WO2013129262A1 - 発泡樹脂芯材複合板の締結構造 - Google Patents

発泡樹脂芯材複合板の締結構造 Download PDF

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Publication number
WO2013129262A1
WO2013129262A1 PCT/JP2013/054597 JP2013054597W WO2013129262A1 WO 2013129262 A1 WO2013129262 A1 WO 2013129262A1 JP 2013054597 W JP2013054597 W JP 2013054597W WO 2013129262 A1 WO2013129262 A1 WO 2013129262A1
Authority
WO
WIPO (PCT)
Prior art keywords
foamed resin
fastening
core material
hole
composite plate
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/JP2013/054597
Other languages
English (en)
French (fr)
Inventor
杉本　明男
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kobe Steel Ltd
Original Assignee
Kobe Steel Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kobe Steel Ltd filed Critical Kobe Steel Ltd
Priority to US14/375,923 priority Critical patent/US9719538B2/en
Priority to CN201380010869.8A priority patent/CN104136785B/zh
Publication of WO2013129262A1 publication Critical patent/WO2013129262A1/ja
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B5/00—Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them
    • F16B5/0096—Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them by using permanent deformation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D39/00—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders
    • B21D39/03—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders of sheet metal otherwise than by folding
    • B21D39/031—Joining superposed plates by locally deforming without slitting or piercing
    • B21D39/032—Joining superposed plates by locally deforming without slitting or piercing by fitting a projecting part integral with one plate in a hole of the other plate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J15/00—Riveting
    • B21J15/02—Riveting procedures
    • B21J15/04—Riveting hollow rivets mechanically
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K11/00—Resistance welding; Severing by resistance heating
    • B23K11/002—Resistance welding; Severing by resistance heating specially adapted for particular articles or work
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
    • B60R13/0206—Arrangements of fasteners and clips specially adapted for attaching inner vehicle liners or mouldings
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B13/00—Dowels or other devices fastened in walls or the like by inserting them in holes made therein for that purpose
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B19/00—Bolts without screw-thread; Pins, including deformable elements; Rivets
    • F16B19/02—Bolts or sleeves for positioning of machine parts, e.g. notched taper pins, fitting pins, sleeves, eccentric positioning rings
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B19/00—Bolts without screw-thread; Pins, including deformable elements; Rivets
    • F16B19/04—Rivets; Spigots or the like fastened by riveting
    • F16B19/08—Hollow rivets; Multi-part rivets
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B5/00—Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them
    • F16B5/04—Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them by means of riveting
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B5/00—Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them
    • F16B5/08—Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them by means of welds or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • B29C65/562—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits using extra joining elements, i.e. which are not integral with the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • B29C65/64—Joining a non-plastics element to a plastics element, e.g. by force
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/723—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered
    • B29C66/7232—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered comprising a non-plastics layer
    • B29C66/72321—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered comprising a non-plastics layer consisting of metals or their alloys
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/727—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being porous, e.g. foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/74—Joining plastics material to non-plastics material
    • B29C66/742—Joining plastics material to non-plastics material to metals or their alloys
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81427—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81431—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single cavity, e.g. a groove
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/737—Articles provided with holes, e.g. grids, sieves
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B5/00—Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them
    • F16B5/01—Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them by means of fastening elements specially adapted for honeycomb panels
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T403/00—Joints and connections
    • Y10T403/49—Member deformed in situ
    • Y10T403/4949—Deforming component is inserted section

Definitions

  • the present invention relates to a fastening structure of a foamed resin core material composite plate for fastening a foamed resin core material composite plate to a counterpart member.
  • a core composite plate may be used (see, for example, Patent Document 1). These are intended to reduce the weight of the automobile, to provide damping performance, sound insulation performance, and the like.
  • Automobile panel members and cover members are often fastened with other members of the same part, such as frame members, or other members by resistance welding or bolt fastening.
  • these members formed of the foamed resin core material composite plate cannot be fastened by resistance welding because a soft foamed resin that does not conduct electricity is interposed as a core material.
  • an object of the present invention is to provide a fastening structure of a foamed resin core material composite plate that can be applied with either bolt fastening or resistance welding and can maintain strong fastening with a counterpart member for a long period of time. is there.
  • the present invention is a fastening structure of a foamed resin core material composite plate in which a foamed resin core material composite plate laminated with a foamed resin core material sandwiched between metal plates is fastened to a counterpart member.
  • the fastening portion of the foamed resin core material composite plate is provided with a through hole and a crushing peripheral edge portion that crushes the foamed resin core material around the through hole, and is fitted into the through hole.
  • the structure which the said fastening member was fastened with the said other party member was employ
  • the metal fastening member inserted into the through hole is crushed by crimping or welding and joined to the peripheral portion, and the fastening member is fastened to the other member, so that the metal fastening member is joined by caulking or welding. It is firmly bonded to the fastening portion of the foamed resin core composite plate. Thereby, any fastening of bolt fastening and resistance welding can be applied, and strong fastening with the counterpart member can be maintained for a long period of time.
  • the fastening member has a cylindrical shape with a pedestal provided with a pedestal at one end of the cylindrical part, and rises from the periphery of the through hole to the crushing peripheral part.
