JP5848886B2 - Foam filler, method for producing structure obtained using the same, and method for filling foam - Google Patents

Description

The present invention relates to a foam filler that fills a hollow structure with a foam, a method for producing a structure obtained by using the foam filler, and a method for filling a foam.

  Conventionally, in order to fill a hollow part of a hollow structure constituting a vehicle or the like with a foam, a foam filler in which a foaming member that foams and hardens by heating is supported by a support member is used (see Patent Document 1). The foam filling tool of Patent Document 1 partitions the hollow portion of the hollow structure with a support member, and fills the foam with the space between the support member and the inner peripheral surface of the hollow structure as a foam filling region.

JP 2002-274427 A

  In the foam filling device in which the hollow portion of the hollow structure is partitioned by the support member, for example, the location required for reinforcement can be set as the foam filling region so that the foam can be filled. This is advantageous from the viewpoint of efficiently exhibiting. In such a foam filling device, since the amount of the foam filled in the hollow portion is reduced, in addition to the effect exhibited by the foam itself, the importance of the expression of the effect due to the cooperation between the foam and the support member Will also increase. In this respect, if the foam and the support member are separated from each other, the transmission of the load between the foam and the support member will be affected. Therefore, it is important to improve the integrity of the foam and the support member. .

The present invention has been made in view of such circumstances, and the purpose thereof is to efficiently exhibit the effect of filling the foam and to facilitate foam filling that enhances the integration between the foam and the support member. Another object is to provide a tool, a method of manufacturing a structure obtained by using the tool, and a method of filling a foam.

In order to achieve the above object, the invention described in claim 1 includes a foamable member that is foamed and cured by heating to become a foam, and a support member on which the foamable member is supported. The foam is disposed in the hollow portion of the hollow structure, and the foam is filled with the foam between the support member and the inner peripheral surface of the hollow structure by partitioning the hollow portion with the support member. The support member is provided with a protruding member that protrudes toward the inner peripheral surface of the hollow structure in the filling region and has a through path, and the foamable member includes The foaming member is disposed on the support member in a state where an insertion portion to be inserted into the through passage is formed in advance and sandwiches both openings of the through passage and the insertion portion is inserted into the through passage . This is the gist.

In this invention, since the filling area | region of a foam is divided and formed by a supporting member, the location where the necessity for reinforcement is high can be set as a filling area | region, for example. Therefore, it becomes easy to efficiently exhibit the effect of filling the foam. And it becomes possible to fill the foam which has the movement control part fitted to the penetration path by arranging the foamable member so as to sandwich both openings of the penetration path. The movement restricting portion restricts the movement of the foam formed on both opening sides of the through path, thereby suppressing the separation between the foam and the support member.
Moreover, the filling part in a penetration path can be accelerated | stimulated by the insertion part in a penetration path. Further, the foamable member can be positioned with respect to the support member and the protruding member using the insertion portion.

  According to a second aspect of the present invention, in the foam filler according to the first aspect, the hollow structure has a cylindrical shape having a longitudinal direction, and the support member has a shape extending along the longitudinal direction of the hollow structure. The main point is to make

According to this configuration, for example, a structure that is difficult to deform with respect to a bending load can be obtained.
The gist of the invention described in claim 3 is that, in the foam filler according to claim 1 or 2, the protruding member has a shape extending along the outer surface of the support member.

According to this configuration, the supporting member can be reinforced by the protruding member described above.
The gist of the invention according to claim 4 is the foam filler according to any one of claims 1 to 3, wherein the protruding member has a plurality of the through passages.

According to this structure, since the movement control part which a foam has can be increased, the separation between the foam and the support member can be further suppressed .

Invention of Claim 5 is a manufacturing method of the structure formed by filling the said foam using the foam filling tool as described in any one of Claims 1-4, Comprising: The said structure Is provided with the hollow structure and the foam, and the foam has a movement restricting portion fitted in the through passage.

The invention according to claim 6 is a foam filling method in which the filling region is filled with the foam using the foam filler according to any one of claims 1 to 4 , wherein the foaming is performed. The gist is to fill a foam having a movement restricting portion fitted in the through passage by heating the foamable member after the filler is disposed in the hollow portion of the hollow structure.

According to the structure manufacturing method and the foam filling method, it is easy to efficiently exert the effect of filling the foam, and it is possible to suppress the separation between the foam and the support member. .

