JP2002120250A - Filling implement of hollow structure and method for filling - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a filling implement of a hollow structure capable of easily forming without necessity of a mold for molding and a method for filling it. SOLUTION: A hollow panel 1 is constituted by connecting an inner panel 2 to an outer panel 3 at their flanges 2f and 3f. The filling implement 10 is installed in a hollow chamber 4 of the panel 1. The implement 10 is constituted by coupling a plurality of plate-like foamable base 30 formed in different sizes corresponding to the change of the sectional shape of the chamber 4 in a longitudinal direction similar to the sectional shape of the chamber 4 by a coupler such as a needle or the like. Further, a pair of holder plates 11 are coupled to both ends of the coupler. The plurality of the bases 30 are foamed by external heating, and filled without gap in the chamber 4 as a foam. The foaming of the base 30 is restricted by the pair of the plates 11.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a filling device for a hollow structure and a method for filling the same, and more particularly, to filling a hollow panel mainly composed of a plurality of panels (for example, a hollow panel of a vehicle body) with a foam. For filling a hollow structure and a filling method for the same.

[0002]

2. Description of the Related Art As a filling tool for filling a hollow structure, a filling device formed of a foamable base material which is foamed by external heating in a hollow chamber of the hollow structure to form a foam and fill the hollow structure is used. Are known. Such a filling tool for a hollow structure is used to fill the hollow structure with a foam, thereby reinforcing the hollow structure, damping the sound, and insulating the sound. Fill the hollow chamber of the hollow structure with foam without gaps,
In order to efficiently enhance the effect of reinforcing the hollow structure, it is preferable that the outer peripheral surface of the foam closely adheres to the inner wall surface of the hollow chamber without any gap. For this purpose, there is a technique of forming a foamable base material for filling a hollow structure with a mold for injection molding or the like, and forming a shape (approximate shape) conforming to the contour of the hollow interior wall of the hollow structure. Are known. When the foamable substrate is formed into a shape conforming to the contour of the hollow chamber wall of the hollow structure, even if the hollow chamber is irregular, for example, the foamable substrate uniformly foams according to the shape, and The hollow space can be filled without gaps by the body.

[0003]

However, for example, hollow panels (hollow structures) constituting a vehicle body include pillars, rocker panels, roof side panels, and the like. These hollow panels have various cross-sectional shapes and sizes. It is diverse.
In order to produce foamable base materials corresponding to these various hollow panel shapes, injection molding dies corresponding to all of them must be prepared, and the time and effort required to manufacture the dies are required. There is a problem that the cost becomes large. The present invention has been made in view of such a problem, and even when the shape of a hollow structure is variously different, the hollow structure can be easily formed without molding a foamable base material with a mold or the like. An object of the present invention is to provide a filler for a hollow structure that can be formed into a shape similar to a hollow chamber of the structure.

[0004]

A first aspect of the present invention for achieving the above object is a filling tool for a hollow structure as described in claim 1. Since the plurality of foamable substrates are connected by the connecting body while maintaining a required interval, each of the plurality of foamable substrates can be fixed at a desired position in the hollow chamber. Further, since the plurality of foamable substrates are each formed in a plate shape similar to the cross-sectional shape of the hollow chamber (the cross-sectional shape perpendicular to the longitudinal direction of the hollow chamber), for example, the cross-sectional shape of the hollow chamber is irregular. Even in such cases, the contour of the foamable base material follows the inner wall surface of the hollow chamber, and an appropriate gap is maintained between the inner wall surface of the hollow chamber and the foamable base material. Further, the plurality of foamable base materials are formed in different sizes corresponding to changes in the cross-sectional shape of the hollow chamber in the longitudinal direction. That is, for example, when the hollow structure has a shape radially spread in the longitudinal direction and the cross-sectional shape of the hollow chamber is proportionally increased in the longitudinal direction,
The plurality of foamable substrates are formed so as to increase proportionally so as to follow the change in the size of the cross-sectional shape. Therefore, an appropriate gap between the inner wall surface of the hollow chamber and the foamable base material (a gap such that the foam can be filled without a gap).
The foamable base material is provided while maintaining the condition. When a plurality of foamable base materials arranged in this way are foamed by external heating to form a foam, the foam closely adheres to the inner wall surface of the hollow structure without gaps, and the foam is filled without gaps over the entire length of the hollow chamber. Is done. Therefore, there is no unfilled portion between the hollow structure and the inner wall surface, and the effect of reinforcing the hollow structure can be efficiently enhanced.