  • a cylindrical vertical wall portion is provided, the cylindrical portion of the fastening member is fitted into the through hole from the proximal end side of the vertical wall portion, the pedestal portion is pressed against the crushing peripheral edge portion, and the vertical wall
  • the fastening member may be crimped to the distal end side of the vertical wall portion so as to expand the distal end side of the cylindrical portion protruding from the distal end side of the portion.
  • the eyelet-shaped member is placed on the outer side of the vertical wall portion so that the eyelet of the eyelet-shaped member is aligned with the through hole, and the tip end side of the cylindrical portion is the tip side of the vertical wall portion via the eyelet-like member. It may be caulked. Thereby, a fastening member can be combined more firmly so that a vertical wall part may be pinched by a cylindrical part and an eyelet-like member.
  • the fastening member has a hat shape having a flange portion at the lower end of the hat portion, and the flange portion is an outer surface of one of the metal plates at a peripheral edge portion of the through hole.
  • the foamed resin core material at the peripheral part of the through hole so that the cap part fitted into the through hole is pressed flat to the outer surface side of the other metal plate in a flat shape.
  • the fastening member has a dish shape including an inclined wall portion that extends to the outer peripheral side around the bottom portion, and the dish-shaped fastening member is inserted into the through-hole,
  • the dish-shaped fastening member By crushing the dish-shaped fastening member together with the foamed resin core at the peripheral edge of the through-hole so as to expand the inclined wall portion into a flat shape toward the foamed resin side between the metal plates,
  • the inclined wall portion squeezed and expanded in the flat shape is sandwiched between the metal plates on the front and back sides of the crushing peripheral portion, and the sandwiched inclined wall portions are welded to the metal plates on the front and back sides of the crushing peripheral portion. It may be a thing.
  • the rigidity in the vicinity of the fastening portion can be increased by forming the step portion on the outer peripheral side of the fastening portion of the foamed resin core material composite plate.
  • the stepped portion After the stepped portion is formed in the unfoamed state, the stepped portion can be easily formed by press molding or the like by foaming the foamed resin. Will not be crushed.
  • the fastening structure of the foamed resin core composite plate according to the present invention includes a through hole in the fastening portion of the foam resin core composite plate, and a crushing peripheral portion obtained by crushing the foamed resin core around the through hole.
  • the metal fastening member provided and inserted into the through hole is crushed by crimping or welding and joined to the peripheral edge so that the fastening member is fastened to the counterpart member. Can be applied, and strong fastening with the counterpart member can be maintained.
  • the longitudinal cross-sectional view which shows the fastening structure of the foaming resin core material composite board of 1st Embodiment (A), (b) is sectional drawing which shows the process in which a level
  • step-difference part is formed in the foaming resin core material composite board of FIG. (A)-(d) is sectional drawing which shows the process in which the fastening structure of FIG. 1 is formed.
  • the longitudinal cross-sectional view which shows the fastening structure of the foaming resin core material composite board of 2nd Embodiment (A), (b) is sectional drawing which shows the process in which the fastening structure of FIG. 4 is formed.
  • FIG. 1, FIG. 2 (a) (b), FIG. 3 (a) (b) (c) (d) shows 1st Embodiment.
  • the foamed resin core composite plate 1 is formed by laminating a polyolefin resin foam resin 1c core material between front and back metal plates 1a and 1b, which are steel plates or aluminum plates. Is done.
  • the fastening portion of the foamed resin core composite plate 1 is provided with a through hole 2 and a crushing peripheral edge portion 3 a formed by crushing the foamed resin 1 c around the through hole 2.
  • the crushing peripheral edge 3 a is provided with a cylindrical vertical wall 4 that rises from the peripheral edge of the through hole 2.
  • the metal fastening member 11 provided with the pedestal portion 11b on one end side of the cylindrical portion 11a is fitted into the through hole 2 from the base end side of the vertical wall portion 4 so as to crush the pedestal portion 11b and press it against the peripheral edge portion 3a. Inserted.
  • the eyelet-shaped member 12 is put on the outside of the vertical wall portion 4, and the eyelet of the eyelet-shaped member 12 is aligned with the through hole 2.
  • the fastening member 11 is crimped to the distal end side of the vertical wall portion 4 via the eyelet-shaped member 12 so as to expand the distal end side of the cylindrical portion 11a protruding from the distal end side of the vertical wall portion 4, and is a foamed resin core material
  • the composite plate 1 is firmly coupled to the fastening portion.
  • Bolts 13 are inserted into the penetrating cylindrical portion 11a, and the fastening member 11 and the counterpart member A are bolted together by tightening the fastening member 11 and the counterpart member A with the nut 14.
  • a step part 5 is formed for increasing the rigidity in the vicinity of the fastening part.
  • FIG. 2 shows a process of forming the stepped portion 5 of the foamed resin core material composite plate 1.
  • step-difference part 5 is formed in the state by which the foamed resin 1c is unfoamed.
  • the foamed resin 1 c is foamed by heating the foamed resin core material composite plate 1 on which the step portions 5 are formed. Accordingly, the stepped portion 5 can be easily formed by press molding or the like, and the foamed resin 1c of the stepped portion 5 is not crushed during the forming.
  • FIG. 3A a crushing portion 3 that crushes the foamed resin 1 c is formed around the fastening portion of the foamed resin core composite plate 1 by press working.
  • FIG.3 (b) by punching the through-hole 2 in the fastening part of the center of the crushing part 3, the crushing peripheral part 3a by which the through-hole 2 was pierced from the periphery of the through-hole 2 is carried out.