  ADVANTAGE OF THE INVENTION According to this invention, while exhibiting the effect by filling of a foam efficiently, it becomes easy to improve the integrity of a foam and a supporting member.

The perspective view which shows a part of hollow structure of embodiment, and a part of foam filler. The perspective view which shows the supporting member which provided the protrusion member. (A) is sectional drawing which shows the hollow structure which has arrange | positioned the foam filling tool, (b) is sectional drawing which shows the state with which the foam was filled in the hollow part. (A) is a perspective view which expands and shows a part of protrusion member which changed the penetration path, (b) is a sectional view which expands and shows the principal part of the foaming filler which changed the foamable member. (A) And (b) is a perspective view which shows the foaming filler which changed the protrusion member. (A) is a perspective view which shows the foaming filler which changed the supporting member, (b) is sectional drawing which shows the foaming filler and hollow structure which changed the supporting member.

An embodiment embodying the present invention will be described in detail with reference to FIGS.
As shown in FIG. 1, the foam filler 11 includes a foamable member 12 that is foamed and cured by heating to become a foam, and a support member 13 that supports the foamable member 12. The foam filler 11 is disposed in the hollow portion of the hollow structure 51.

  The hollow structure 51 has a polygonal cylindrical shape having a longitudinal direction, and is formed by joining the first component member 51a and the second component member 51b. Each of the constituent members 51a and 51b has a shape obtained by dividing the hollow structure 51 into two parts along the longitudinal direction, and a plurality of bent portions are formed along the longitudinal direction. Due to such a plurality of bent portions, the cross-sectional shape of the hollow structure 51 is set to a predetermined polygonal shape. The hollow structure 51 of the present embodiment is formed from a metal material and constitutes a part of the vehicle structure.

  The foamable member 12 is obtained by molding a foamable material by a known molding method such as extrusion molding, press molding, injection molding or the like. In addition to the base material, the foaming agent, and the crosslinking agent, the foamable material appropriately contains a filler, a plasticizer, and the like. Examples of the substrate include synthetic resins, elastomers, and rubbers. Examples of the synthetic resin include polyolefin, epoxy resin, phenol resin, urethane resin, acrylic resin, styrene resin, EVA (ethylene / vinyl acetate copolymer), and the like. Examples of the elastomer include RB (polybutadiene elastomer), SBS (styrene / butadiene / styrene block copolymer), SIS (styrene / isoprene / styrene block copolymer), SEBS (styrene / ethylene / butylene / styrene block copolymer) and the like. Can be mentioned. As rubber, NR (natural rubber), SBR (styrene / butadiene rubber), BR (butadiene rubber), NBR (nitrile rubber), CR (chloroprene rubber), IR (isoprene rubber), IIR (butyl rubber), EPDM (ethylene) And propylene diene terpolymer), UR (urethane rubber), ENR (epoxidized natural rubber), EPM (ethylene / propylene rubber), and the like. 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.

  As shown in FIGS. 1 and 2, the support member 13 of the present embodiment has a plate shape, and has a U-shaped cross-sectional shape by bending along the inner peripheral shape of the hollow structure 51. The support member 13 defines the hollow portion by being disposed in the hollow portion of the hollow structure 51. By this section, a filling region for filling the foam is formed between the outer surface on the bulging side of the support member 13 and the inner peripheral surface of the hollow structure 51. On the other hand, the space between the back surface of the outer surface of the support member 13 and the inner peripheral surface of the first component member 51a is a non-filling region that is not filled with foam. The support member 13 has a shape extending in the longitudinal direction of the hollow structure 51. Such a support member 13 is formed of a resin material (polyamide in the present embodiment) that can withstand heating for foaming and curing the foamable member 12. The support member 13 may be provided with a locking portion that locks into a locking hole formed in the hollow structure 51, for example, as necessary.

  The support member 13 is provided with a plurality of protruding members 14 that protrude toward the inner peripheral surface of the hollow structure 51 in the filling region. Each projecting member 14 has a shape extending along the outer surface of the support member 13 on the filling region side, and is arranged so as to extend along the longitudinal direction of the hollow structure 51. As shown in FIG. 3A, the tip of each protruding member 14 is disposed away from the inner peripheral surface of the hollow structure 51, and the tip of each protruding member 14 and the inner peripheral surface of the hollow structure 51 are arranged. The foam is filled in between. Each projecting member 14 is formed of a resin material that can withstand heating for foaming and curing the foamable member 12, as with the support member 13. In the present embodiment, the support member 13 and each protruding member 14 are integrally formed using polyamide.

