposed. なお、電着塗装の乾燥は、例えば150〜170度の温度に保持することにより行われる。 The drying of the electrodeposition coating is carried out by maintaining the temperature of, for example, 150-170 degrees.

以下、発泡補強部材30を成形する方法について具体的に説明する。 It will be specifically described below a method of forming a foamed reinforcing member 30.

図6に示すように、発泡補強部材30の成形に用いる成形型60は、発泡補強部材30の周壁部36における稜線部41〜44を挟んだ両側近傍部間に亘る連続部分を外側から成形する4つの固定コア61〜64と、隣り合う固定コア61〜64間に挟まれて配設されるとともに周壁部36における前記連続部分を除いた残りの部分、すなわち上面部31、下面部32、内側面部33及び外側面部34の各中央部55〜58を外側から成形する4つの可動コア65〜68とを有する。 As shown in FIG. 6, the mold 60 used for molding the foamed reinforcing member 30, forming a continuous portion over between sides vicinity sandwiching the ridge portion 41 to 44 of the peripheral wall portion 36 of the foam reinforcing member 30 from the outside four fixed core 61 to 64, the remaining portion except for the continuous portion of the peripheral wall portion 36 while being sandwiched between the fixed adjacent core 61 to 64 arranged, i.e. the upper surface portion 31, a lower surface portion 32, the inner each central portion 55 to 58 of the surface 33 and outer surface 34 and a four movable core molded from the outside 65 to 68. また、成形型60は、周壁部36全体を内側から成形するとともに複数のリブ37を成形する複数の内側コア69を更に有する。 Further, the mold 60 further includes a plurality of inner cores 69 for molding a plurality of ribs 37 as well as forming the entire peripheral wall 36 from the inside. 発泡補強部材30の周壁部36を成形する内側コア69の成形面と、該成形面に対向する各固定コア61〜64の成形面とは、周壁部36の板厚を規定する間隔を空けて配置されている。 And the molding surface of the inner core 69 for molding the peripheral wall 36 of the foam reinforcing member 30, the molding surface of the fixed core 61 to 64 opposed to the molding surface, with a spacing that defines the thickness of the peripheral wall portion 36 It is located. 一方、各可動コア65〜68は、これに対向する内側コア69の成形面に対して、近接または離間する方向に移動可能に設けられているが、成形型60を型締めした状態においては、周壁部36の板厚よりも小さな間隔を空けて配置されている。 On the other hand, the movable core 65 to 68, relative to the molding surface of the inner core 69 opposite thereto, but is provided movably in a direction toward or away from, in a state where the mold 60 and mold clamping is They are arranged at a smaller spacing than the thickness of the peripheral wall portion 36.

成形の際は、先ず、成形型60を型締めした状態で、図示しない射出装置により発泡性樹脂材料Pを成形型60のキャビティSに射出して充填する。 During molding, first, in a state where the mold 60 and mold clamping is filled by injecting a foaming resin material P in the cavity S of the mold 60 by a not shown injection unit. 型締めした状態の成形型60において、可動コア65〜68の成形面とこれに対向する内側コア69の成形面との間隔は、固定コア61〜64の成形面とこれに対向する内側コア69の成形面との間隔に等しくなっており、これにより、発泡性樹脂材料Pの射出充填完了時において、周壁部36を構成する発泡性樹脂材料Pの板厚は全周に亘って略等しくなるようになっている。 In the mold 60 of the mold clamping state, the distance between the molding surface of the inner core 69 to the molding surface opposed thereto of the movable core 65 to 68, the inner core 69 to the molding surface opposed thereto of the stationary core 61 to 64 has become equal to the distance between the molding surface of, thereby, at the time of injection filling completion of the foamable resin material P, the thickness of the foamable resin material P which constitutes the peripheral wall portion 36 is substantially equal over the entire circumference It has become way.