  • a cylindrical vertical wall portion 4 that rises is formed.
  • the cylindrical portion 11a of the fastening member 11 is fitted and inserted from the base end side of the vertical wall portion 4, and the pedestal portion 11b is crushed and pressed against the peripheral edge portion 3a.
  • the eyelet-shaped member 12 is put on the outer side of the front end surface and the outer peripheral surface of the vertical wall portion 4.
  • the fastening member 11 is the vertical wall part 4 via the eyelet-shaped member 12 so that the front end side of the cylindrical part 11a which protrudes from the front end side of the vertical wall part 4 may be expanded. It can be crimped on the tip side.
  • the other member A is bolted to the fastening member 11 by fastening the fastening member 11 and the other member A with the bolt 13 and the nut 14 that are fitted and inserted into the cylindrical portion 11 a. .
  • the fastening member 11 and the counterpart member A are fastened by bolt fastening.
  • the pedestal portion 11b and the counterpart member A can be fastened by resistance welding by a configuration in which the pedestal portion 11b of the fastening member 11 closes one end side of the cylindrical portion 11a.
  • FIG. 4 and 5 (a) and 5 (b) show a second embodiment.
  • a hat-shaped metal fastening member 15 having a flange portion 15b at the lower end of the hat portion 15a is used.
  • a through hole 2 is provided in the fastening portion of the foamed resin core composite plate 1 similar to that of the first embodiment.
  • the cap portion 15 a of the fastening member 15 is fitted into the through hole 2, and the flange portion 15 b is pressed against the lower surface side of the back metal plate 1 b around the through hole 2.
  • the fastening member 15 crushes the inserted cap portion 15a together with the core material of the foamed resin 1c around the through-hole 2 so as to be expanded in a flat shape toward the upper surface side of the front metal plate 1a.
  • the cap portion 15a and the flange portion 15b which are expanded in a flat shape, sandwich the metal plates 1a, 1b on the front and back of the crushed peripheral portion 3a around the through hole 2 where the foamed resin 1c is crushed, It is firmly coupled to the metal plates 1a and 1b by resistance welding 16a.
  • the counterpart member A is fastened to the ceiling portion of the cap portion 15a that closes the through hole 2 by resistance welding 17a.
  • a stepped portion for increasing rigidity is formed on the outer peripheral side of the fastening portion of the foamed resin core composite plate 1 as in the first embodiment.
  • FIGS. 5A and 5B show a process of forming the fastening structure of the second embodiment.
  • the cap part 15a of the fastening member 15 is inserted by insertion in the through-hole 2 provided in the fastening part of the foamed resin core material composite board 1 from the downward direction.
  • the fastening member 15 is set between the punch 21 and the die 22 by pressing the flange portion 15 b against the lower surface side of the metal plate 1 b on the back side at the peripheral edge portion of the through hole 2.
  • the punch 21 is a flat head punch.
  • the die 22 is formed with a circular convex portion 22a that fits into the cap portion 15a and an annular concave portion 22b into which the flange portion 15b fits on the die surface with which the metal plate 1b abuts.
  • the punch 21 is lowered to a position where the ceiling portion of the cap portion 15 a hits the convex portion 22 a of the die 22.
  • the punch 21 crushes the cap portion 15a together with the foamed resin 1c around the through hole 2 so as to expand the cap portion 15a in a flat shape toward the upper surface side of the front metal plate 1a.
  • the metal plates 1a and 1b on the front and back sides of the crushing peripheral edge portion 3a in which the foamed resin 1c is crushed are sandwiched between the cap portion 15a and the flange portion 15b that are expanded in a flat shape.
  • the expanded cap portion 15a and the flange portion 15b are joined to the front and back metal plates 1a and 1b by resistance welding 16a, and the mating member A is attached to the ceiling portion of the cap portion 15a. Fastened by resistance welding 17a.
  • the metal plates 1a and 1b on the front and back sides of the foamed resin core composite plate 1 are aluminum alloy plates
  • the metal plate 1a of the aluminum alloy plate is formed by forming the metal fastening member 15 with an aluminum-plated steel plate. The welding strength with 1b can be increased.
  • the surface plating layer of the fastening member 15 is aluminum with a high heat ray reflectance, the effect which prevents the heat conduction to the foamed resin 1c by the fastening member 15 absorbing a heat ray can also be anticipated.
  • FIGS. 6, 7 and 8 (a) and 8 (b) show a third embodiment.
  • a dish-shaped metal fastening member 18 having an inclined wall portion 18 b that extends to the outer peripheral side around the bottom portion 18 a is used.
  • the through hole 2 is provided in the fastening portion of the foamed resin core material composite plate 1 similar to the first embodiment, and the fastening member 18 is inserted into the through hole 2.
  • the inclined wall portion 18b is crushed together with the foamed resin 1c around the through hole 2 so as to be expanded in a flat shape toward the foamed resin 1c side between the front and back metal plates 1a, 1b.
  • the inclined wall portion 18b expanded so as to be sandwiched between the metal plates 1a and 1b of the crushing peripheral edge portion 3a around the through-hole 2 where the foamed resin 1c is crushed is formed by resistance welding 16b and the metal on the front and back sides. It is firmly coupled to the plates 1a and 1b.
