Method for filling with a coating-type foaming agent

Abstract

To provide a technique capable of filling inside a hollow member with a foaming agent without a gap.SOLUTION: A coating type foaming agent filling method includes: an installation step of installing a plate-like member inside a hollow member; a coating step of coating a coating type foam filler to the plate-like member; and a baking step of heating and baking the coating type foam filler and the plate-like member, after the coating step.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to a method for filling a coating-type foaming agent.

Background Art

[0002] A technique for enhancing sound insulation by filling a hollow portion of a member such as an automobile pillar is known. In Patent Document 1, a technique for filling the inside of a pillar by expanding a bag-shaped object containing a foaming agent is described.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, when the shape of the pillar is complicated, it is difficult to sufficiently fill the inside of the pillar with the bag-shaped object, and there is a risk of gaps.

Means for Solving the Problems

[0005] The present disclosure has been made to solve the above problems and can be realized in the following forms. (1) According to the first aspect of the present disclosure, a method for filling a coating-type foaming agent is provided. This method for filling a coating-type foaming agent includes an installation step of installing the plate-shaped member so that the peripheral edge of the plate-shaped member is close to the inner surface of the hollow member, and the plate-shaped member Top surface a coating step of applying a coating-type foaming filler to the plate-shaped member, and a baking step of heating and baking the coating-type foaming filler and the plate-shaped member after the coating step. (2) A second embodiment of the present disclosure provides a method for filling with a coating-type foaming agent. This method includes an installation step of installing a plate-shaped member such that the peripheral edge of the plate-shaped member is in close proximity to the inner surface of the hollow member; an application step of applying a coating-type foaming agent to the inner surface of the hollow member above the plate-shaped member after the installation step; and a baking step of heating and baking the coating-type foaming agent after the application step.

[0006] (1) According to a first embodiment of the present disclosure, a method for filling with a coating-type foaming agent is provided. This method for filling with a coating-type foaming agent includes an installation step of installing a plate-shaped member inside a hollow member, an application step of applying a coating-type foaming agent to the plate-shaped member, and a baking step of heating and baking the coating-type foaming agent and the plate-shaped member after the application step. This type of coating-type foaming agent filling method allows for the foaming agent to be filled into the hollow member without gaps while suppressing dripping during baking, thanks to the presence of a plate-like member. (2) A second embodiment of the present disclosure provides a method for filling with a coating-type foaming agent. This method includes an installation step of installing a plate-shaped member inside a hollow member; an application step of applying a coating-type foaming agent to the inner surface of the hollow member above the plate-shaped member after the installation step; and a baking step of heating and baking the coating-type foaming agent after the application step. This type of coating-type foaming agent filling method allows for the foaming agent to be filled into the hollow member without gaps while suppressing dripping during baking, thanks to the presence of a plate-like member.

[0007] Furthermore, this disclosure can be implemented in various forms, for example, in the form of a plate-shaped member used in a coating-type foaming agent filling method. [Brief explanation of the drawing]

[0008] [Figure 1] This is a flowchart showing an example of sound insulation processing. [Figure 2] This is a diagram illustrating the installation process. [Figure 3] This is an explanatory diagram of the coating process. [Figure 4] This flowchart shows an example of sound insulation processing in the second embodiment. [Figure 5] This is an explanatory diagram of the coating process in the third embodiment. [Modes for carrying out the invention]

[0009] A. First Embodiment: Figure 1 is a flowchart showing an example of sound insulation processing. Sound insulation processing is a process that enhances sound insulation by filling the hollow parts of the material to be processed with a coating-type foam filler.

[0010] In step S100, a plate-shaped member is installed inside a hollow member having a hollow section. This step is also called the "installation step". In this embodiment, the hollow member is a pillar of an automobile. The plate-shaped member is a member made of metal or resin. Any material can be used for the plate-shaped member as long as it can withstand the baking temperature in the baking step described later. The plate-shaped member can be any shape such that the periphery of the plate-shaped member and the inner surface of the hollow member are close enough that the coated foam filler does not drip from the gap between the periphery of the plate-shaped member and the hollow member during the baking step described later.

[0011] The shape of the plate-like member is preferably substantially similar to the cross-sectional shape of the hollow member. More specifically, the plate-like member is preferably shaped such that there is a gap of about 3 mm between at least a portion of the periphery of the plate-like member and the inner surface of the hollow member. This prevents the electrodeposited paint from accumulating when the hollow member passes through the electrodeposited paint tank.

[0012] Figure 2 is an explanatory diagram of the installation process. As shown in Figure 2, the plate-shaped member 20 has a shape substantially similar to the cross-sectional shape of the hollow member 10, and a part of the periphery of the plate-shaped member 20 is joined to the inner surface of the hollow member 10. The plate-shaped member 20 also has a joint portion 21 that is joined to the hollow member 10. In this embodiment, the plate-shaped member 20 is joined to the hollow member 10 by welding the joint portion 21 to the hollow member 10. However, the joining method is not limited to welding; it may also be joined using an adhesive that can withstand the baking temperature in the baking process described later, or the joining portion 21 may be fitted into a groove provided in the hollow member 10.