なお、発泡性樹脂材料Pに用いる樹脂としては、PP樹脂、PA6樹脂、PA66樹脂、MXD樹脂などの樹脂を用いることができ、該樹脂に、フィラーとしてガラス繊維、炭素繊維、樽区などを含有させるようにしてもよい。 As the resin used for the foamable resin material P, PP resin, PA6 resin, PA66 resin, it is possible to use a resin such as MXD resin contained in the resin, glass fiber, carbon fiber as a filler, and barrel-ku it may be allowed to. より具体的には、例えば、30重量%ガラス繊維を含有させたポリアミド6樹脂である商品名:T−402(東洋紡績株式会社製)を用いることができる。 More specifically, for example, trade name is a polyamide 6 resin containing 30 wt% glass fibers: it is possible to use T-402 (manufactured by Toyobo Co., Ltd.). また、発泡性樹脂材料Pに用いる発泡剤としては、超臨界状態にした二酸化炭素又は窒素等の不活性ガスを用いることができ、その他の物理発泡剤、炭酸水素ナトリウム等の化学発泡剤、或いは、気化等により膨張可能な膨張剤と該膨張剤を内包する球殻状のシェルとからなる熱膨張性マイクロカプセルを使用することも可能である。 As the blowing agent used in foaming resin material P, it is possible to use an inert gas such as carbon dioxide or nitrogen and the supercritical state, other physical blowing agents, chemical blowing agents such as sodium hydrogen carbonate, or it is also possible to use a thermally expandable microcapsule comprising a spherical shell of the shell enclosing the inflatable swelling agent and said swelling agent by vaporization or the like.

次に、図7に示すように、可動コア65〜68を、キャビティSの容積を拡大するように成形型60の外側に向かってコアバックさせる。 Next, as shown in FIG. 7, the movable core 65 to 68, to the core back toward the outside of the mold 60 so as to enlarge the volume of the cavity S. これにより、キャビティS内の樹脂材料Pは、発泡補強部材30の周壁部36における前記中央部55〜58を構成する部分において、発泡が促進されながら可動コア65〜68のコアバックに追従して膨張する。 Thus, the resin material P in the cavity S is the portion constituting the central portion 55 to 58 of the peripheral wall portion 36 of the foam reinforcing member 30, following the core back of the movable core 65 to 68 while bubbling is promoted expanding. このようにして、発泡補強部材30の周壁部36の前記中央部55〜58は、稜線部41〜44を挟んだ両側近傍部間に亘る連続部分と略同じ厚みになるまで板厚を径方向外側へ拡大しながら発泡成形される。 In this manner, the central portion 55 to 58 of the peripheral wall portion 36 of the foam reinforcing member 30, radial plate thickness to be substantially the same thickness as the continuous portion over between sides vicinity sandwiching the ridge portion 41 to 44 It is foamed molded while expanding outward.

このようにして成形された発泡補強部材30において、周壁部36の前記中央部55〜58は、稜線部41〜44を挟んだ両側近傍部間に亘る連続部分に比べて発泡倍率が高い高発泡部Hとなるのに対して、稜線部41〜44を挟んだ両側近傍部間に亘る連続部分は、前記中央部55〜58に比べて発泡倍率が低い低発泡部Lとなる。 In the foamed reinforcing member 30 molded in this manner, the central portion 55 to 58 of the peripheral wall portion 36, a high foaming expansion ratio is higher than the continuous portion over between sides vicinity sandwiching the ridge portion 41 to 44 whereas the part H, successive portions over between sides vicinity sandwiching the ridge portion 41-44, the expansion ratio becomes low low foaming portion L as compared with the central portion 55 to 58. この低発泡部Lでは、樹脂材料Pに含まれる発泡剤により僅かながら発泡するが、その発泡倍率は高発泡部Hに比べて著しく低いため、低発泡部Lにおいては、非発泡で成形する場合と同様の高い支持強度を得ることができる。 In the low foaming unit L, but foaming slightly by blowing agent contained in the resin material P, because significantly lower than the expansion ratio is high expansion portion H, the low foaming portion L in the case of forming a non-foamed it is possible to obtain a high supporting strength of same as. そして、発泡補強部材30は、高い支持強度を有する低発泡部Lにおいて中空本体17の稜線部11d,11e,12d,12eに接着されるため、補強面において特に重要なこの稜線部11d,11e,12d,12eを効果的に補強することができる。 Then, the foamed reinforcing member 30 is higher ridge portion 11d of a support strength hollow in the low foaming unit L body 17, 11e, 12d, to be adhered to 12e, particularly important this ridge portion 11d in the reinforcement surface, 11e, 12d, 12e can be effectively reinforced.