  • the counterpart member A is fastened to the bottom 18a of the fastening member 18 by resistance welding 17b.
  • a stepped portion for increasing rigidity is formed on the outer peripheral side of the fastening portion of the foamed resin core composite plate 1 as in the first embodiment.
  • FIG. 7 shows the dish-shaped fastening member 18.
  • the inclined wall portion 18b is provided with a flat portion 18c having no inclination on the outer peripheral side in order to facilitate the deformation of the crushing peripheral edge portion 3a between the metal plates 1a and 1b.
  • the notch 18d is inserted. Note that a plurality of the fastening members 18 can be used in a stacked manner.
  • FIG. 8A and 8B show a process of forming the fastening structure of the third embodiment.
  • a dish-shaped fastening member 18 is inserted into the through-hole 2 provided in the fastening portion of the foamed resin core composite plate 1, and the punch 23 and the die 24 are interposed.
  • the punch 23 is provided with a circular step portion 23 a that abuts the fastening member 18, and the die 24 is provided with a circular step portion 24 a on which the fastening member 18 is placed.
  • the height of each step part 23a, 24a is formed substantially equal to the thickness of the metal plates 1a, 1b on the front and back sides.
  • the punch 23 is lowered.
  • the punch 23 crushes the inclined wall portion 18b of the fastening member 18 between the step portions 23a and 24a so as to be expanded in a flat shape toward the foamed resin 1c side between the front and back metal plates 1a and 1b. Further, the punch 23 crushes the foamed resin 1c around the through hole 2 between the punch 23 on the outer peripheral side of each stepped portion 23a, 24a and the die 24.
  • the expanded inclined wall portion 18b is sandwiched between the metal plates 1a and 1b on the front and back of the crushed peripheral edge portion 3a in which the foamed resin 1c is crushed.
  • the opposing member A is connected to the bottom portion 18 a of the fastening member 18 by resistance welding 17 b by joining the expanded inclined wall portion 18 b to the front and back metal plates 1 a and 1 b by resistance welding 16 b. It is concluded with.
  • the counterpart member A is fastened by resistance welding, but the fastening members 15 and 19 and the counterpart member A can be fastened by bolt fastening.