A second aspect of the present invention is a filler for a hollow structure as described in claim 2. The connecting body is formed of a member that can be bent along the longitudinal direction of the hollow chamber, for example, a member such as a wire. Even when the hollow structure is curved in the longitudinal direction, the connecting body is bent. By adjusting the shape of the hollow structure to the shape of the hollow structure, the foamable base material can be easily arranged at a required interval.

According to a third aspect of the present invention, there is provided a filler for a hollow structure as described in claim 3. Since the holder plate is connected to at least one of both ends of the connected body, when the foamable base material is foamed by external heating to form a foam, the foam is regulated by the holder plate. Does not spread. As a result, in the hollow chamber of the hollow structure, the foamable base material can be foamed only at the site that requires filling, and the hollow structure can be filled with a small amount of the foamable base material without waste. Can be.

A fourth invention of the present application is a method for filling a hollow structure as described in claim 4. In such a method for filling a hollow structure, a plurality of plate-like foamable base materials which are similar to the cross-sectional shape of the hollow chamber of the hollow structure and have various sizes are prepared in advance, and the plurality of foamed base materials are prepared. A filler can be formed by sequentially selecting a foamable base material having the same shape or slightly smaller than the cross-sectional shape of the hollow chamber from the conductive base materials along the longitudinal direction of the hollow chamber, and connecting them with a connecting body. . Therefore, it is not necessary to prepare a mold for injection molding or the like corresponding to the shape of the hollow chamber every time the shape of the hollow chamber is variously different, and the production of the foamable base material becomes easy. Further, since the cross-sectional shape of the plate-like foamable base material does not change along the longitudinal direction of the hollow chamber, it can be easily formed by extrusion or the like. When the filler configured as described above is disposed along the longitudinal direction of the hollow chamber, an appropriate gap (foam is formed) between the inner wall surface and the foamable base material over the entire length of the hollow chamber in the longitudinal direction. A gap that can be filled without gaps is maintained. When the foamable base material is foamed by external heating, the foam is filled without gaps over the entire length of the hollow chamber.

[0008]

FIG. 1 shows a first embodiment of the present invention.
This will be described below with reference to FIGS. As shown in FIGS. 2 and 3, a hollow panel (for example, a center pillar or the like of a vehicle body) 1 is formed by spot welding an inner panel 2 and an outer panel 3 to each other at flange portions 2 f and 3 f. It is configured as a structure. A filler 10 is mounted on the hollow panel 1 at a desired position in the hollow chamber 4.

As shown in FIG. 1, the filler 10 includes a pair of holder plates 11, a connecting body 20, and a required number of foamable substrates 30. The pair of holder plates 11 are formed of a metal plate such as an iron plate, and are formed by bending the support plate portion 12 in a direction orthogonal to the longitudinal direction of the hollow chamber 4 and one end of the support plate portion 12 at right angles. It has the mounting part 13 integrally. In addition, a connection hole 14 is formed in a substantially central portion of the support plate portion 12 of the pair of holder plates 11,
A connecting body 20 composed of a wire or the like is inserted into the connecting hole 14. A rod-shaped engaging piece 15 having a length larger than the outer diameter of the connecting hole 14 is connected to both ends of the connecting body 20, and the engaging piece 15 is engaged with the connecting hole 14 to form a pair. Are connected via a connecting body 20.