また、発泡補強部材30の周壁部36は、高発泡部Hが設けられることで軽量化が図られているため、サイドシル10、ひいては車体全体の軽量化に貢献することができる。 Further, the peripheral wall portion 36 of the foam reinforcing member 30, since the weight reduction is achieved by the high foaming unit H is provided, the side sill 10 can thus contribute to a reduction in the weight of the whole vehicle body.

さらに、周壁部36の稜線部41〜44は、固定コア61〜64により成形された低発泡部Lであるため、この稜線部41〜44において、所謂コアバック法により発泡成形される場合に生じるような形状ダレを防止して、所望の板厚を確実に確保することができる。 Furthermore, the ridge line portions 41 to 44 of the peripheral wall portion 36 are the low foaming portion L which is formed by the fixed core 61 to 64, in the ridge portions 41-44, occurs when the foamed molded by a so-called core back method to prevent shape sagging as it is possible to reliably ensure the desired thickness. したがって、図5に示すように、中空本体17の内部に発泡補強部材30を配設したとき、発泡補強部材30の周壁部36と中空本体17の内壁面との隙間が所望の間隔よりも大きく拡がることを防止でき、これにより、この隙間に一定の厚みで層状に設けた発泡接着剤15を発泡、膨張させる際、この発泡接着剤15の発泡倍率が過剰に高くなることを防止できる。 Accordingly, as shown in FIG. 5, when the interior of the hollow body 17 is disposed a foam reinforcing member 30, the gap between the inner wall surface of the peripheral wall portion 36 and the hollow body 17 of foam the reinforcing member 30 is greater than the desired spacing it can be prevented to spread, thereby foaming the foaming adhesive 15 provided in layers with a constant thickness in the gap, when inflated, can be prevented expansion ratio of the foamed adhesive 15 is excessively high. そのため、中空本体17の稜線部11d,11e,12d,12eの内壁面に対する発泡補強部材30の接着部分において、適切な倍率で発泡した発泡接着剤15により高い接着強度が得られるため、この稜線部11d,11e,12d,12eを一層効果的に補強することができる。 Therefore, since the ridge portion 11d of the hollow body 17, 11e, 12d, in the adhesive portion of the foamed reinforcing member 30 relative to the inner wall surface of the 12e, high adhesive strength by foamed adhesive 15 to foam at the appropriate magnification is obtained, the ridge portion 11d, 11e, 12d, 12e and can be further effectively reinforced.

なお、発泡補強部材30の成形に関して、上記のように周壁部36がコアバック法により発泡成形されているが、隔壁部35についても同様にコアバック法を用いて発泡成形することで、該隔壁部35の板厚を厚くすることが可能である。 Incidentally, with respect to the shaped foam reinforcing member 30, but the peripheral wall 36 as described above are foamed molded by the core-back method, by foam molding using a core back method in the same manner for the partition wall 35, partition wall thickness parts 35 can be a thickening. この場合、重量の増加を抑制しつつ発泡補強部材の強度及び剛性を向上させることができ、補強部材の補強効果をさらに効果的に高めることができる。 In this case, it is possible to improve the strength and rigidity of the foamed reinforcing member while suppressing the increase in weight, it is possible to more effectively enhance the reinforcing effect of the reinforcing member.

以上、上述の実施形態を挙げて本発明を説明したが、本発明は上述の実施形態に限定されるものではない。 Having described the present invention by way of the above embodiments, the present invention is not limited to the embodiments described above.

例えば、上述の実施形態では、中空構造物としてのサイドシル10に本発明を適用する場合について説明したが、例えばセンタピラーなど、サイドシル以外の車体構成部材、又は、中空本体の内部に発泡補強部材が配設された車体構成部材以外の中空構造物にも等しく適用することができる。 For example, in the embodiment described above has described the case of applying the present invention to the side sill 10 of a hollow structure, for example, a center pillar, etc., the vehicle body constituent member other than the side sill or the internal foaming reinforcing member of the hollow body it can equally apply to disposed the body constituent hollow structures other than members.