[0013] In step S110 (see Figure 1), a coating-type foaming filler is applied to the upper surface of the plate-shaped member 20 installed in step S100. This step is also called the "coating step". The upper surface refers to the upper surface along the direction of gravity in the coating step and the baking step. The coating-type foaming filler is a thermal decomposition type chemical foaming agent. For the organic thermal decomposition type foaming agent, an organic foaming agent containing dinitrosopentamethylenetetramine or azodicarbonamide, or an inorganic foaming agent containing sodium bicarbonate can be used. In this embodiment, the coating-type foaming filler is an organic thermal decomposition type foaming agent containing OBSH (4,4-oxybisbenzenesulfonyl hydrazide). The coating-type foaming filler may be applied by spraying, or by brushing or rolling.

[0014] Figure 3 is an explanatory diagram of the coating process. As shown in Figure 3, in this embodiment, the coating-type foaming filler 30 is applied to the entire surface of the plate-shaped member 20.

[0015] In step S120 (see Figure 1), the coated foam filler 30 applied in step S110 and the plate-shaped member 20 are heated and baked. This process is also called the "baking process".

[0016] According to the coating-type foaming agent filling method of this embodiment described above, the plate-shaped member 20 prevents the coating-type foaming agent 30 from dripping during baking, while the coating-type foaming agent 30 can be filled into the hollow member without any gaps.

[0017] In addition, the plate-like member 20 has a shape substantially similar to the cross-sectional shape of the hollow member 10, and a part of the peripheral edge of the plate-like member 20 is joined to the inner surface of the hollow member 10. Therefore, it is possible to further suppress the dripping of the coating-type foam filler 30 during baking. Also, when the hollow member 10 passes through, for example, an electrodeposition paint tank, it is possible to prevent the electrodeposition paint from staying on the plate-like member 20.

[0018] Moreover, compared with the case of performing sound insulation processing by molding a resin foam material along the internal shape of the hollow member 10, sound insulation processing can be performed easily and at a low cost.

[0019] B. Second Embodiment: FIG. 4 is a flowchart showing an example of the sound insulation processing in the second embodiment. The sound insulation processing in the second embodiment is different from the sound insulation processing in the first embodiment in that the coating step is performed before the installation step, and the baking step is the same as in the first embodiment.

[0020] In step S105, the coating-type foam filler 30 is applied to the upper surface of the plate-like member 20 that is not joined to the hollow member 10. Here, the upper surface refers to the upper surface along the gravitational direction in the coating step and the baking step.

[0021] In step S115, the plate-like member 20 coated with the coating-type foam filler 30 is joined to the hollow member 10. When joining the plate-like member 20 to the hollow member 10, it is preferable that the joining portion 21 is provided sufficiently large so as to avoid the coated coating-type foam filler 30 from adhering to the equipment performing the joining step.

[0022] According to the coating-type foaming agent filling method of the second embodiment described above, the same effects as those of the first embodiment can be achieved. That is, the plate-like member 20 can suppress the dripping of the coating-type foam filler 30 during baking and fill the hollow member with the coating-type foam filler 30 without gaps.

[0023] C. Third Embodiment: The sound insulation treatment in the second embodiment differs from the sound insulation treatment in the first embodiment in that a coating-type foaming filler 30 is applied to the hollow member 10 during the coating process, while the other processes are the same as in the first embodiment.

[0024] Figure 5 is an explanatory diagram of the coating process in the third embodiment. As shown in Figure 5, the coating-type foam filler 30 is applied to the inner surface of the hollow member 10 at the top of the plate-shaped member 20. The "top" refers to the upper side along the direction of gravity during the coating and baking processes.

[0025] The coating-type foaming agent filling method of the third embodiment described above can achieve the same effects as the first embodiment. That is, the plate-shaped member 20 prevents the coating-type foaming agent 30 from dripping during baking, while the coating-type foaming agent 30 can be filled into the hollow member without any gaps.

[0026] D. Other embodiments: (D1) In the embodiment described above, the plate-shaped member 20 has a joint portion 21 and is joined to the hollow member 10 via the joint portion 21. However, the plate-shaped member 20 may be joined to the hollow member 10 via other members. For example, the plate-shaped member 20 may be joined via a portion of the hollow member 10 that protrudes into the hollow part of the hollow member 10, or it may be joined via a member that spans from one surface of the hollow part of the hollow member 10 to another surface.

[0027] (D2) In the second embodiment described above, the coating-type foam filler 30 may be applied again after the bonding process in step S115.

[0028] This disclosure is not limited to the embodiments described above, and can be implemented in various configurations without departing from its spirit. For example, the technical features in the embodiments corresponding to the technical features in each form described in the summary of the invention can be replaced or combined as appropriate in order to solve the problems described above or to achieve some or all of the effects described above. Furthermore, if a technical feature is not described as essential in this specification, it can be deleted as appropriate. [Explanation of Symbols]

[0029] 10...Hollow member, 20...Plate-shaped member, 21...Joint, 30...Coated foam filler

Claims

1. A method for filling with a coating-type foaming agent, Installation step: Installing the plate-shaped member such that its peripheral edge is in close proximity to the inner surface of the hollow member; A coating step of applying a coating-type foaming filler to the upper surface of the plate-shaped member, A method for filling with a coating-type foaming agent, comprising a baking step of heating and baking the coating-type foaming agent and the plate-shaped member after the coating step.

2. A method for filling with a coating-type foaming agent, Installation step: Installing the plate-shaped member such that its peripheral edge is in close proximity to the inner surface of the hollow member; Following the installation step, a coating step is performed in which a coating-type foaming filler is applied to the inner surface of the hollow member on the upper part of the plate-shaped member, A method for filling with a coating-type foaming agent, comprising a baking step of heating and baking the coating-type foaming agent after the coating step.

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