  As shown in an enlarged view in FIG. 2, a plurality of through passages 15 are formed in the protruding member 14. Each through passage 15 is formed by a pair of standing portions 16 that are erected on the support member 13, and a connecting portion 17 that connects the erected portions 16 at positions separated from the support member 13. Each through passage 15 is provided in a direction different from the extending direction of the protruding member 14 and extends along the outer surface of the support member 13. In FIG. 2, the through-passage 15 is omitted in the drawing showing the entire support member 13, but a plurality of through-holes are formed in the entire projection members 14 so as to be equally spaced along the longitudinal direction. A path 15 is arranged.

  As shown to Fig.3 (a), the foamable member 12 is arrange | positioned at the outer surface of the supporting member 13 used as the filling area | region 52 side. More specifically, the foamable member 12 is disposed between the protruding members 14 and outside the protruding members 14 located on both sides in the short direction of the support member 13. Then, as shown in an enlarged view in FIG. 3A, the foamable member 12 is disposed so as to sandwich both opening portions 15 a that are both end portions of the through passage 15, thereby foaming in the through passage 15. The body is to be filled. Each foamable member 12 can be fixed to the support member 13 via an adhesive layer or an adhesive layer, for example.

Next, the filling and operation of the foam using the foam filler 11 will be described.
After the foam filler 11 is disposed on the first component member 51a, the second component member 51b is joined to the first component member 51a by spot welding or the like, for example, to be disposed at a predetermined position of the hollow portion. At this time, as shown to Fig.3 (a), a hollow part is divided by the support member 13 into the filling area | region 52 and the non-filling area | region of a foam. By such a partition, for example, a portion requiring high reinforcement can be set as the filling region 52. In the case of the hollow structure 51 constituting a part of the vehicle structure as in the present embodiment, for example, the vehicle outer side and the vehicle inner side are partitioned by the support member 13 so that the vehicle outer side is set as the filling region 52. be able to. In addition, when the hollow structure 51 is inclined or when the hollow structure 51 is moved after the foam filler 11 is disposed, the foam filler 11 is predetermined by the above-described locking portion, adhesive, or the like. The position is fixed.

  Next, foaming of the foamable member 12 is started by heating the foam filler 11 from the outside at a predetermined temperature. By performing this heating for a predetermined time, as shown in FIG. For this heating, for example, a drying process when painting the hollow structure 51 can be used. However, the heating process is not limited to this, and a known heating device using electricity, steam, or the like may be used. By applying the foam filler 11 to the hollow structure 51 in this way, a structure 61 with improved strength, rigidity, vibration damping and the like is obtained.

  Here, the foamable member 12 is disposed so as to sandwich both opening portions 15a which are both ends of the through passage 15, so that the inside of the through passage 15 is enlarged as shown in FIG. The foam 21 is filled. Thereby, the foam 21 having the movement restricting portion 21 a fitted in the through passage 15 is filled. More specifically, the foamable member 12 that has started to foam by being heated expands and flows, enters from both openings of the through-passage 15 and cures, thereby forming the movement restricting portion 21a. The movement restricting portion 21 a restricts the movement of the foam 21 formed on the both openings 15 a side of the through passage 15. Thereby, the separation between the foam 21 and the support member 13 is suppressed. The movement restricting portion 21a of the present embodiment is integrated in the through passage 15 and connects the foams 21 formed on both opening portions 15a side. In the movement restricting portion 21 a, for example, the strength is higher than that of the movement restricting portion divided at the central portion of the through passage 15, and it is difficult to detach from the through passage 15. For this reason, the state fitted to the through passage 15 is easily maintained.

  The foam 21 formed on the both openings 15a side of the through passage 15 is connected to the inner peripheral surface of the hollow structure 51, and the front end surface of the protruding member 14 and the inner peripheral surface of the hollow structure 51 It is united between. Thereby, for example, a load or vibration applied from the outside of the hollow structure 51 is not transmitted directly to the protruding member 14 but is transmitted via the foam 21.

