JPH0242662B2 - - Google Patents

Description

[Detailed description of the invention]

The present invention relates to a reinforcing material for forming reinforcing ribs that are adhered to automobile plate materials, particularly plate materials used for car body outer panels such as automobile door panels and roof panels, and are foamed and hardened to form reinforcing ribs that are integrated with the plate material. . 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 completely bond both the reinforcing material and the plate material 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 (Japanese Patent Application No. 114731/1984). 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 attached to the part of the plate material 2a that requires reinforcement as shown in FIG. By foaming, reinforcing ribs 13 as shown in FIG. 2B are firmly formed on the plate material 2a. However, in this case, if the foam material 15 foams abnormally, the resin material 16 will be pulled by the foam material 15 more than necessary, making it difficult to obtain a stable bonding area between the resin material 16 and the plate material 2a, and in some cases, the resin material 16 will be stretched more than necessary. Material 1
6 may peel off from the plate material 2a, reducing the reinforcing effect. Therefore, when trying to widen the width of the resin material 16 to increase the bonding area with the plate material 2a, although peeling of the resin material 16 can be prevented, the degree of adhesion between the resin material 16 and the plate material 2a is too strong, and the foamed material As a result, the height of the reinforcing ribs 13 becomes low, and a sufficient reinforcing effect cannot be expected. Further, the resin material 16 occupies a large portion of the total cost of the reinforcing material 14, and increasing the width of the resin material 16 increases the cost accordingly, which is not economically desirable. This invention was made by focusing on the points mentioned above, and by forming the edges of the resin material into an uneven shape to ensure the bonding area and not preventing the foaming of the foam material. The purpose is to solve the above points. The present invention will be explained below based on the drawings. FIGS. 4-7A and 7B are diagrams showing a first embodiment of the present invention. In the figure, reference numeral 20 denotes a plate material, and reinforcing materials 21 are attached to the parts of the plate material 20 that require reinforcement, and reinforcing ribs 13 are formed there. In this case, a longitudinal portion of the plate 20 is selected as a portion of the plate 20 that requires reinforcement, and a 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. ℃) and has flexibility, adhesiveness, and adhesion at room temperature, and melamine-based, phenol-based, urea-based resin materials, and others may also be used. Note that these resin materials 22 are sticky at room temperature,
If the adhesiveness is lacking or the adhesiveness or adhesiveness is weak, it is sufficient to add a material with high adhesiveness or adhesiveness to one side surface 25 corresponding to the plate material 20 in advance. Examples of thermosetting epoxy resin materials include bisphenol A type epoxy resins Epicote #828 and #1004 (both manufactured by Yuka Ciel Co., Ltd.) and thermoplastic polyester resin Vylon #500 (manufactured by Toyo Boseki Co., Ltd.).
or the above Epicote #828,
Platamide, a nylon resin copolymerized with #1004
A mixture of H103P (manufactured by Nippon Rilsan Co., Ltd.) with a curing agent such as dicyandiamide is preferable. Glass fiber or other reinforcing material 24 may be added to the surface or surface portion of the resin material 22 in advance.
Glass cloth is suitable as the reinforcing material 24, 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 24 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 Nitto Boseki) showed good performance. The foamed material 23 is preferably a foamed epoxy resin sheet, but is not limited to this. It is foamed prior to the hardening of the resin material 22 at the baking temperature (120°C to 180°C) in the painting process, and the volume is adjusted to an appropriate magnification. expands 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: the above-mentioned Epikote #1004 is added with Hiker CTBN (manufactured by B.F. Gudryutsch), which is a nitrile rubber containing a carboxyl group, and further contains a dicyandiamide type. It is preferable to add, for example, Vinyhole AK#2 (manufactured by Eiwa Kasei Co., Ltd.) as a foaming agent to an epoxy resin composition containing a curing agent. Furthermore, the resin material 21 including the resin material 22 and the foam material 23 is formed to have a thin sheet shape as a whole, and the resin material 22 is attached onto the foam material 23 in a state that covers the entire foam material 23. ing. Further, the foamed material 23 is located on one side 25 of the resin material 22, that is, the surface that corresponds to the plate material 20, in the longitudinal direction of the center, which is a part thereof, and the remaining peripheral portion is This is the adhesive surface 26. Furthermore, the edge of the resin material 22 is previously formed into an uneven shape with respect to the edge of the foam material 23, but in this case, the shape of the resin material 22 is a rectangular shape,