以上のように、本発明によれば、中空本体の内部に配設される補強部材として発泡補強部材を用いることで中空構造物の軽量化を図りつつ、この発泡補強部材により中空本体の特に稜線部を効果的に補強することができるため、例えばサイドシルなどの車体構成部材の製造技術分野において好適に利用される可能性がある。 As described above, according to the present invention, while achieving weight reduction that the hollow structure using foaming reinforcing member as a reinforcing member disposed in the interior of the hollow body, in particular ridge of the hollow body by the foamed reinforcing member since parts can be effectively reinforced, for example, it could be suitably used in the art for the manufacture of vehicle body component member such as the side sill.

10,100:サイドシル、11d,11e,12d,12e:中空本体の稜線部、15,105:発泡接着剤、17:中空本体、30,40,110:発泡補強部材、36,116:発泡補強部材の周壁部、41〜44:発泡補強部材の稜線部、60,120:成形型、61〜64:固定コア、65〜68:可動コア、H:周壁部の高発泡部、L:周壁部の低発泡部、P,P1:発泡性樹脂材料、S,S1:キャビティ。 10,100: side sill, 11d, 11e, 12d, 12e: edge line of the hollow body, 15,105: foamed adhesive, 17: hollow body, 30,40,110: foaming reinforcing member, 36,116: foam reinforcement member the peripheral wall portion of 41 to 44: ridge portion of the foamed reinforcing member, 60, 120: mold, 61 to 64: the fixed core, 65 to 68: the movable core, H: high expansion portion of the peripheral wall, L: peripheral wall portion of the low foaming unit, P, P1: foamable resin material, S, S1: cavity.

Claims (7)