The effects exhibited by this embodiment will be described below.
(1) Since the filling region 52 of the foam 21 is partitioned and formed by the support member 13, it is easy to efficiently exhibit the effect of filling the foam 21. Then, the foamable member 12 is disposed so as to sandwich the two openings 15a of the through passage 15 so that the foam 21 having the movement restricting portion 21a fitted to the through passage 15 can be filled. . The movement restricting portion 21 a restricts the movement of the foam 21 formed on the both openings 15 a side of the through-passage 15, whereby the separation between the foam 21 and the support member 13 can be suppressed. For this reason, it becomes easy to improve the integrity of the foam 21 and the support member 13. As a result, the effect of the linkage between the foam 21 and the support member 13 is easily exhibited.

  (2) The hollow structure 51 has a cylindrical shape having a longitudinal direction, and the support member 13 has a shape extending along the longitudinal direction of the hollow structure 51. Thereby, for example, a structure 61 that is difficult to be deformed with respect to a bending load can be obtained.

(3) Since the protruding member 14 has a shape extending along the outer surface of the support member 13, the support member 13 can be reinforced by the protruding member 14.
(4) The protruding member 14 has a plurality of through passages 15. Thereby, since the movement control part 21a which the foam 21 has can be increased, the separation between the foam 21 and the support member 13 can be further suppressed. As a result of the increased integrity of the foam 21 and the support member 13, the effect of the linkage between the foam 21 and the support member 13 is further easily exhibited.

  (5) In the structure filled with the foam 21 using the foam filler 11, the foam 21 has an embedded movement restricting portion 21 a fitted in the through-passage 15. Moreover, in the filling method of the foam 21, after the foam filler 11 is disposed in the hollow portion of the hollow structure 51, the foamable member 12 is heated to have the movement restricting portion 21 a fitted in the through passage 15. The foam 21 is filled. According to the filling method of the structure 61 and the foam body 21, the effect of filling the foam body 21 can be efficiently exhibited, and the integrity of the foam body 21 and the support member 13 can be enhanced.

(Example of change)
The above embodiment may be modified as follows.
-Although the said penetration path 15 is formed in square pillar shape, the shape is not specifically limited, For example, as shown to Fig.4 (a), it can also change into elliptical column shape. For example, it can also be changed to a triangular prism shape, a cylindrical shape, or the like.

  The movement restricting portion 21a is integrated in the through passage 15 and connects the foams 21 formed on the both opening portions 15a side, but is divided into divided bodies in the through passage 15. Also good. Even in this case, the separation between the foam 21 and the support member 13 can be suppressed by the movement restricting portion 21 a fitted in the through passage 15. For example, the movement restricting portion 21a integrated in the through passage 15 can be formed by expanding both the openings 15a or reducing the length of the through passage 15.

  -As shown in FIG.4 (b), the foamable member 12 can also be changed into the foamable member 12 which has the insertion part 12a inserted in the penetration path 15. FIG. In this case, the filling of the foam 21 can be promoted by the insertion portion 12 a in the through passage 15. Thereby, it becomes possible to easily form the movement restricting portion 21a in which the foams 21 formed on the both opening portions 15a side are connected together in the through passage 15. Further, the foamable member 12 can be positioned with respect to the support member 13 and the protruding member 14 by using the insertion portion 12a. Therefore, for example, the work of attaching the foamable member 12 to a predetermined position of the support member 13 can be performed smoothly. Moreover, as shown in FIG.4 (b), it can also be utilized as a fixing | fixed part which fixes the foamable member 12 on the outer surface of the supporting member 13 by setting it as the insertion part 12a fitted to the opening part 15a.

  In addition, the number of the insertion parts 12a is not specifically limited. For example, FIG. 4B shows a mode in which the pair of insertion portions 12 a are inserted from both openings of the through passage 15, but the insertion portion is inserted from one opening of the through passage 15. You can also. Further, for the protruding member 14 having a plurality of through passages 15, an insertion portion can be applied to at least one through passage 15.

  The protruding member 14 is provided from one end to the other end in the longitudinal direction of the support member 13. For example, as illustrated in FIG. 5A, the protruding member 14 is partially extended in the longitudinal direction of the support member 13. Can also be provided. In addition, the number of the protrusion members 14 is not specifically limited, It can change suitably.

  The protruding member 14 has a shape extending along the outer surface of the support member 13, but has a longitudinal direction within the surface along the outer surface of the support member 13, for example, as shown in FIG. It is also possible to change to a protruding member 14 that does not.