Since both longitudinal ends of the foamed material 23 are exposed, only both longitudinal sides 27, which are part of the edges of the resin material 22, are formed into an uneven shape. Moreover, the concave and convex portions 28 and convex portions 29 are formed in a triangular waveform. The width W ₁ between the concave portions 28 of the resin material 22 is set to a length that will not peel off even if the foamed material 23 expands during heating and foaming, and the width W ₂ between the convex portions 29 is set to a length that is long enough to prevent the foamed material 23 from peeling off even if the foamed material 23 expands during heating and foaming. Reinforcement rib 13
be long enough to maintain adhesive strength. In addition, the triangular waveform concave portion 28 and convex portion 2 on both long sides 27
9 is symmetrical with respect to the axis X as shown in FIG. 7A, but may be asymmetrical as shown in FIG. 7B. In order to form the reinforcing ribs 13 using the reinforcing material 21, the reinforcing material 21 is first attached to the plate material 20 that requires reinforcement, such as the outer panel of an automobile. In this case, since the adhesive surface 26 of the resin material 22 has adhesive properties, if the resin material 22 is pressed against the plate material 20, it can be reliably adhered. Next, when the reinforcing material 21 together with the plate material 20 is heat-treated at 140° C. to 180° C. using, for example, an oven used in an automobile painting process, the foaming material 23 foams while the resin material 22 is softened, and is further heated. As this continues, the curing reaction of the resin material 22 progresses and it adheres to the plate material 20, forming the reinforcing ribs 13. In this case, the degree of adhesion of the resin material 22 to the plate material 20 during foaming of the foamed material 23 is not so high due to the presence of the recesses 28, so the foamed material 23 is foamed to a sufficient height, and after curing, the convex portions 29 increases the adhesive section modulus with the plate material 20, thereby reliably improving the rigidity of the plate material 20. FIGS. 8A and 8B show a second embodiment. In this embodiment, both long sides 31 of the resin material 30 are preliminarily formed into an uneven shape having circular wave-shaped recesses 32 and protrusions 33. In addition, in FIG. 8A, when the concave portion 32 and the convex portion 33 are symmetrical with respect to the axis X,
FIG. 8B shows an asymmetric case. The other configurations and operations are the same as those in the first embodiment, and their explanations will be omitted. FIGS. 9A and 9B show a third embodiment. In this embodiment, both long sides 41 of the resin material 40 are formed in advance into an uneven shape having square wave-shaped recesses 42 and protrusions 43. Further, FIG. 9A shows a case where the recessed portion 42 and the convex portion 43 are symmetrical with respect to the axis X, and FIG. 9B shows a case where they are asymmetrical. Next, a test example is shown. The width of the foam material is 10mm, and the width of the resin material is 40mm and 50mm.
The width of the conventionally shaped reinforcing material and the foamed material 23 is 10 mm,
Recesses 28, 32, 42 of resin materials 22, 30, 40
The width between them _W1 is 30mm, the width between the protrusions 29, 33, and 43
W ₂ is 50mm, convex part and convex part (or concave part and concave part)
The reinforcing material 21 of each shape of the first to third embodiments with a gap t of 30 mm was attached to the test piece and foamed and cured under almost the same conditions, and the foaming height and breaking load of each were determined. Upon investigation, the results shown in the following table were obtained. For this breaking load test, a method was adopted in which a test piece having foam-cured reinforcing ribs was suspended and supported on a test piece support stand, and the central part of the test piece was pressed and bent with a load-bearing indenter.

