JPH0240549B2 - JIDOSHAYOITAZAINOHOKYOZAI - Google Patents

Description

[Detailed Description of the Invention] This invention forms reinforcing ribs that are adhered to automobile plate materials, particularly plate materials used for vehicle body exterior panels such as automobile door panels and roof panels, and are foam-cured and integrated with the plate material. Concerning reinforcing materials.

Conventionally, as shown in FIG. 1A, B, and C, glass fibers,
It is known that a plate material is reinforced by pasting a thermosetting resin material 4 attached with a reinforcing material 3 such as non-woven fabric, and heating and curing this resin material 4 (Utility Model Publication No. 55-101659). issue). 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 plate material, but such shaping is difficult, and moreover, the plate material is usually press-formed, and depending on the conditions of the press process, the plate material There was a problem in that it was very difficult to make perfect contact between the reinforcing material and the plate due to variations in the amount of spring back.

Therefore, as shown in FIG.
An automobile plate material in which a reinforcing rib 13 consisting of a thermosetting resin part 11 and a foamed part 12 to which glass fiber or other reinforcing material 10 has been added in advance is integrally formed on the inner surface or rust-preventive coating 9, and its The manufacturing method was first proposed (Patent Application No. 114731-1983). 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. 3A is used. This reinforcing material 14 is an uncured resin in which the reinforcing material 10 is added to an unfoamed foamed material 15 (for example, a band-shaped foamed material such as a foamed polyethylene sheet or a foamed epoxy sheet) that foams when heated. The material 16 (for example, an uncured epoxy sheet) is laminated in advance.

Then, this reinforcing material 14 is pasted on the part of the plate material 2a that requires reinforcement as shown in FIG.
Auxiliary ribs 13 as shown in FIG. 2 are firmly formed on the plate material 2a.

However, in this case, the resin material 16 is attached to the plate material 2a and covers and wraps the entire foam material 15.
Since the reinforcing material 5 is not exposed to the outside, the amount of the resin material 16, which accounts for a large proportion of the cost of the reinforcing material 14, increases, and the cost increases accordingly.

Therefore, the part of the resin material 16 that is attached to the plate material 2a is removed to the extent that it does not affect reinforcement, that is, a part of the end of the resin material 16 is made to correspond to the end position of the foamed material 15, and the resin material Foam material 1 at the end of 16
It may be possible to reduce costs by exposing the ends of the foam rods 15, but in this case, the ends of the foam rods 15 are exposed to the outside air, so the foam material 15 is particularly exposed to the epoxy resin. If the foam material 15 is made of a material that has the property of absorbing water, water will be absorbed and retained within the foam material 15, and this water will gradually penetrate into the resin material 16 side, harden the resin material 16, and provide a reinforcing effect. There is a risk that this may cause a decrease in the performance, and improvements in this respect have been desired.

This invention was made by focusing on the points mentioned above, and is made by attaching and integrating an unfoamed sheet-like foam material to one side of an uncured sheet-like resin material, leaving the adhesive surface to the plate material. In reinforcing materials for automobile panels, which have a structure in which the ends of the foam material come into contact with the outside air at the ends of the resin material, the ends of the foam material exposed to the outside air are coated with water- and moisture-resistant resin. The purpose is to solve the above points by covering with a film.

The present invention will be explained below based on the drawings.

FIG. 4 to FIG. 9 are diagrams showing an embodiment of the present invention. In the figure, reference numeral 20 denotes a plate material, and reinforcing materials 21 are attached to parts of the plate material 20 that require reinforcement.
In this case, the plate material 2 is the part that requires reinforcement.
The lateral region 0 is selected, and the reinforcing material 21 is attached thereto. The reinforcing material 21 is mainly composed of an uncured sheet-like resin material 22 and an unfoamed sheet-like foam material 23.

The uncured sheet-like resin material 22 constituting the reinforcing material 21 is preferably a thermosetting epoxy resin material, but is not limited thereto. Melamine-based, phenol-based, urea-based resins, and other resin materials may be used as long as they harden at a temperature of 0.3 °C and have flexibility, adhesiveness, and adhesion at room temperature. In addition, if these resin materials 22 lack adhesiveness and adhesiveness at room temperature or have weak adhesiveness and adhesiveness, a material with high adhesiveness and adhesiveness is added in advance to one side 24 corresponding to the plate material 20. It is also possible to keep it.