  1. 中空本体の内部に発泡補強部材が配設された中空構造物であって、 A hollow structure foaming reinforcing member is disposed within the hollow body,
    前記発泡補強部材は、全周に亘って略一定の厚みを有し且つ少なくとも一部が発泡成形された板枠状の周壁部を備え、 The foam reinforcing member includes a peripheral wall portion of the entire periphery over a substantially constant thickness and at least a part of which is foam-molded plate frame shape,
    該周壁部は、前記中空本体の内壁面に接着剤を介して接着結合され、 The peripheral wall portion is adhesively bonded via an adhesive to the inner wall surface of the hollow body,
    前記周壁部における前記中空本体の稜線部への接着部分は、前記周壁部における残りの部分に比べて発泡倍率が低い樹脂部分からなることを特徴とする発泡補強部材が配設された中空構造物。 Bonding portions of the ridge portion of the hollow body in the circumferential wall, hollow structures foamed reinforcing member, wherein a foaming ratio compared to the rest consisting of lower resin portion in the peripheral wall portion is disposed .
  2. 前記周壁部は、発泡接着剤を介して前記中空本体の内壁面に接着結合され、 The peripheral wall portion is adhesively bonded to the inner wall surface of the hollow body through the foamed adhesive,
    前記周壁部と前記中空本体の内壁面との間隔は全周に亘って略一定であることを特徴とする請求項1に記載の発泡補強部材が配設された中空構造物。 The hollow structure foaming reinforcing member is disposed of claim 1, wherein the distance between the inner wall of the hollow body and the peripheral wall portion is substantially constant over the entire circumference.
  3. 前記中空構造物は、車体の一部を構成する車体構成部材であることを特徴とする請求項1または請求項2に記載の発泡補強部材が配設された中空構造物。 It said hollow structure, hollow structure foaming reinforcing member is disposed of claim 1 or claim 2 characterized in that it is a vehicle body component member that constitutes a part of the vehicle body.
  4. 中空本体の内部に発泡補強部材が配設された中空構造物の製造方法であって、 Internal foaming reinforcing member of the hollow body is a method for producing disposed hollow structure,
    全周に亘って略一定の厚みを有する周壁部を備え、且つ、発泡性樹脂材料が成形型のキャビティ内に充填された後に該成形型の少なくとも一部がキャビティの容積を拡大する方向にコアバックされることで前記周壁部における前記中空本体の稜線部の内壁面に対する接着部分が残りの部分に比べて発泡倍率が低くなるように発泡成形された発泡補強部材を準備する準備工程と、 Includes a peripheral wall portion having a substantially constant thickness over the entire circumference, and the core in a direction in which at least a portion of the forming die after the foaming resin material is filled into the mold cavity to expand the volume of the cavity a preparation step of preparing a foam reinforcing member bonded portion is expansion ratio as compared with the remaining portion being foam-molded so as to be lower with respect to the inner wall surface of the ridge portion of the hollow body in the peripheral wall by being back,
    該準備工程の後、前記発泡補強部材の前記周壁部において前記発泡倍率が低い部分を、前記中空本体の内壁面に接着剤を介して接着結合する接着工程と、を有することを特徴とする発泡補強部材が配設された中空構造物の製造方法。 After said preparing step, the said expansion ratio is lower portions in the peripheral wall of the foaming reinforcing member, characterized by having a a bonding step of bonding bonded via an adhesive to the inner wall surface of the hollow body blowing method for producing a hollow structure reinforcement member is disposed.
  5. 前記準備工程の前に、前記発泡補強部材を成形する成形工程を有し、 Prior to said preparing step includes a molding step of molding the foamed reinforcing member,
    該成形工程では、前記稜線部の内壁面に対する前記発泡補強部材の前記周壁部の接着部分を成形する複数の固定型と、隣り合う該固定型間に挟まれて配設されるとともに前記周壁部の残りの部分を成形する複数の可動型とを備えた成形型を用いて、該成形型のキャビティに発泡性樹脂材料を充填した後、前記キャビティの容積を拡大する方向に前記可動型をコアバックすることで前記残りの部分を発泡させながら、前記発泡補強部材を成形することを特徴とする請求項4に記載の発泡補強部材が配設された中空構造物の製造方法。 The molding step, the peripheral wall portion and a plurality of fixed molding the adhered portion of the peripheral wall of the foaming reinforcing member against the inner wall surface of the ridge portion, while being sandwiched between adjacent solid fixed arranged core using a mold and a plurality of movable molds for molding the rest, after filling a foaming resin material into the molding mold cavity, said movable mold in the direction of expanding the volume of the cavity while blowing the remaining portion by back method of hollow structural foaming reinforcing member is disposed of claim 4, characterized by molding the foamed reinforcing member.
  6. 前記接着工程では、前記発泡補強部材の周壁部を、前記中空本体の内壁面に対して全周に亘って略一定の間隔を空けて対向配置し、前記周壁部と前記中空本体の内壁面との間に発泡接着剤を配設した後、該発泡接着剤を発泡させ、該発泡接着剤を介して前記周壁部を前記中空本体に接着結合することを特徴とする請求項4または請求項5に記載の発泡補強部材が配設された中空構造物の製造方法。 In the bonding step, the peripheral wall of the foaming reinforcing member, opposed spaced a substantially constant distance along the entire circumference against the inner wall surface of the hollow body, the inner wall surface of the hollow body and the peripheral wall portion after disposing the foaming adhesive between, by foaming foam adhesive according to claim 4 or claim 5 through the blowing adhesive characterized by adhesively bonding the peripheral wall to the hollow body method for producing a hollow structure foaming reinforcing member is disposed according to.
  7. 前記中空構造物は、車体の一部を構成する車体構成部材であり、 It said hollow structure is a vehicle body component member that constitutes a part of the vehicle body,
    前記接着工程では、車体の塗装乾燥時の熱によって前記発泡接着剤を発泡させることを特徴とする請求項4から請求項6のいずれか1項に記載の発泡補強部材が配設された中空構造物の製造方法。 Wherein in the bonding step, hollow structure foam reinforcement member is disposed according to claims 4 to any one of claims 6 by heat during coating drying of the vehicle body, characterized in that foaming said foaming adhesive method of manufacturing a thing.
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