JPS6356859B2 - - Google Patents

Description

[Detailed Description of the Invention] This invention is applied to a plate material, particularly a plate material used for car body outer panels such as automobile door panels and roof panels, and other plate materials, and is then foamed and cured to form reinforcing ribs that are integrated with the plate material. Concerning reinforcement materials for

Conventionally, as shown in FIG.
Door outer panel 2 [metal plate material 2
A thermosetting resin material 4 to which a reinforcing material 3 such as glass fiber or non-woven fabric has been attached in advance is attached to the inner surface of a],
It is known that the plate material is reinforced by heating and curing the resin material 4. In the figure, 5 is a door inner panel, 6 is a door window sash, 7 is a side window glass, and 8 is an outside door handle.

However, in this conventional example, the desired reinforcing effect cannot be obtained unless the thickness of the resin material 4 is considerably increased, and the amount of resin material used is large, resulting in a correspondingly high production cost and weight. There was a problem that the number of people was also increasing. As another conventional example, it is also known to adhere a reinforcing material that has been molded and hardened in advance to a plate material. However, in this case, it is necessary to mold the reinforcing material so that it perfectly matches the shape of the board, but such molding is difficult, and it is extremely difficult to perfectly bond both the reinforcing material and the board. There was a problem.

Therefore, as shown in FIG. 2 A and B, the present applicant added glass fiber or other reinforcing material 10 in advance to the inner surface of the metal plate material 2a that is the door outer panel 2 or to the anti-rust coating 9. We have previously proposed an automobile plate material in which a reinforcing rib 13 consisting of a thermosetting resin part 11 and a foamed part 12 is integrally formed, and a method for manufacturing the same (Japanese Patent Publication No. 44187/1987). According to this proposed invention, all of the above conventional problems are solved.

By the way, in order to form this reinforcing rib 13,
A reinforcing material 14 as shown in FIG. 3 is used. This reinforcing material 14 is made of an unfoamed foam material 15 that foams when heated (for example, a foamable polyethylene sheet made of polyethylene containing a foaming agent,
An uncured resin material 16 [for example, an uncured so-called B-stage epoxy sheet] to which the reinforcing material 10 is added to a band-shaped foam material such as a foamable epoxy sheet made of an epoxy resin containing a foaming agent] are laminated in advance. This reinforcing material 14
is adhered to the plate-shaped portion to be reinforced by its own adhesiveness, and then heated to foam the foam material 15 and harden the resin material 16, thereby forming the reinforcing ribs 13 as shown in FIG. is firmly formed on the plate material 2a.

In order to provide the reinforcing ribs 13 with sufficient strength over a certain height, the foam material 15 must be foamed so that the foamed portion 12 has a sufficient height after foaming. , the thickness of the foam material 15 has to be correspondingly large to some extent, and therefore even if it is in the form of a temporary sheet, the foam material 1
Plate material 2a that has bending resistance (a certain degree of rigidity) in itself and has a complicated curved surface or a bent part with a small curvature.
Plate material 2 made of resin material 16 that is difficult to deform following the shape of
When the foamed material 15 is foamed, the portion where the resin material 16 is not in close contact with the plate material 2a is further enlarged, reducing the reinforcing effect. It was desired to improve the

This invention has been made with attention to the above points, and includes an uncured sheet-like resin material that leaves a surface for adhesion to the plate material on one side, and attaches and integrates an unfoamed foam material thereto. Forming discontinuities that allow the foam material to follow the shape of the board material, in other words, attaching small pieces of unfoamed foam material to multiple pieces of resin material, thereby improving the foam material's ability to follow the shape of the board material. The purpose is to improve the adhesion of the resin material to the plate material.