  • the metal fastening member is formed in a cylindrical shape with a pedestal, a hat shape, or a dish shape, but is not limited to these embodiments.
  • the fastening member may be any member that can be firmly bonded to the crushing peripheral portion of the foamed resin core composite plate by caulking or welding.
  • the front and back metal plates of the foamed resin core composite plate are steel plates or aluminum plates, but the front and back metal plates are aluminum plated steel plates, other surface-treated steel plates, surface-treated aluminum alloy plates, etc. Other metal plates can also be used.
  • a metal fastening member can be formed with an aluminum plating steel plate, another surface treatment steel plate, an aluminum plywood board, a surface treatment aluminum plywood board, etc.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Connection Of Plates (AREA)
  • Bolts, Nuts, And Washers (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)

Description

発泡樹脂芯材複合板の締結構造
　本発明は、発泡樹脂芯材複合板を相手方部材と締結する発泡樹脂芯材複合板の締結構造に関する。
　自動車の各種アウタパネル、インナパネル等のパネル部材や、ヒートインシュレータ、フロアアンダカバー等のカバー部材には、鋼板やアルミニウム板等の金属板間に発泡樹脂の芯材を挟むことにより形成される発泡樹脂芯材複合板が用いられることがある（例えば、特許文献１参照）。これらは、自動車の軽量化や、制振性能、遮音性能等の付与を目的としている。
　自動車のパネル部材やカバー部材は、抵抗溶接やボルト締結によって、同じパーツの他の部材やフレーム部材等の相手方部材と締結されることが多い。しかしながら、発泡樹脂芯材複合板で形成されたこれらの部材は、電気を通さない軟質の発泡樹脂が芯材として介在するので、抵抗溶接による締結ができない。また、ボルト締結によっても、相手方部材と強固に締結できないという難点がある。
　発泡樹脂芯材複合板をボルト締結によって相手方部材と強固に締結する手段としては、複合板に設けたボルト孔にボルトを挿通し、複合板の厚みよりも長い胴部と鍔部からなる円筒状部材をボルトとボルト孔との間に介在させる締結構造が提案されている。この構造では、ボルトで円筒状部材の胴部を締め込むことにより、芯材層側へはみ出し変形した胴部と鍔部または相手方部材との間で表裏の金属板が挟持される。また、同様にボルト孔に挿通したボルトとボルト孔との間に、円錐面を有する複数の皿ばねを介在させる締結構造が提案されている（例えば、特許文献２参照）。この構造では、ボルトで皿ばねを締め込むことにより、扁平に変形して芯材層側へはみ出した皿ばねと座金または相手方部材との間で、表裏の金属板が挟持される。
日本国特開２００９－９０５２２号公報 日本国特開２０１１－１３３０８８号公報
　特許文献２に記載された発泡樹脂芯材複合板の締結構造によれば、締結当初は強固な締結が可能である。しかしながら、このような構造では、ボルトの締め込みにより芯材層側へはみ出す円筒状部材の胴部または皿ばねと表裏面の金属板との間や、複数の皿ばねの層間に、ボルトの締結力が作用する領域で芯材の発泡樹脂が入り込む。この入り込んだ熱膨張係数の大きい発泡樹脂が、気温差、エンジンからの熱等で生じる冷熱サイクルによる膨張、収縮の繰り返しや、車の振動等によって徐々に抜け出すため、ボルトの締結力が経時的に低下するという問題がある。また、この締結構造は、簡便な抵抗溶接による締結には適用できないという問題もある。
　そこで、本発明の課題は、ボルト締結と抵抗溶接のいずれの締結も適用でき、相手方部材との強固な締結を長期間維持することができる発泡樹脂芯材複合板の締結構造を提供することである。
　上記の課題を解決するために、本発明は、金属板間に発泡樹脂の芯材を挟んで積層した発泡樹脂芯材複合板を相手方部材と締結する発泡樹脂芯材複合板の締結構造であって、前記発泡樹脂芯材複合板の締結部に、貫通孔と、この貫通孔の周囲で前記発泡樹脂の芯材を押し潰した押し潰し周縁部と、が設けられ、前記貫通孔に嵌挿された金属製の締結部材をカシメ付けまたは溶接によって前記押し潰し周縁部に結合することにより、前記締結部材が前記相手方部材と締結される構成を採用した。