【table】

[Table] As shown in the table above, if the width of the resin material is 40 mm with the conventional shape, a sufficient foaming height can be obtained, but the resin material will peel off continuously and the breaking load will be low. When the width is set to 50mm, the foaming height becomes lower. Furthermore, if the gap t between the convex parts is too large, peeling will occur, especially in the concave parts, so it is preferable to make the gap t about the width of the resin material. Also, the smaller t is, the less the negative effect will be, but if it is too small, the strength will be reduced due to the notch effect, so it is preferably set to at least half the width of the resin material. On the other hand, when the resin material was shaped as in the first and second examples, a sufficient foam height was obtained and the breaking load increased in both cases. Furthermore, when the resin material is configured as in the third embodiment, the concave part of the resin material peels off, but in this case, the peeled part is only the concave part and is not continuous, and moreover, the convex part is reliably bonded, so the conventional shape is It was found that the breaking load was higher than in the case of the conventional method, and that the necessary reinforcing effect could be obtained. In these examples, the width of the resin material was 40 mm on average, and there was no unevenness.
The breaking load is larger compared to the case of 40mm wide resin material. When using such reinforcing materials, if the convex portions and concave portions have the same shape, the convex portion of one reinforcing material becomes the concave portion of the adjacent reinforcing material, and by cutting out multiple resin materials from a large sheet with a mold, waste can be avoided. The cost is almost the same as that of a straight resin material with a width of 40 mm. Furthermore, in the above,
In the above example, a foamed material is attached to a rectangular resin material with both longitudinal ends exposed, and an uneven shape is formed only on both longitudinal sides, which are part of the edges of the resin material. For example, although not shown in the drawings, the entire edge of the resin material may be formed into an uneven shape so that both ends of the foam material are not exposed, and the shape of the resin material is not limited to the above-mentioned rectangular shape, but may also be rectangular, rectangular, etc. A rectangular, circular, or oval shape is also possible, and it is sufficient if a part or all of the edges thereof are formed with an uneven shape. As explained above, according to this invention,
The structure is such that an unfoamed sheet-like foam material is attached and integrated with one side of an uncured sheet-like resin material, leaving the adhesive surface to the plate material, and the edges of the resin material are made into an uneven shape. By cutting the foam, the adhesive force of the resin material can be prevented from interfering with the foam material due to the presence of the unevenly shaped recesses, and a sufficient foam height can be obtained. Due to the presence of the uneven convex portions, it is possible to reliably secure the adhesion area to the plate material, and as a result, the rigidity of the plate material can be reliably improved. This has the effect of reducing costs by saving on the amount of resin used, which accounts for a large portion of the cost.

[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 sectional view taken along the - line of Figure 2 A, and Figures 3 A and 3 are
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 the first embodiment, FIG. 5A is an enlarged cross-sectional view taken along the line in FIG. 4, FIG. An enlarged cross-sectional view along the line, and a cross-sectional view showing the state after foaming and hardening.
Figure 7A is a front view showing a resin material with a symmetrical uneven shape;
8A and 8B show the second embodiment, and FIGS. 9A and 9B are front views corresponding to FIGS. B shows the third embodiment, and is a front view corresponding to FIG. 7A and B, respectively. 20...Plate material, 21...Reinforcement material, 22,30,
40... Resin material, 23... Foaming material, 24... Reinforcement material, 25... One side, 26... Adhesive surface, 27,3
1, 41... Long side, 28, 32, 42... Concave portion, 29, 33, 43... Convex portion, W ₁ ... Width between concave portions, W ₂ ... Width between convex portions, X... Axis .

Claims (1)

[Scope of Claims] 1. A reinforcing material for automobile plates, which is made by integrally adhering an unfoamed sheet-like foam material to one side of an uncured sheet-like resin material, leaving the adhesive surface to the plate material. A reinforcing material for a plate material for an automobile, characterized in that the edge of the resin material is formed into an uneven shape.