  -Although the said protrusion member 14 is provided so that it may space apart from the internal peripheral surface of the hollow structure 51, you may change into the protrusion member 14 which touches the internal peripheral surface of the hollow structure 51. FIG. In this case, the through passage 15 is preferably formed in the vicinity of the support member 13 from the viewpoint of suitably suppressing the separation between the foam 21 and the support member 13.

  The penetrating path 15 is formed so as to extend along the short direction of the hollow structure 51. For example, as shown in FIG. You may change suitably according to etc.

  The support member 13 has a shape that extends along the longitudinal direction of the hollow structure 51. In this regard, as shown in FIG. 6A, by setting the dimension along the longitudinal direction of the hollow structure 51 smaller than the dimension along the short direction of the hollow structure 51, for example, local You may change to the foam filler for the purpose of reinforcement.

  -Although the said support member 13 has comprised the shape bent along the inner peripheral shape of the hollow structure 51, the shape of the support member 13 can be suitably changed according to the location etc. in a hollow part. . For example, as shown in FIG. 6B, the support member may be changed to a flat plate.

  -Although the said supporting member 13 and the protrusion member 14 are comprised from the resin material, you may comprise from a metal material. The support member 13 and the projecting member 14 are integrally formed. However, after the members are separately formed, they can be integrated by, for example, adhesion or welding.

-You may reinforce the supporting member 13 by providing the protrusion which does not have a through-passage in the surface used as the filling area | region 52 side of the supporting member 13, or the surface used as the non-filling area side.
-Although the said foamable member 12 is arrange | positioned at the outer surface of the supporting member 13, you may arrange | position a foamable member in the front end surface of the protrusion member 14 further.

  The foamable member 12 is molded separately from the support member 13 and then attached to the support member 13. However, the foamable member 12 is foamable by insert molding in which the support member 13 provided with the projecting member 14 is disposed in the mold. The attachment and molding of the member 12 can also be performed simultaneously.

  The foam filler 11 is applied to the hollow structure 51 that constitutes a part of the vehicle structure. For example, the foam filler 11 is applied to a hollow structure used for railways, ships, aircraft, buildings, etc. Also good. Moreover, the shape of a hollow structure and a hollow part is not specifically limited, For example, a cylindrical hollow structure may be sufficient. Note that the overall shape and dimensions of the support member 13 and the foamable member 12 can be appropriately changed according to the shape of the hollow portion of the hollow structure to be applied, the setting of the filling region 52 of the foam 21, and the like.

  DESCRIPTION OF SYMBOLS 11 ... Foam filler, 12 ... Foamable member, 12a ... Insertion part, 13 ... Supporting member, 14 ... Projection member, 15 ... Through-passage, 15a ... Opening part, 16 ... Standing part, 17 ... Connection part, 21 ... Foam, 21a ... movement restricting portion, 51 ... hollow structure, 51a ... first component, 51b ... second component, 52 ... filling region, 61 ... structure.

Claims (6)

A foamable member that is foamed and cured by heating to become a foam, and a support member that supports the foamable member, is disposed in a hollow portion of a hollow structure, and the hollow portion is A foam filling device that fills the foam with a space between the support member and the inner peripheral surface of the hollow structure as a filling region of the foam by partitioning with a support member,
The support member is provided with a protruding member that protrudes toward the inner peripheral surface of the hollow structure in the filling region and has a through-passage,
In the foamable member, an insertion portion to be inserted into the through passage is formed in advance,
A foam filling device , wherein the foamable member is disposed on the support member in a state where both openings of the through passage are sandwiched and the insertion portion is inserted into the through passage .   The foam filler according to claim 1, wherein the hollow structure has a cylindrical shape having a longitudinal direction, and the support member has a shape extending along the longitudinal direction of the hollow structure.   The foam filler according to claim 1 or 2, wherein the protruding member has a shape extending along an outer surface of the support member.   The foaming filler according to any one of claims 1 to 3, wherein the protruding member includes a plurality of the through passages. It is a manufacturing method of the structure formed by filling the said foam using the foam filling tool as described in any one of Claim 1 to 4, Comprising: The said structure is the said hollow structure and the said foam and a body, said foam manufacturing method of a structure characterized by having a movement restricting portion fitted to said through-passage. A foam filling method for filling a foam into the filling region using the foam filler according to any one of claims 1 to 4 ,
After the foam filling device is disposed in the hollow portion of the hollow structure, the foaming member is heated to fill the foam having the movement restricting portion fitted in the through passage. Body filling method.

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