　すなわち、貫通孔に嵌挿した金属製の締結部材を、カシメ付けまたは溶接によって押し潰し周縁部に結合し、締結部材を相手方部材と締結することにより、カシメ付けまたは溶接によって金属製の締結部材が発泡樹脂芯材複合板の締結部に強固に結合される。これにより、ボルト締結と抵抗溶接のいずれの締結も適用でき、相手方部材との強固な締結を長期間維持できる。
　上記発泡樹脂芯材複合板の締結構造は、前記締結部材が、円筒部の一端側に台座部を設けた台座付き円筒形状を有し、前記押し潰し周縁部に、前記貫通孔の周縁から立ち上がる筒状の縦壁部が設けられ、前記締結部材の円筒部を前記縦壁部の基端側から前記貫通孔に嵌挿して、前記台座部を前記押し潰し周縁部に押し当て、前記縦壁部の先端側から突出する前記円筒部の先端側を押し拡げるように、前記締結部材が前記縦壁部の先端側にカシメ付けられるものであってもよい。
　鳩目状部材の鳩目を前記貫通孔に合わせるように、前記鳩目状部材が前記縦壁部の外側に被せられ、前記鳩目状部材を介して、前記円筒部の先端側が前記縦壁部の先端側にカシメ付けられるものであってもよい。これにより、円筒部と鳩目状部材とで縦壁部を挟持するようにして、締結部材をより強固に結合することができる。
　上記発泡樹脂芯材複合板の締結構造は、前記締結部材が、帽子部の下端に鍔部を備える帽子形を有し、前記鍔部を前記貫通孔の周縁部で一方の前記金属板の外面側に押し当て、前記貫通孔に嵌挿された前記帽子部を他方の前記金属板の外面側へ扁平形状に押し拡げるように、前記貫通孔の周縁部の前記発泡樹脂の芯材と一緒に前記帽子部を押し潰すことにより、前記扁平形状に押し拡げた帽子部と前記鍔部とで前記押し潰し周縁部の表裏の前記金属板が挟持され、且つこの挟持する前記帽子部と前記鍔部とが前記押し潰し周縁部の表裏の前記金属板に溶接されるものであってもよい。
　上記発泡樹脂芯材複合板の締結構造は、前記締結部材が、底部の周囲に外周側へ拡がる傾斜壁部を備える皿形を有し、前記皿形の締結部材を前記貫通孔に嵌挿し、前記金属板間の発泡樹脂側へ前記傾斜壁部を扁平形状に押し拡げるように、前記皿形の締結部材を前記貫通孔の周縁部の前記発泡樹脂の芯材と一緒に押し潰すことにより、前記扁平形状に押し拡げた傾斜壁部が前記押し潰し周縁部の表裏の前記金属板で挟持され、且つこの挟持される前記傾斜壁部が前記押し潰し周縁部の表裏の前記金属板に溶接されるものであってもよい。
　前記発泡樹脂芯材複合板の前記締結部の外周側に段差部が形成されることにより、締結部近傍の剛性を高めることができる。
　前記発泡樹脂が未発泡の状態で前記段差部が形成されたのち、前記発泡樹脂が発泡させられることにより、プレス成形等によって段差部を容易に形成することができ、成形時に段差部の発泡樹脂が押し潰されることもない。
　本発明に係る発泡樹脂芯材複合板の締結構造は、発泡樹脂芯材複合板の締結部に貫通孔と、この貫通孔の周囲で発泡樹脂の芯材を押し潰した押し潰し周縁部とを設け、貫通孔に嵌挿した金属製の締結部材を、カシメ付けまたは溶接によって押し潰し周縁部に結合し、締結部材を相手方部材と締結するようにしたので、ボルト締結と抵抗溶接のいずれの締結も適用でき、相手方部材との強固な締結を維持することができる。
第１の実施形態の発泡樹脂芯材複合板の締結構造を示す縦断面図 （ａ）、（ｂ）は、図１の発泡樹脂芯材複合板に段差部を形成する過程を示す断面図 （ａ）～（ｄ）は、図１の締結構造を形成する過程を示す断面図 第２の実施形態の発泡樹脂芯材複合板の締結構造を示す縦断面図 （ａ）、（ｂ）は、図４の締結構造を形成する過程を示す断面図 第３の実施形態の発泡樹脂芯材複合板の締結構造を示す縦断面図 図６の締結部材を示す外観斜視図 （ａ）、（ｂ）は、図６の締結構造を形成する過程を示す断面図
　以下、図面に基づき、本発明の実施形態を説明する。図１、図２（ａ）（ｂ）、図３（ａ）（ｂ）（ｃ）（ｄ）は、第１の実施形態を示す。図１に示すように、発泡樹脂芯材複合板１は、鋼板またはアルミニウム板である表裏の金属板１ａ、１ｂ間に、ポリオレフィン系樹脂の発泡樹脂１ｃの芯材を挟んで積層することにより形成される。この発泡樹脂芯材複合板１の締結部には、貫通孔２と、貫通孔２の周囲の発泡樹脂１ｃを押し潰して形成された押し潰し周縁部３ａと、が設けられる。押し潰し周縁部３ａには、貫通孔２の周縁から立ち上がる筒状の縦壁部４が設けられる。円筒部１１ａの一端側に台座部１１ｂを設けた金属製の締結部材１１は、台座部１１ｂを押し潰し周縁部３ａに押し当てるように、縦壁部４の基端側から貫通孔２に嵌挿される。縦壁部４の外側には鳩目状部材１２が被せられ、鳩目状部材１２の鳩目が貫通孔２に合わせられている。締結部材１１は、縦壁部４の先端側から突出する円筒部１１ａの先端側を押し拡げるように、鳩目状部材１２を介して縦壁部４の先端側にカシメ付けられ、発泡樹脂芯材複合板１の締結部に強固に結合されている。貫通した円筒部１１ａにはボルト１３が嵌挿され、ナット１４で締結部材１１と相手方部材Ａとを締め付けることにより、締結部材１１と相手方部材Ａがボルト締結されている。発泡樹脂芯材複合板１の締結部の外周側には、締結部近傍の剛性を高めるための段差部５が形成されている。
　図２は、前記発泡樹脂芯材複合板１の段差部５を形成する過程を示す。まず、図２（ａ）に示すように、発泡樹脂１ｃが未発泡の状態で段差部５が形成される。こののち、図２（ｂ）に示すように、段差部５を形成した発泡樹脂芯材複合板１を加熱することにより、発泡樹脂１ｃを発泡させる。したがって、プレス成形等によって段差部５が容易に成形でき、成形時に段差部５の発泡樹脂１ｃが押し潰されることもない。