[0010] A required number (five in the present embodiment) of the foamable base material 30 is provided in the longitudinal direction of the connecting body 20. The plurality of foamable base materials 30 are formed in a plate shape from a synthetic resin foamable material mixed with a foaming agent and foamed by external heating. As shown in FIG. 1, a plurality of plate-like foamable base materials 30 are provided with through holes 31 having substantially the same diameter as the outer diameter of the connecting body 20, and the connecting body 20 is inserted into the through holes 31. And then penetrate, the plurality of foamable substrates 30
Are connected via a connecting body 20. The plurality of foamable base materials 30 are fitted in the insertion holes 31 at a required interval in the longitudinal direction of the connecting body 20, but in the present embodiment, these insertion holes 31 and the outer periphery of the connecting body 20 are fitted. It is held in the required position by the frictional force between the surface. The plurality of foamable base materials 30 may be held by bonding the insertion hole 31 and the outer peripheral surface of the connecting body 20 with an adhesive or the like, and the means for holding is not limited. Before the pair of holder plates 11 are connected to both ends of the connector 20, the plurality of foamable substrates 30
And connected.

The manner in which the filler 10 constructed as described above is disposed in the hollow chamber 4 of the hollow panel 1 will be described with reference to FIGS. Here, FIG. 2 is a perspective view showing a state in which the filler 10 is disposed in the hollow chamber 4 of the hollow panel 1 and immediately before the inner panel 2 and the outer panel 3 are joined. FIG. 3 is a cross-sectional view of the hollow panel 1 and the filler 10 in FIG.
This shows a state after the inner panel 2 and the outer panel 3 have been joined.

First, the inner panel 2 and the outer panel 3
Before spot welding is performed on each of the flange portions 2f and 3f, the mounting portions 13 of the pair of holder plates 11 are mounted.
Are attached to the inner wall surface of the inner panel 2 at a required interval by spot welding or the like. Thereby, the plurality of foamable substrates 30 connected to the connecting body 20 are:
The hollow chamber 4 is disposed between the pair of holder plates 11 while maintaining a required interval along the longitudinal direction. Each of the plurality of foamable substrates 30 is formed in a plate shape similar to the cross-sectional shape of the hollow chamber 4 (the cross-sectional shape in a direction perpendicular to the longitudinal direction of the hollow chamber 4). That is, in the present embodiment, the cross section of the hollow chamber 4 has a substantially square shape, but the plurality of foamable base materials 30 each have a substantially square plate shape similar to the cross sectional shape of the hollow chamber 4. .

When the shape of the hollow panel 1 changes radially, for example, along the longitudinal direction (in the present embodiment, it becomes a tapered quadrangular prism (frustum of quadrangular pyramid)), a cross section of the hollow chamber 4 is formed. The shape varies depending on its longitudinal position and is not uniform. In such a case, an extremely large gap is formed between the foamable base material 30 and the inner wall surface of the hollow chamber 4 so that an unfilled portion does not occur when foaming is performed. Is preferably made to correspond (approximate) to the shape of the contour of the inner wall of the hollow chamber 4. Therefore, in the longitudinal direction of the hollow chamber 4, at a place where the cross-sectional shape is large, a large plate-shaped foamable base material 30 is selected so as to match the cross-sectional shape, and the connecting body 20 is disposed at the place. connect. Conversely, in a place where the cross-sectional shape of the hollow chamber 4 is small, a small plate-shaped
Is selected and connected to the connecting body 20 so as to be disposed at that location. That is, the sectional shape of the hollow chamber 4 is
Even if it changes along the longitudinal direction of the plate and is not uniform, a plate-like foamable base material 30 having a maximum size or a slightly smaller size that can be arranged in the hollow chamber 4 is sequentially selected, and the selected plural When the foamable base material 30 is connected by the connecting body 20, an appropriate gap (a gap that can be filled with the foam without any gap) is maintained between the hollow chamber 4 and the inner wall surface over the entire length of the hollow chamber 4. The filling tool 10 can be constituted. In addition, since the plurality of foamable substrates 30 are each formed in a shape similar to the cross-sectional shape of the hollow chamber 4, even when the cross-sectional shape of the hollow chamber 4 is variously different (for example, other than a substantially square shape) , Pentagonal, circular, etc.), the shape of the foamable base material 30 follows the cross-sectional shape (contour).
Can be prevented from foaming without gaps, and unfilled portions can be prevented from being generated in the hollow chamber 4. In addition, if the plate-shaped foamable base material 30 is similar to the cross-sectional shape of the hollow chamber 4 and a plurality of materials having various sizes are prepared in advance by extrusion or the like,
By combining a plurality of plate-shaped foamable base materials 30 having different sizes, it is possible to flexibly cope with a case where the cross-sectional shape of the hollow panel 1 changes variously along the longitudinal direction.

