JPS6152789B2 - - Google Patents

Description

[Detailed description of the invention] The present invention relates to a reinforcing material that contributes to weight reduction.

For example, automobiles are being made lighter to save resources and energy. If we reduce the thickness of the material or reduce the number of structural members to reduce the weight, the strength will decrease, and if we take a car door as an example, the strength of various parts will decrease, the rigidity of the outer panel surface will be insufficient, especially the tension rigidity, In addition, problems such as poor operational feel may occur.

This requires reinforcement from another perspective.
Since reinforcing with heavy metal plates runs counter to weight reduction, some proposals have been made to strengthen the entire or local part of the door outer panel using light resin plates.

However, the conventionally proposed reinforcement using resin plates simply involves attaching a thin resin plate to the inner surface of the door outer panel, so the reinforcing effect is poor due to the lack of thickness.
Increasing the wall thickness will result in an increase in weight, and if a filler material is inserted between the resin plate and the inner surface of the door outer panel to increase the thickness, it will not be able to follow the shape or the structure will be complicated, making it impractical. It was something I didn't have.

The present invention has been developed in view of the above-mentioned problems, and since it is flexible in an uncured or semi-cured state before use, it can easily follow the shape of the part to be reinforced, and the bead-shaped bulge can be prevented. The object of the present invention is to provide a reinforcing material that hardens after being formed and installed, and, in combination with reinforcing fibers, effectively reinforces a target area with sufficient thickness with a small amount of material.

The present invention will be explained below based on illustrated embodiments.
Note that the same parts are given the same reference numerals.

FIGS. 1 to 3 show the first reinforcing material according to the present invention.
An example is shown, and in the state before use shown in FIGS. 1 and 2, the reinforcing material 1 is made up of a bead forming material 3 having a width narrower than the reinforcing resin layer under the reinforcing resin layer 2. Reinforcing fibers 4 are sandwiched between the forming material 3 and the reinforcing resin layer 2, and the lower surface of the hem 21 of the reinforcing resin layer 2, which extends wider than the width of the bead forming material 3, forms a mounting surface 22.

As the reinforcing resin layer 2, thermosetting resins, particularly epoxy resins, are suitable, but melamine resins, phenol resins, urea resins, etc. may also be used. These resins may be cured by heating, or may be cured at room temperature, and may also be thermoplastic resins that can maintain sufficient strength at the operating temperature. Then, the reinforcing resin layer 2
is prepared into a flexible prepreg state in an uncured or semi-cured state before use, and the mounting surface 22
As shown in FIG. 2, when used on an elevated surface, etc., it is made to have adhesive properties or is made to have adhesive strength with an adhesive so that it can be attached.

As the bead forming material 3, a foamable sheet such as a foamed polyethylene sheet is used, which has flexibility before foaming and foams when heated. The foamable sheet may be either a thermoplastic resin or a thermosetting resin, and may also be a foam material that can be foamed at room temperature, but a hard sheet is preferable because it has a greater reinforcing effect.

Although the reinforcing fibers 4 are sandwiched between the bead forming material 3 and the reinforcing resin layer 2, they may be sandwiched before the bead forming material 3 is foamed. The reinforcing fiber 4 is glass fiber, carbon fiber, metal wire, hemp,
Organic and inorganic fibers such as nylon and paper are used in the form of woven, non-woven, and single fibers.

As shown in FIG. 2, the reinforcing material 1 is pasted and mounted with its mounting surface 22 in contact with the panel A. At this time,
Since the reinforcing resin layer 2 and the bead forming material 3 have flexibility, they have good followability to the shape of the panel A, and since the bead forming material 3 is a foamed sheet before foaming, the followability is particularly good. , the mounting surface 22 is firmly attached to the panel A. When panel A and reinforcing material 1 are heated from this state, the viscosity of reinforcing resin layer 2 temporarily decreases and it becomes more closely attached to panel A.
On the other hand, the bead forming material 3 foams to have a larger cross section, and the reinforcing resin layer 2 is pushed up, forming a bead-like bulge 23 before it hardens. At the same time, the reinforcing fibers 4 rise while remaining on the bead forming material 3 and are sandwiched between the reinforcing resin layer 2 and the reinforcing resin layer 2. As the heating progresses over time, the reinforcing resin layer 2 hardens and follows the shape of the panel A to form a reinforcing material 1 as shown in FIG. 3.

FIG. 4 shows a second embodiment of the reinforcing material, and the reinforcing resin layer 2 includes a reinforcing resin layer 24 reinforced with upper glass fibers and a soft resin layer 25 that foams when hardened and hardens with a predetermined elasticity. It is composed of two layers, and
A film 26 made of polyester or the like is attached to the surface. Therefore, the lower surface of the soft resin layer 25 appears on the mounting surface 22. On the other hand, in panel A,
A rust preventive film 4 is applied. The bead forming material 3 is the first
This is similar to the example.

The reinforced resin layer 24 improves the reinforcing effect by reinforcing the reinforcing resin layer 2 with fibers, and in addition to glass fibers, various organic and inorganic fibers such as carbon fibers, metal wires, hemp, nylon, and paper may be used. It can be strengthened by woven fabric, non-woven fabric, single fiber kneading, embedding, attachment, etc.