　図３（ａ）～（ｄ）は、第１実施形態の締結構造を形成する過程を示す。まず、プレス加工によって、図３（ａ）に示すように、発泡樹脂芯材複合板１の締結部の周囲に、発泡樹脂１ｃを押し潰した押し潰し部３が形成される。そして、図３（ｂ）に示すように、押し潰し部３の中央の締結部に貫通孔２を打ち抜くことにより、貫通孔２が打ち抜かれた押し潰し周縁部３ａに、貫通孔２の周縁から立ち上がる筒状の縦壁部４が形成される。
　こののち、図３（ｃ）に示すように、縦壁部４の基端側から締結部材１１の円筒部１１ａが嵌挿され、台座部１１ｂが押し潰し周縁部３ａに押し当てられる。さらに、縦壁部４の先端面と外周面の外側に、鳩目状部材１２が被せられる。そして、図３（ｄ）に示すように、縦壁部４の先端側から突出する円筒部１１ａの先端側を押し拡げるように、締結部材１１が、鳩目状部材１２を介して縦壁部４の先端側にカシメ付けられる。最後に、図１に示したように、円筒部１１ａに嵌挿したボルト１３およびナット１４で、締結部材１１と相手方部材Ａとを締め付けることにより、締結部材１１に相手方部材Ａがボルト締結される。
　上述した第１の実施形態では、ボルト締結によって締結部材１１と相手方部材Ａが締結されている。しかしながら、締結部材１１の台座部１１ｂが円筒部１１ａの一端側を閉塞するような構成によって、この台座部１１ｂと相手方部材Ａを抵抗溶接によって締結することもできる。
　図４および図５（ａ）（ｂ）は、第２の実施形態を示す。この発泡樹脂芯材複合板の締結構造においては、図４に示すように、帽子部１５ａの下端に鍔部１５ｂを有する帽子形の金属製締結部材１５が用いられる。第１の実施形態と同様の発泡樹脂芯材複合板１の締結部には、貫通孔２が設けられている。締結部材１５の帽子部１５ａが貫通孔２に嵌挿され、鍔部１５ｂが貫通孔２の周囲で裏側の金属板１ｂの下面側に押し当てられる。締結部材１５は、嵌挿された帽子部１５ａを、表側の金属板１ａの上面側へ扁平形状に押し拡げるように、貫通孔２の周囲の発泡樹脂１ｃの芯材と一緒に押し潰す。これにより、扁平形状に押し拡げた帽子部１５ａと鍔部１５ｂとが、発泡樹脂１ｃが押し潰された貫通孔２の周囲の押し潰し周縁部３ａの表裏の金属板１ａ、１ｂを挟持し、抵抗溶接１６ａで、金属板１ａ、１ｂに強固に結合されている。相手方部材Ａは、貫通孔２を閉塞する帽子部１５ａの天井部に、抵抗溶接１７ａで締結されている。図示は省略するが、発泡樹脂芯材複合板１の締結部の外周側には、第１の実施形態と同様に、剛性を高めるための段差部が形成されている。
　図５（ａ）（ｂ）は、第２実施形態の締結構造を形成する過程を示す。まず、図５（ａ）に示すように、発泡樹脂芯材複合板１の締結部に設けた貫通孔２に、締結部材１５の帽子部１５ａが下方から嵌挿される。鍔部１５ｂを貫通孔２の周縁部で裏側の金属板１ｂの下面側に押し当てて、締結部材１５がポンチ２１とダイス２２の間にセットされる。ポンチ２１は平頭ポンチである。ダイス２２には、金属板１ｂが当接するダイス面に、帽子部１５ａに嵌まり込む円形の凸部２２ａと、鍔部１５ｂが嵌まり込む環状の凹部２２ｂが形成されている。
　こののち、図５（ｂ）に示すように、ポンチ２１が帽子部１５ａの天井部がダイス２２の凸部２２ａに当たる位置まで下降される。ポンチ２１は、帽子部１５ａを表側の金属板１ａの上面側へ扁平形状に押し拡げるように、貫通孔２の周囲の発泡樹脂１ｃと一緒に押し潰す。発泡樹脂１ｃが押し潰された押し潰し周縁部３ａの表裏の金属板１ａ、１ｂは、扁平形状に押し拡げられた帽子部１５ａと鍔部１５ｂとで挟持される。最後に、図４に示したように、押し拡げられた帽子部１５ａと鍔部１５ｂとが表裏の金属板１ａ、１ｂに抵抗溶接１６ａで結合され、相手方部材Ａが帽子部１５ａの天井部に抵抗溶接１７ａで締結される。なお、発泡樹脂芯材複合板１の表裏の金属板１ａ、１ｂがアルミニウム合金板である場合には、金属製の締結部材１５をアルミニウムめっき鋼板で形成することにより、アルミニウム合金板の金属板１ａ、１ｂとの溶接強度を高めることができる。また、締結部材１５の表面めっき層は熱線反射率の高いアルミニウムであるため、締結部材１５が熱線を吸収することによる発泡樹脂１ｃへの熱伝導を防止する効果も期待できる。
　図６、図７および図８（ａ）（ｂ）は、第３の実施形態を示す。この発泡樹脂芯材複合板の締結構造では、図６に示すように、底部１８ａの周囲に外周側へ拡がる傾斜壁部１８ｂを有する皿形の金属製締結部材１８が用いられる。第１の実施形態と同様の発泡樹脂芯材複合板１の締結部には貫通孔２が設けられ、締結部材１８が貫通孔２に嵌挿される。傾斜壁部１８ｂは、表裏の金属板１ａ、１ｂ間の発泡樹脂１ｃ側へ扁平形状に押し拡げられるように、貫通孔２の周囲の発泡樹脂１ｃと一緒に押し潰される。発泡樹脂１ｃが押し潰された貫通孔２の周囲の押し潰し周縁部３ａの金属板１ａ、１ｂ間に挟持されるように押し拡げられた傾斜壁部１８ｂは、抵抗溶接１６ｂで、表裏の金属板１ａ、１ｂに強固に結合している。相手方部材Ａは締結部材１８の底部１８ａに抵抗溶接１７ｂで締結されている。図示は省略するが、発泡樹脂芯材複合板１の締結部の外周側には、第１の実施形態と同様に、剛性を高めるための段差部が形成されている。
　図７は、前記皿形の締結部材１８を示す。傾斜壁部１８ｂには、押し潰し周縁部３ａの金属板１ａ、１ｂ間への押し拡げ変形を容易にするために、外周側に傾斜のない平坦部１８ｃが設けられるとともに、外周側からの複数の切込み１８ｄが入れられている。なお、この締結部材１８は複数枚重ねて用いることもできる。
　図８（ａ）（ｂ）は、第３実施形態の締結構造を形成する過程を示す。まず、図８（ａ）に示すように、発泡樹脂芯材複合板１の締結部に設けた貫通孔２に、皿形の締結部材１８が嵌挿され、ポンチ２３とダイス２４との間にセットされる。ポンチ２３には、締結部材１８に当接される円形の段部２３ａが設けられ、ダイス２４には、締結部材１８を載せる円形の段部２４ａが設けられている。各段部２３ａ、２４ａの高さは、表裏の金属板１ａ、１ｂの厚みと略等しく形成されている。