As described above, the filling device 10 is used for the inner panel 2.
With the flange 2f of the inner panel 2
And the flange 3f of the outer panel 3 are spot-welded, so that the filling tool 1 is inserted into the hollow chamber 4 of the hollow panel 1.
0 is attached. In addition, although the example which attached the attachment part 13 to the inner panel 2 by spot welding was shown above,
It may be joined by other joining means, for example, by screwing, clipping, or the like, and the means for attaching the joining means is not limited.

FIG. 4 is a sectional view showing a state in which the foamable base material 30 is foamed by external heating to form a foam 32 and is filled in the hollow chamber 4 of the hollow panel 1. The plurality of foamable base materials 30 are integrally bonded to each other when foamed by external heating to form a foam 32, and are filled into the hollow chamber 4 of the hollow panel 1 without gaps. The fixing position of each foamable substrate 30 in the longitudinal direction and the size (volume) of each foamable substrate 30 are appropriately set.

When a plurality of foamable substrates 30 are foamed by external heating, the progress of the foams 32 is restricted by the pair of holder plates 11. That is, leakage of the foam 32 from a predetermined area in the hollow chamber 4 sandwiched between the pair of holder plates 11 is blocked. Thereby, the foamable base material 30 can be mainly foamed only in a predetermined region in the hollow chamber 4 sandwiched between the pair of holder plates 11, and the gap between the hollow chamber 4 and the foam 32 can be more reliably formed. Without filling. Here, a plurality of foamable substrates 3
0 is mainly composed of a synthetic resin having an adhesive property to a metal surface or a synthetic resin surface, and a foaming agent and a reinforcing material such as a fibrous substance such as glass fiber are mixed with the synthetic resin to obtain a baked paint for a vehicle body. It is desirable to form from a foaming material that becomes foamed by heat at the time (for example, a temperature of about 110 ° C. to 190 ° C.) and becomes a highly rigid foam, in consideration of effects such as blocking and reinforcement. Examples of the foamable material having such an adhesive property and being a highly rigid foam include, for example, JP-A-8-20
No. 8871, JP-A-11-158313 and the like. Since the foam 32 is tightly attached to the inner wall surface of the hollow chamber 4 without any gap and integrally bonded thereto, for example, when an external force acts on the hollow panel 1, the external force is directly applied to the foam 32. Transmitted and absorbed. Therefore, when the filler 10 is used for reinforcing the hollow panel 1, the hollow panel 1 can be reinforced efficiently.

Next, a second embodiment of the present invention will be described with reference to FIG.
This will be described with reference to FIG. FIG. 5 shows a state in which a plurality of foamable base materials 41 and a pair of holder plates 43 are connected by a connecting body 42 to form a filler 40 and are disposed in the hollow chamber 4 of the hollow panel 1. . In the second embodiment, a required number (four in the present embodiment) of the foamable base materials 41 are provided in the longitudinal direction of the connecting body 42. The plurality of foamable substrates 41 are formed in a spherical shape by a foamable material. In the plurality of spherical foamable base materials 41,
An insertion hole 44 having substantially the same diameter as the outer diameter of the connecting body 42 is provided so as to penetrate the center thereof, and when the connecting body 42 is inserted and penetrated into the insertion hole 44, a plurality of foamable base materials 41 are formed. Are connected via a connecting body 42.