The soft resin layer 25 is provided to prevent sink marks on the surface of the panel A caused by expansion and contraction of the resin, and is effective if it is provided at least on the mounting surface 22. If the elasticity of the soft resin layer 25 is too low, the reinforcing effect of the reinforcing material 1 will be reduced, but since the degree of occurrence of sink marks varies depending on the thickness of the panel A, etc., it is set in advance so that it has a predetermined elasticity. In addition, the soft resin layer 25
can also be used with a hard resin layer that is not reinforced with fibers.

The film 26 is used to prevent adhesion to the reinforcing resin layer 21 when it becomes sticky, making it easier to handle, and the same purpose can be achieved using powder.

When the panel A is a steel plate, the antirust film 5 is
In order to prevent rust from occurring due to poor paint coverage, especially at interfaces, a zinc-treated film, paint film, etc. is applied to the surface of panel A. Each configuration added in the second embodiment can be selectively added to and used in the first embodiment as appropriate.

FIG. 7 shows the experimental results of the reinforcing fibers sandwiched between the reinforcing resin layer and the bead forming material.

A reinforcing material is attached and hardened to a steel plate with a width of 55 mm x length of 200 mm x plate thickness of 0.7 mm, a bending span of 100 mm, and a bending speed of 5 mm/
In the experiment, wire A was equivalent to a metal wire, with a stainless steel foil of 20 mm width and 0.05 mm thick being held between them, and wire B being a wire with carbon fiber held between them.
Line C was not clamped by anything, and it was observed that the rigidity was improved by about 50% with stainless steel foil and about 20% with carbon fiber.

Next, a reinforced panel effectively reinforced by the reinforcing material 1 will be explained with reference to FIGS. 5 and 6.

The object shown in Fig. 5 is an automobile door, and the outer panel 6 is relatively flat, so if the weight is reduced and the thickness of the steel plate is reduced, the rigidity will be insufficient, and the surface tension will be insufficient and the rigidity will become uneven. In addition, the feeling of operation as a door tends to be poor. Looking at the panel 6, the upper side 61, lower side 62, front side 63, and rear side 64 are supported by the inner plate and have high rigidity, and the character line 65 also has high rigidity because it has a thick cross section. The center and surrounding areas have low rigidity and require reinforcement. However, attaching and hardening the reinforcing material only to the central portion does not have much effect. This is because there is no foundation to share the load of that part.

In the embodiment shown in FIG.
The reinforcing material 1 is stretched over the parts and hardened, and the low-rigidity part in the center between them is reinforced, and furthermore, the reinforcing material 1 is extended to the lower side 62 to reinforce the lower low-rigidity part. Furthermore, the reinforcing material 1 is spread between the front side 63 and the rear side 64 to reinforce the entire upper low-rigidity region.

In the embodiment shown in FIG. 6, an upper character line 66 and a lower bead-like character line 6
Spread reinforcing material 1 between it and 7 and harden it.
The intermediate flat surface 68 is reinforced.

If the reinforcing material 1 is arranged as in each of the above embodiments,
Since the load on the low-rigidity portion is transmitted to and supported by the high-rigidity portion via the reinforcing member 1, the reinforcing effect is significantly improved.

Note that the shape of the reinforcing material itself or its arrangement in the device is not limited to a straight line, but may be curved, or may be arranged in a grid or other appropriate pattern.

According to the reinforcing material according to the present invention, since it is flexible before use, it adheres closely to the shape of the object to be reinforced with good followability, so there is no need for shaping. Moreover, after the installation and curing, a bead-shaped bulge with sufficient height is formed, and together with the reinforcing fibers sandwiched between the reinforcing resin layer and the bead forming material, it exhibits high rigidity. It can be strongly reinforced, and compared to those using flat plates, it has a high weight ratio effect, contributes to weight reduction, and is low cost. For products that are cured or foamed by heat, the furnace used in the painting process of automobile production lines can be used as is. In addition, it can be made into a highly practical reinforcing material by applying anti-rust measures, fiber reinforcement, sink mark measures, etc.

[Brief explanation of the drawing]

1 to 3 show a first embodiment of the reinforcing material, FIG. 1 is a perspective view, FIG. 2 is a perspective view and cross-sectional view of the installed state before hardening and foaming, and FIG. 3 is a similar view. Shown after curing and foaming. FIG. 4 shows a second embodiment of the reinforcing member, and shows a perspective view and a cross-sectional view of the reinforcing member in the installed state. FIG. 5 is a front view of an automobile door showing an embodiment of the reinforcing panel, and FIG. 6 is a vertical sectional view of the automobile door showing another embodiment of the reinforcing panel. FIG. 7 is a diagram showing the experimental results. DESCRIPTION OF SYMBOLS 1... Reinforcing material, 2... Reinforcing resin layer, 21... Hem part, 22... Mounting surface, 23... Bead-shaped bulging part,
24... Reinforced resin layer, 25... Soft resin layer, 26
... Film, 3 ... Bead forming material, 4 ... Reinforcing fiber, 5 ... Rust prevention film, 6 ... Panel.

Claims (1)

[Claims] 1. Below the reinforcing resin layer, which is flexible in an uncured or semi-cured state before use, is narrower in width than the reinforcing resin layer, and is unfoamed and flexible before the reinforcing material is attached,
A bead-forming material that foams to form a bead-shaped bulge on the reinforcing resin layer after installation is applied, reinforcing fibers are sandwiched between the bead-forming material and the reinforcing resin layer, and the bead-forming material is A reinforcing material characterized in that the lower surface of the hem of the reinforcing resin layer that protrudes wider than the width serves as a mounting surface.