The present invention will be explained below based on the drawings. FIGS. 4 to 6 are diagrams showing an embodiment of the present invention. In the figure, reference numeral 20 denotes a plate material, and this plate material 20 has a bent portion 22 in the horizontal direction, and a reinforcing material 23 is pasted in the vertical direction so as to intersect with the bent portion 22. The reinforcing material 23 is
An unfoamed sheet-like foamed material 26 is integrally attached to one side 25 of an uncured sheet-like resin material 24, leaving adhesive surfaces 25a and 25b to the plate material 20 on both sides. The resin material 24 is a thermosetting resin material that is flexible and sticky at room temperature, such as a thermosetting epoxy resin, such as bisphenol A type epoxy. Epicoat #828, #1004 (manufactured by Yuka Ciel Co., Ltd.) mixed with thermoplastic polyester resin Vylon #500 (manufactured by Toyobo Co., Ltd.), or Epikot #828, #1004 mixed with Platamide H103P, a copolymerized nylon resin ( (manufactured by Nippon Rilsan Co., Ltd.) is preferably mixed with a curing agent such as dicyandiamide, but melamine-based, phenol-based, or urea-based resins may also be used, and not only thermosetting resins but also those that cure at room temperature. It may be made of a resistant resin material, and if it does not have adhesiveness at room temperature, the entire one side 25 or the adhesive surface 2
An adhesive may be applied to 5a and 25b. A reinforcing material 28 is attached to or embedded in the other side surface 27 of the resin material 24 . As the reinforcing material 28, the resin material 2
4 and can impart toughness to the resin material 24, glass cloth with a thickness of 0.22 mm and a density of 19 warp threads/25 mm and a weft thread of 18 threads/25 mm, such as alkali-free cloth (WF230 100N manufactured by Nittobo Co., Ltd.) ,
Glass fiber, carbon fiber, organic nonwoven fabric such as polyester or polypropylene, kraft paper, or the like can be used. As the foam material 26, a foamed polyethylene sheet, a foamed epoxy sheet, or the like, which foams when heated, can be used.Prior to the thermosetting of the resin material 24, the material expands in volume at an appropriate magnification and lifts the central portion of the resin material 24. The material is not particularly limited as long as it can form the reinforcing ribs 13 on the plate material 20. Therefore, regardless of whether it is soft or hard, the foaming is not limited to foaming by heating, but may also be a foaming material that foams at room temperature. Further, a large number of the unfoamed sheet-like foamed materials 26 are arranged in the longitudinal direction with gaps 29, so that the foamed materials have a discontinuous shape. Then, the unfoamed sheet-like foam material 26 can be easily bent through the gap 29 between the foam material pieces.
Therefore, when attaching the reinforcing material 23 to the plate material 20, the foamed material 26 easily follows the shape of the bent portion 22, even though the bent portion 22 is present in the plate material 20, and bends. By following the shape of the resin material 20, the adhesion surfaces 25a and 25b of the resin material 24 will surely come into close contact with the plate material 20, and in this state,
For example, if the reinforcing material 23 is heat-treated together with the plate material 20 in a drying oven in the baking painting process of a car body, the foaming 26 will precede the resin material 24 and the resulting swelling of the resin material 24 will harden, ensuring that the plate material 20 An integral reinforcing rib 13 will be formed. In the above case, the foamed material 26 is formed in the form of a plurality of small pieces lined up to follow the shape of the plate material 20; however, this is not particularly limited to this example; When the portion 22 is specified, one or more slits corresponding to the position and shape of the bent portion 22 may be provided instead of providing the gaps 29 between the large number of small pieces of foam material in advance.

In addition, it is preferable to use foamed epoxy as the composition of the foaming material, but in that case, the above-mentioned Epicoat
An epoxy resin composition is prepared by adding carboxyl group-containing nitrile rubber Hiker CTBN (manufactured by BF Gutudoritsu Co., Ltd.) to #1004 and a dicyandiamide-based curing agent. ) is better.

FIG. 7 shows another embodiment. In this embodiment, instead of the unfoamed sheet-like foamed material 26 formed in the discontinuous state, a large number of unfoamed foamed materials 30 in the form of beads, pellets, etc. are used as pieces of the resin material 4. By leaving adhesive surfaces 25a and 25b on the side surface 25 and closely adhering the material using the adhesiveness of the resin material itself or using an epoxy adhesive, it is possible to easily follow the shape of the plate material 20. I have to. Further, if the foamed materials 30 or the foamed materials 30 and the resin material 24 are difficult to adhere to each other, an adhesive may be applied between them. As the bead-shaped foam material, cross-linked beaded polyethylene containing a foaming agent (for example, Eperan: manufactured by Kanefuchi Kagaku Co., Ltd.),
Foamed styrene beads (for example, Hi-Beads manufactured by Hitachi Chemical Co., Ltd.) are used.

Next, a test example is shown.

First, as the foaming material 30, we selected an epoxy foaming material in which Vinyhole AK #2 was added as a foaming agent to an epoxy resin consisting of the above-mentioned Epicoat #1004, Hiker CTBN, and a dicyandiamide-based curing agent in the form of 1 mm square particles. , a width 10 in the center of an uncured epoxy sheet as a resin material 24 with a width of 50 mm.
5Kg
When the reinforcing material 23, which is crimped with a roller of Following this, the uncured epoxy sheet was also able to reliably adhere to the back side of the door outer panel.

As explained above, according to this invention,
The structure is placed on one side of an uncured sheet-like resin material.
The foam material Although the foam material has a certain thickness dimension, it can be deformed and bent to follow the shape of a board material that has a complicated curved surface or a bent part with a small curvature, and this improves the versatility of the foam material. In addition, by improving the conformability of the foam material to the plate material, it is possible to improve the adhesion of the resin material to the plate material, and as a result, it is possible to easily and reliably form reinforcing ribs by heating the foam material and resin material. The effect is that it can be done.

[Brief explanation of drawings]

1A is a front explanatory view of a conventional door; FIG. The figure is a perspective explanatory view of the main part of the door outer panel that has already been proposed as a solution to the problem of the conventional example, the same (b) is a cross-sectional explanatory view taken along the - line of Fig. 2 (a), and Fig. 3 is the view before reaching Fig. 2 (b). 4 is a perspective view showing an embodiment of the present invention, FIG. 5 is an enlarged sectional view taken along the line of FIG. 4, and FIG. 6 is an enlarged sectional view taken along the line of FIG. 4. FIG. 7 is a sectional view similar to FIG. 5 showing another embodiment. 20... Plate material, 23... Reinforcing material, 24... Resin material, 25... One side, 25a... Adhesive surface, 25b
...Adhesion surface, 26... Sheet-shaped foam material, 29...
... Gap, 30... Granular foam material.

Claims (1)

[Claims] 1. Reinforcement for reinforcing a plate material, characterized in that a plurality of small pieces of unfoamed foam material are lined up and integrated on one side of an uncured sheet-like resin material, leaving an adhesive surface for the plate material. Material.