FIG. 6 is a sectional view taken along the line BB of FIG. 5, in which the inner panel 2 and the outer panel 3 are joined and the filler 40 is disposed in the hollow chamber 4 of the hollow panel 1. The state is shown. Each of the plurality of foamable substrates 41 is formed in a spherical shape having an outer diameter corresponding to a cross-sectional shape of the hollow chamber 4 (a cross-sectional shape in a direction perpendicular to the longitudinal direction of the hollow chamber 4). That is, the hollow panel 1 has a tapered quadrangular prism shape (frustum of quadrangular pyramid), and the cross-sectional shape of the hollow chamber 4 varies from place to place along the longitudinal direction, but the hollow chamber differs from place to place. In consideration of the width and height of the cavity 4, it is of a size that can be arranged without difficulty in the hollow chamber 4 (there is strong contact with the inner wall surface of the hollow chamber 4, so that there is no hindrance in the arrangement. The spherical foamable base material 41 is formed so as to have an outer diameter of about the same size and a size that does not cause an extremely large gap between the inner wall surface of the hollow chamber 4 and the inner wall. . In order to configure such a filling tool 40, for example, the hollow chamber 4
Along the longitudinal direction, the height and the width of the hollow chamber 4 are measured for each place where the foamable base material 41 is disposed, and the smallest dimension is less than the smallest dimension among them, and the outer diameter is as large as possible. The spherical body 41 is connected to the connecting body 42 at each location so that the spherical foamable base material 41 is provided. Thereby, the plurality of foamable base materials 41 are arranged along the shape of the hollow chamber 4 so as to maintain an appropriate gap (a gap that does not cause an unfilled portion) between itself and the inner wall surface. , Such a foamable base material 41
Is foamed by external heating, the foam is
Is filled evenly without gaps. The mode in which the foam is filled in the hollow chamber 4 of the hollow panel 1 is the same as the mode in the first embodiment, that is, the mode shown in FIG.
In order to flexibly cope with the case where the shape of the hollow chamber 4 is variously different, a plurality of spherical foamable base materials 41 are prepared in advance by extrusion molding or the like having various outside diameters. It is preferable to configure the filler 40 by combining the foamable base materials 41 having different outer diameters.

Hereinafter, a third embodiment of the present invention will be described with reference to FIG. FIG. 7 shows a hollow panel 57 in which a plurality of foamable substrates 51 and a pair of holder plates 53 are connected by a connecting body 52 to form a filler 50, and an inner panel 55 and an outer panel 56 are joined.
FIG. 6 is a cross-sectional view showing a state in which the inside of the hollow chamber 58 is disposed.
The connecting body 52 that connects the plurality of foamable substrates 51 is formed of a member (for example, a wire, a resin thread, a rope, a wire, a chain, or the like) that can be bent along the longitudinal direction of the hollow chamber 58. In the present embodiment, the connector 52 is made of wire. As shown in FIG. 7, the hollow panel 57 is bent at a substantially semi-perpendicular angle from the middle along the longitudinal direction. In addition, at a portion of the hollow panel 57 which is bent at a substantially semi-right angle, the size of the cross-sectional shape of the hollow chamber 58 is radially expanded toward the front. Even in such a case, by bending the connecting body 52 along the longitudinal direction of the hollow chamber 58, the entire filling tool 50 has a bent shape corresponding to the shape of the hollow panel 57, and the plurality of foamable base materials 51 are formed. It can be fixed to a desired position in the hollow chamber 58 at a desired interval. In addition, at a portion ahead of the bent portion of the hollow panel 57, the cross-sectional shape of the hollow chamber 58 changes and gradually increases. However, in this case, as in the first embodiment, the cross-sectional shape of the hollow chamber 58 also increases. A plurality of foamable base materials 51 are formed in a plate-like shape similar to the shape and gradually increasing in response to a change in the cross-sectional shape of the hollow chamber 58 in the longitudinal direction.
By forming, an appropriate gap is secured between the inner wall surface and the foamable base material 51 over the entire length of the hollow panel 57. When the foamable base material 51 configured as described above is foamed by external heating, the foam adheres without gap according to the change in the inner wall surface of the hollow chamber 58, and foams inside the hollow chamber 58 without generating an unfilled portion. Can be filled with the body.