Examples of thermosetting epoxy resin materials include bisphenol A type epoxy resins Epicoat #828 and #1004 (both manufactured by Yuka Ciel Co., Ltd.) and thermoplastic polyester resin Vylon #500 (manufactured by Toyobo Co., Ltd.).
or a mixture of the above Epicote #828,
Platamide, a copolymerized nylon resin, is added to #1004.
H103P (manufactured by Nippon Rilsan Co., Ltd.) is preferably mixed with a curing agent such as dicyandiamide.

Glass fiber or other reinforcing material 25 can be added to the surface or surface portion of the resin material 22 in advance.
Glass cloth is suitable as the reinforcing material 25, but other materials include glass fiber, glass fiber nonwoven fabric, carbon fiber, polyester nonwoven fabric,
Polypropylene nonwoven fabric, kraft paper, etc. may also be used. Moreover, such a reinforcing material 25 is a resin material 22
The manner of addition to the resin material 22 is arbitrary, such as covering the surface of the resin material 22 or embedding it in the same surface portion.

In addition, as a glass cloth, for example, a thickness of 0.22
mm, weaving density warp 19/25mm, weft 18/25
mm (WF230100N manufactured by Nittobo Co., Ltd.) showed good performance.

The foamed material 23 is preferably a foamed epoxy resin sheet, but is not limited to this. It foams before the resin material 22 hardens at the baking temperature (120°C to 180°C) in the painting process, and expands in volume at an appropriate magnification. and has heat resistance sufficient to withstand the baking temperature,
In addition, any material can be used as long as it is lightweight, regardless of whether it is closed cell or open cell.

When using a foamed epoxy resin sheet as a foaming material, for example, the composition is as follows: Hiker CTBN (manufactured by BF Gutdrich Co., Ltd.), which is a carboxyl group-containing nitrile rubber, is added to the above-mentioned Epicoat #1004, and a dicyandiamide-based curing agent is added. For example, Vinyhole AK #2 (manufactured by Hyowa Kasei Co., Ltd.) may be added as a foaming agent to the epoxy resin composition.
It is better to add

The reinforcing material 21 including the resin material 22 and the foam material 23 is formed so as to have a thin sheet shape as a whole. That is, the resin material 22 is the foam material 23.
It is attached to the top so as to cover the foam material 23. Therefore, the foam material 23 is located on one side 24 of the resin material 22 (the surface that corresponds to the plate material 20) in the longitudinal direction of the central portion 24a, and the remaining both sides are attached to the plate material 20. The surface 24b is formed. Further, both ends 22a of the resin material 22 in the longitudinal direction (lateral direction) are the same as the ends 22a of the foam material 23 in the longitudinal direction.
3a, the end 23a of the foamed material 23 is exposed at the end 22a of the resin material 22,
exposed to the outside air. If both ends 23a of the foam material 23 are left exposed, the exposed ends 23a of the foam material 23 after foaming and curing of the reinforcing material 21
Moisture enters and stays in the foam material 23 from a, and this water in the foam material 23 penetrates into the resin material 22 and softens the hardened resin material 22, so both exposed ends of the foam material 23 23a is covered with a water and moisture resistant resin film 26. As the resin film 26, for example, a polyester film can be used. Furthermore, the resin film 26 is made large enough to follow the expansion of the foam material 23 even when the foam material 23 foams, and is designed to reliably cover the end portion 23a of the foam material 23 even after foaming and hardening. be made into in particular,
For example, as shown in FIG. 8A, one end of a cylindrical resin film 26 on the opening 27 side is heat-sealed to form a bag shape, and the end 23a of the foam material 23 is opened from the other end on the opening 28 side.
After inserting the resin film 26, both sides 29 of the resin film 26 may be bent along the shape of the foam material 23, or as shown in FIG. After inserting the end portion 23a of the foam material 23 halfway into the resin film 26 from the other end opening 28 side, the one end opening 27 side and both side portions 29 may be sequentially bent along the shape of the foam material 23. good.

Then, using such a reinforcing material 21, the plate material 2
0, first replace the reinforcing material 21 with the resin material 22.
After it is attached to, for example, the outer panel of an automobile with the attachment surface 24b, it is heat-treated using, for example, an oven in the painting process. Then, as the resin material 22 softens, the foam material 23 foams and expands, and when heating is continued, the resin material 22 hardens, forming the tall reinforcing ribs 13.
is integrally formed on the plate material 20. In this case, since the resin film 26 is formed to be large in advance, it will not break when the foam material 23 foams and expands, and will follow the foaming and expansion of the foam material 23, ensuring that the foam material 23 will be exposed when the foam material 23 hardens. Both ends 23a are covered to prevent moisture from entering and staying in the foam material 23.

Next, the reinforcing material 21 covers both exposed ends 23a of the foamed material 23 with the resin film 26 as described above.
and a reinforcing material that does not cover both exposed ends 23a of the foam material 23, each reinforcing material is attached to a test piece, foamed and cured, and then heated at a temperature of 50° C. and a relative humidity of 98% RH. When the bending strength retention rate was examined on different days under humidification conditions, the results shown in Figure 9 were obtained. In this case, the thickness of the resin film 26 is
A 6μ polyester film was used. In FIG. 9, A shows the case where the film is covered with a resin film, and B shows the case where the film is not covered with the resin film. In this way, B's bending strength retention rate decreases to around 60%, while A's
We were able to maintain over 70%. Therefore, when both exposed end portions 23a of the foam material 23 are covered with the resin film 26, the bending strength retention rate can be improved by 10% or more compared to the case where they are not covered. In addition, this test was conducted under high temperature and high humidity conditions of 50℃ and 98% RH.If the outer panel of an automobile is reinforced and used under normal temperature and humidity conditions, 90%
A similar bending strength retention rate can be expected.

10 and 11 show other embodiments. In this embodiment, the plate material 30 has parts requiring reinforcement in the vertical direction, such as an outer panel of an automobile door, and a moisture distribution path is specified in one direction from the top to the bottom.
This shows the case of reinforcing. The reinforcing material 21 is attached to the plate material 30 in the vertical direction, and both exposed end portions 23a of the foam material 23 are located above and below the plate material 30. In this case, there is a risk that moisture may enter the foam material 23 only at the upper exposed end 23a, so only this upper exposed end 23a is covered with the resin film 26.
I try to cover it with The other configurations and operations are the same as those in the previous embodiment, and their explanations will be omitted.

Although the case where the end face of the foam material 23 and the end face of the reinforcing material 21 are on the same plane has been described, the foam material 23
Of course, if the end of the foam material 23 protrudes beyond the end of the reinforcing material 21, the end surface of the foam material 23 may
Even if the foam material 23 is located inward from the end surface of
Similar effects can be obtained even when the end of the tube is exposed to the outside air.

As explained above, according to this invention,
Its structure is such that an unfoamed sheet-like foam material is attached to one side of an uncured sheet-like resin material, leaving the adhesive surface to the plate material, and the end of the foam material is the end of the resin material. In reinforcing materials for automobile panels that come in contact with or are exposed to the outside air, we decided to cover the ends of this foamed material with a water- and moisture-resistant resin film. Although it is possible to reduce costs by reducing the amount of resin used, which accounts for a large proportion of costs, it is possible to reliably prevent moisture from penetrating and staying in the foam, and as a result, it is possible to prevent moisture from flowing from the foam to the resin. This has the effect of preventing softening of the resin material due to penetration and reliably maintaining the reinforcing effect of the reinforcing material.

[Brief explanation of drawings]

FIG. 1A is a front explanatory view of a conventional automobile door; FIG. Second
Figure A is a perspective explanatory view of the main parts of the door outer panel that has already been proposed as a solution to the conventional example, Figure 3 is a cross-sectional view taken along the line - - in Figure 2 A, and Figure 3 A and B are the
Figure 3A shows the reinforcing material before it reaches the plate material, Figure 3B shows each cross section after it is pasted on the plate material, and Figure 4 shows the reinforcing material according to the present invention. A perspective view showing one embodiment, FIG. 5A is an enlarged sectional view taken along the line in FIG. 4, FIG. 5B is a sectional view showing the state after foaming and curing, and FIG. Enlarged cross-sectional view,
Figure 8 is a cross-sectional view showing the state after foaming and curing, Figure 7 is a perspective view showing the state when the resin material and foam material are attached, and Figure 8 A and B are the edges of the foamed material with resin films. FIG. 9 is a characteristic diagram showing the bending strength retention rate of a plate reinforced with a reinforcing material, FIG. 10 is a perspective view showing another example, and FIG. FIG. 11 is a perspective view showing a state in which the resin material and foam material shown in FIG. 10 are attached. 20, 30... Plate material, 21... Reinforcing material, 22... Resin material, 23... Foaming material, 24... One side, 24a... Center part, 24b... Adhering surface, 25... Reinforcing material, 22a... Both ends of resin material, 23a...Both exposed ends of foam material, 2
6...Resin film, 27, 28...Opening of resin film, 29...Both sides of resin film.

Claims (1)

[Claims] 1 An unfoamed sheet-like foam material is integrally attached to one side of an uncured sheet-like resin material, leaving the adhesive surface to the plate material, and the end of the foam material is the end of the resin material. A reinforcing material for an automobile plate exposed to outside air, characterized in that the end portion of the foamed material is covered with a water- and moisture-resistant resin film.