　こののち、図８（ｂ）に示すように、ポンチ２３が下降される。ポンチ２３は、各段部２３ａ、２４ａの間で締結部材１８の傾斜壁部１８ｂを、表裏の金属板１ａ、１ｂ間の発泡樹脂１ｃ側へ扁平形状に押し拡げるように押し潰す。また、ポンチ２３は、各段部２３ａ、２４ａの外周側のポンチ２３とダイス２４との間で貫通孔２の周囲の発泡樹脂１ｃを押し潰す。発泡樹脂１ｃが押し潰された押し潰し周縁部３ａの表裏の金属板１ａ、１ｂ間に、押し拡げた傾斜壁部１８ｂが挟持される。最後に、図６に示したように、押し拡げた傾斜壁部１８ｂを表裏の金属板１ａ、１ｂに抵抗溶接１６ｂで結合することにより、相手方部材Ａが締結部材１８の底部１８ａに抵抗溶接１７ｂで締結される。
　上述した第２および第３の実施形態では、抵抗溶接によって相手方部材Ａが締結されるが、締結部材１５、１９と相手方部材Ａはボルト締結によって締結することもできる。
　上述した各実施形態では、金属製の締結部材が、台座付き円筒状、帽子形、または皿形に形成されているが、これらの各実施形態に限定されない。締結部材は、カシメ付けまたは溶接によって発泡樹脂芯材複合板の押し潰し周縁部に強固に結合できるものであればよい。
　上述した各実施形態では、発泡樹脂芯材複合板の表裏の金属板は鋼板またはアルミニウム板であるが、表裏の金属板は、アルミニウムめっき鋼板や他の表面処理鋼板、表面処理アルミニウム合金板等の他の金属板とすることもできる。また、金属製締結部材は、アルミニウムめっき鋼板、他の表面処理鋼板、アルミニウム合板板、表面処理アルミニウム合板板等で形成することができる。
　以上、本発明の各実施形態について説明したが、本発明は上述の実施形態に限られるものではなく、特許請求の範囲に記載した限りにおいて様々に変更して実施することが可能である。本出願は２０１２年２月２７日出願の日本特許出願（特願２０１２－０４０１８３）に基づくものであり、その内容はここに参照として取り込まれる。
１　発泡樹脂芯材複合板
１ａ、１ｂ　金属板
１ｃ　発泡樹脂
２　貫通孔
３　押し潰し部
３ａ　押し潰し周縁部
４　縦壁部
５　段差部
１１　締結部材
１１ａ　円筒部
１１ｂ　台座部
１２　鳩目状部材
１３　ボルト

Claims (7)

  1. 　金属板間に発泡樹脂の芯材を挟んで積層した発泡樹脂芯材複合板を相手方部材と締結する発泡樹脂芯材複合板の締結構造であって、
    　前記発泡樹脂芯材複合板の締結部に、貫通孔と、この貫通孔の周囲で前記発泡樹脂の芯材を押し潰した押し潰し周縁部と、が設けられ、
    　前記貫通孔に嵌挿された金属製の締結部材をカシメ付けまたは溶接によって前記押し潰し周縁部に結合することにより、前記締結部材が前記相手方部材と締結されることを特徴とする発泡樹脂芯材複合板の締結構造。
  2. 　前記締結部材が、円筒部の一端側に台座部を設けた台座付き円筒形状を有し、
    　前記押し潰し周縁部に、前記貫通孔の周縁から立ち上がる筒状の縦壁部が設けられ、
    　前記締結部材の円筒部を前記縦壁部の基端側から前記貫通孔に嵌挿して、前記台座部を前記押し潰し周縁部に押し当て、前記縦壁部の先端側から突出する前記円筒部の先端側を押し拡げるように、前記締結部材が前記縦壁部の先端側にカシメ付けられた請求項１に記載の発泡樹脂芯材複合板の締結構造。
  3. 　鳩目状部材の鳩目を前記貫通孔に合わせるように、前記鳩目状部材が前記縦壁部の外側に被せられ、
    　前記鳩目状部材を介して、前記円筒部の先端側が前記縦壁部の先端側にカシメ付けられた請求項２に記載の発泡樹脂芯材複合板の締結構造。
  4. 　前記締結部材が、帽子部の下端に鍔部を備える帽子形を有し、
    　前記鍔部を前記貫通孔の周縁部で一方の前記金属板の外面側に押し当て、前記貫通孔に嵌挿された前記帽子部を他方の前記金属板の外面側へ扁平形状に押し拡げるように、前記貫通孔の周縁部の前記発泡樹脂の芯材と一緒に前記帽子部を押し潰すことにより、前記扁平形状に押し拡げた帽子部と前記鍔部とで前記押し潰し周縁部の表裏の前記金属板が挟持され、且つこの挟持する前記帽子部と前記鍔部とが前記押し潰し周縁部の表裏の前記金属板に溶接された請求項１に記載の発泡樹脂芯材複合板の締結構造。
  5. 　前記締結部材が、底部の周囲に外周側へ拡がる傾斜壁部を備える皿形を有し、
    　前記皿形の締結部材を前記貫通孔に嵌挿し、前記金属板間の発泡樹脂側へ前記傾斜壁部を扁平形状に押し拡げるように、前記皿形の締結部材を前記貫通孔の周縁部の前記発泡樹脂の芯材と一緒に押し潰すことにより、前記扁平形状に押し拡げた傾斜壁部が前記押し潰し周縁部の表裏の前記金属板で挟持され、且つこの挟持される前記傾斜壁部が前記押し潰し周縁部の表裏の前記金属板に溶接された請求項１に記載の発泡樹脂芯材複合板の締結構造。
  6. 　前記発泡樹脂芯材複合板の前記締結部の外周側に段差部が形成された請求項１から５のいずれか１項に記載の発泡樹脂芯材複合板の締結構造。
  7. 　前記発泡樹脂が未発泡の状態で前記段差部が形成されたのち、前記発泡樹脂が発泡させられた請求項６に記載の発泡樹脂芯材複合板の締結構造。
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JP5893955B2 (ja) 2016-03-23

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