The present invention is not limited to the above embodiment. In the first embodiment, an example is shown in which the pair of holder plates 11 are formed by bending a metal plate such as an iron plate into a substantially L shape, but the present invention is not limited to this. 11 may be formed of a heat-resistant synthetic resin or the like. The shape of the holder plate 11 may be any shape as long as it is a plate shape substantially similar to the cross-sectional shape of the hollow chamber and can regulate the foaming of the foamable base material, and is not limited to the above embodiment. Although the example in which the both ends of the connecting body 20 and the pair of holder plates 11 are connected by the engagement of the bar-shaped engaging pieces 15 is shown, it may be connected by other means. For example, the holder plate 11 and the end of the connecting body 20 may be directly joined by welding. Although the hollow panel 1 shows an example in which the cross-sectional shape is substantially square,
The present invention is not limited to this, and the present invention can be applied to hollow panels having various cross-sectional shapes such as a triangle, a pentagon, and a circle. Further, the case where the hollow structure is the hollow panel 1 such as the center pillar of the vehicle body is illustrated, but the hollow structure is a hollow structure other than the vehicle body, for example, a building such as a building or a ship. The present invention can be applied to such cases.

[0021]

As described above, according to the present invention, even when the shape of the hollow structure is variously different, the hollow structure can be easily formed without forming a foamable base material with a mold or the like. And a filling tool for a hollow structure that can be formed into a shape similar to the hollow chamber. Further, when the filler is provided in the hollow structure, the hollow chamber can be filled without gaps, so that the effect of reinforcing the hollow structure and the like can be efficiently increased.

[Brief description of the drawings]

FIG. 1 is a perspective view showing an appearance of a filler according to a first embodiment of the present invention.

FIG. 2 is a perspective view showing a state in which the filler is provided in the hollow chamber of the hollow panel in the first embodiment.

FIG. 3 is a cross-sectional view taken along the line AA of FIG. 2 and shows a state where a filler is provided in a hollow chamber of the hollow panel.

FIG. 4 is a cross-sectional view showing a state where the hollow chamber of the hollow panel is filled with a foam.

FIG. 5 is a perspective view showing a state in which a filler is provided in a hollow chamber of a hollow panel in a second embodiment of the present invention.

6 is a cross-sectional view taken along the line BB of FIG. 5 and shows a state in which a filler is disposed in the hollow chamber of the hollow panel.

FIG. 7 is a cross-sectional view showing a state in which a filler is provided in a hollow chamber of a hollow panel in a third embodiment of the present invention.

[Explanation of symbols]

 1, 57 hollow panel 2, 55 inner panel 3, 56 outer panel 2f, 3f flange section 4, 58 hollow chamber 10, 40, 50 filler 11, 43, 53 holder plate 12 support plate section DESCRIPTION OF SYMBOLS 13 ... Mounting part 14 ... Connection hole 15 ... Engagement piece 20, 42, 52 ... Connection body 30, 41, 51 ... Foamable base material 31, 44, 54 ... Insertion hole 32 ... Foam

Claims (4)

[Claims] 1. A filling tool for filling a hollow structure, wherein the filling device is disposed along a longitudinal direction of a hollow chamber of the hollow structure.
A plurality of foamable base materials filling the hollow structure by foaming by external heating to form a foam, and a connecting body for connecting the plurality of foamable base materials at a required interval in the hollow chamber are provided. The plurality of foamable substrates each have a plate shape similar to the cross-sectional shape of the hollow chamber, and are formed in different sizes corresponding to changes in the cross-sectional shape of the hollow chamber in the longitudinal direction. Filling tool for hollow structures. 2. The filling tool for a hollow structure according to claim 1, wherein the connecting member is a member that can be bent along a longitudinal direction of a hollow chamber of the hollow structure. Filler. 3. The filling tool for a hollow structure according to claim 1, wherein at least one end of both ends of the connecting body has foaming of a foamable base material. A filler for a hollow structure to which a regulating holder plate is connected. 4. A method for filling a hollow structure, comprising: a plate-like shape similar to a cross-sectional shape of a hollow chamber of the hollow structure;
And, prepare a plurality of foamable substrates formed in different sizes corresponding to changes in the longitudinal direction of the cross-sectional shape of the hollow chamber, the prepared foamable substrate at a required interval Connecting a holder plate that regulates foaming of the foamable base material to at least one end of both ends of the connected body to form a filler; and Disposing the filler along the longitudinal direction of the hollow chamber; and foaming the expandable base material by external heating in the hollow chamber to form a foam, and filling the hollow chamber with the foam. A method for filling a hollow structure, comprising: