Foamed resin product with shaft-shaped clip

Abstract

To provide a resin foam article with a shaft-like insertion clip that can be fitted stably to a fitting object, and a resin foam molding tool capable of molding the resin foam article with the shaft-like insertion clip.SOLUTION: A resin foam article 1 with a shaft-like insertion clip comprises the shaft-like insertion clip 2 etc., and a resin foam body. The shaft-like insertion clip 2 etc., extend in an axial direction passing a shaft center C, and also have a base part formed on one side and an insertion part formed on the other side. The shaft-like insertion clip 2 etc., include a first clip 2a etc., and a second clip 2b etc., and has the base part embedded in the resin form body. Parts, fitted to at least the fitting object, of the insertion part of the first clip 2a etc., and second clip 2b etc., are so sectioned, perpendicularly to the axial direction of the shaft-like insertion clip 2 etc., that a first outer diameter 6 in a first direction is smaller than a second outer diameter 7 in a second direction.SELECTED DRAWING: Figure 2

Description

Technical Field

[0005] , , ,

[0001] The present invention relates to a foamed resin product in which a clip-shaped member is embedded, and a foamed resin mold for molding the foamed resin product.

Background Art

[0002] Conventionally, a configuration in which a locking portion such as a clip is attached to a shock energy absorber has been proposed. For example, according to the description in Patent Document 1, an EA material made of a synthetic resin such as rigid urethane foam is attached to a trim as a member via a locking portion. The locking portion has a cylindrical portion, an anchor projecting outward in a flange shape from the rear end of the cylindrical portion, a flange projecting outward in a flange shape from the front end of the cylindrical portion, and a plurality of protrusions projecting in a direction parallel to the cylindrical axis direction from the front end surface of the cylindrical portion. The EA material is described as being attached to the trim by applying it to the trim while inserting the protrusions into the openings.

[0003] According to this, since the base portion of the protrusion is embedded in the EA material, the bonding strength between the protrusion and the EA material can be increased. Further, by providing the base portion of the locking portion so as not to penetrate the EA material, it is described that the shock absorption characteristics of the EA material in the vicinity of the locking portion can be enhanced.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, Patent Document 1 has the following problems. The locking part is attached by elastically deforming the claw part relative to the mounting hole. Generally, in clip insertion parts that involve elastic deformation, such as the locking part, when viewed in cross-section perpendicular to the insertion direction, a notch is formed to form the claw part, and the radial length differs in parts in the circumferential direction. That is, when the clip insertion part is attached to the mounting hole, play occurs between the clip and the mounting hole in the shorter diameter portion due to the notch, etc.

[0006] The problems of the conventional example will be explained with reference to Figures 17 and 18. Figure 17(a) shows the state in which the clip-attached foam resin product 51 is being attached to the object to be attached 40, and Figure 17(b) shows the state in which the clip-attached foam resin product 51 is attached to the object to be attached 40. Figure 18 is a plan view of the state in Figure 17(b) as seen from above. As shown in Figure 17, the direction of the line connecting the axis center of the first clip 52a and the axis center of the second clip 52b is defined as the first direction, and the direction of the line passing through each axis center and perpendicular to the first direction is defined as the second direction. As shown in Figure 17(a), the first clip 52a is inserted into the mounting hole 41a, and the second clip 52b is inserted into the mounting hole 41b. The cross-section of the first clip 52a and the second clip 52b perpendicular to the axial direction is not a perfect circle but a so-called flattened shape. The shapes of the first clip 52a and the second clip 52b are schematic shapes drawn to explain the problems. The first clip 52a and the second clip 52b each have a short-diameter portion 56 and a long-diameter portion 57. For example, the short-diameter portion 56 corresponds to the claw shape itself, or a notch or groove portion for forming the claw shape.

[0007] In conventional examples, the short-diameter portion 56 and long-diameter portion 57 of the first clip 52a and the second clip 52b are not restricted in either the first or second direction. For example, as shown in Figure 17, the first clip 52a has its short-diameter portion 56 formed in the first direction and its long-diameter portion 57 formed in the second direction. The second clip 52b has its long-diameter portion 57 formed in the first direction and its short-diameter portion 56 formed in the second direction. For example, the mounting hole 41a is circular, and the mounting hole 41b is elongated, with the short-diameter dimension being the same as the diameter of the mounting hole 41a, and the long-diameter dimension being larger than the diameter of the mounting hole 41a.

[0008] Figure 18 shows the state in which the clip-equipped foam resin product 51 is attached to the object to be attached 40. As shown in Figure 18(a), a gap g is created on both sides in the second direction between the mounting hole 41b and the second clip 52b. Then, as shown in Figure 18(b), the second clip 52b rotates around the first clip 52a.

[0009] Furthermore, although not shown in the diagram, if the first clip 52a is oriented in the same direction as the second clip 52b, a gap will also be created in the second direction between the mounting hole 41a and the first clip 52a. As a result, the foamed resin product 51 with the clip will vibrate as it moves in the second direction. In other words, in the example described in Patent Document 1, when there are two or more clip insertion parts equipped with locking parts, the direction in which the short-diameter portion is formed is not considered, and it is conceivable that the attached foamed resin product 51 with the clip will vibrate with rotation or movement in the second direction.

[0010] In addition, the examples in Figures 17 and 18 show cases where a gap g occurs on both sides in the second direction between the mounting hole 41b and the second clip 52b. However, even if no gap g occurs, runout may occur if the dimensions of the first clip 52a and / or the second clip 52b in the second direction are short. For example, if the first clip 52a and / or the second clip 52b are attached with elastic deformation in the second direction, the holding force due to the elastic force is small, and runout may occur.

[0011] The objective of the present invention is to solve the problems of the past and to provide a foamed resin product with a shaft-shaped insert clip that can be stably attached to an object having two or more attachment points, and further to provide a foamed resin molding die capable of molding a foamed resin product with a shaft-shaped insert clip. [Means for solving the problem]

[0012] A foamed resin product with an axial insert clip according to a first aspect of the present invention comprises an axial insert clip and a foamed resin body, wherein the axial insert clip extends along an axial direction passing through its axis, has a base formed on one side and an insertion portion formed on the other side, the axial insert clip includes a first clip and a second clip, the base is embedded in the foamed resin body, in a plan view from the side of the insertion portion, the direction of the line connecting the axis center of the first clip and the axis center of the second clip is defined as the first direction, and the direction of the line passing through the axis center and perpendicular to the first direction is defined as the second direction, and in at least the portion of the insertion portion of the first clip and the second clip that is attached to the object to be attached, the cross-section of the axial insert clip cut perpendicular to the axial direction has a first outer diameter, which is the maximum outer diameter in the first direction, that is smaller than the second outer diameter, which is the maximum outer diameter in the second direction.

[0013] According to this, in a foamed resin product with a shaft-shaped insert clip, the first outer diameter in the first direction of the shaft-shaped insert clip is smaller than the second outer diameter in the second direction. When the shaft-shaped insert clip is attached to a mounting hole in an object to be attached, the occurrence of play between it and the mounting hole in the second direction is suppressed. Therefore, when a foamed resin product with a shaft-shaped insert clip is attached to two mounting points on an object to be attached, the occurrence of vibration accompanied by rotation or movement in the second direction can be suppressed.

[0014] Furthermore, the foamed resin product with the shaft-shaped insertion clip may have a first flange portion at the boundary between the base portion and the insertion portion, and a second flange portion at the tip of the base portion, wherein at least a portion of the first flange portion is exposed from the surface of the foamed resin body, and the second flange portion is embedded in the foamed resin body.

[0015] In this case, at least a portion of the first flange of the shaft-shaped insert clip is exposed from the surface of the foamed resin body, while the second flange is embedded in the foamed resin body. Therefore, the shaft-shaped insert clip's holding strength is increased by gripping the foamed resin body between the first and second flanges, thus preventing it from falling out when attached to the object.

[0016] Furthermore, the foamed resin product with the shaft-shaped insert clip may have the first clip and the second clip having a shaft portion and an umbrella portion protruding from the shaft portion at the insertion part, and the umbrella portion may form the first outer diameter and the second outer diameter.

[0017] In this case, since the umbrella portion of the shaft-shaped insert clip forms the first and second outer diameters, the foamed resin product with the shaft-shaped insert clip can be fastened to the object to be attached while suppressing axial play.

[0018] Furthermore, the foamed resin product with the shaft-shaped insertion clip may have multiple umbrella-shaped portions in the axial direction. In this case, since the shaft-shaped insertion clip has multiple umbrella-shaped portions in the axial direction, it can be attached to objects with different plate thicknesses at the mounting holes.

[0019] A foamed resin mold according to a second aspect of the present invention is a resin mold for molding a foamed resin product with an axial insert clip, comprising a first mold and a second mold, one of which is an upper mold and the other a lower mold, wherein the first mold comprises a plurality of inserts capable of holding an axial insert clip, each insert having a recess into which the axial insert clip can be inserted, the recess having an insert-side engaging portion extending in the depth direction of the recess, and the insert-side engaging portions are arranged along the direction of alignment of adjacent recesses.

[0020] According to this, the foamed resin mold has an inner member side engaging portion in a recess into which an axial insertion clip can be inserted, and the inner member side engaging portion is formed along the arrangement direction of the recesses. When the axial insertion clip has a clip side engaging portion that can engage with the inner member side engaging portion, the clip side engaging portions are formed in a state arranged along the arrangement direction of the recesses. Therefore, the foamed resin mold can form a foamed resin body with an axial insertion clip that can be stably attached to the attachment object.

[0021] In addition, in a part of the recess of the foamed resin mold, an inclined surface that expands toward the insertion port side may be formed. In this case, since an inclined surface that expands toward the insertion port side is formed in a part of the recess of the foamed resin mold, the脱模 resistance from the axial insertion clip is reduced. Therefore, the foamed resin mold can easily demold the foamed resin product with an axial insertion clip.

Brief Description of the Drawings

[0022] [Figure 1] It is a diagram for explaining a state in which an axial insertion clip 2 is embedded in a foamed resin product 1a of the first embodiment according to the first aspect of the present invention, showing the foamed resin product 1a with an axial insertion clip. [Figure 2] It is a cross-sectional view showing cross-section I-I in FIG. 1. [Figure 3] (a) is a cross-sectional view showing cross-section II-II in FIG. 2 and showing the axial insertion clip 2, and (b) is an enlarged view of part A in FIG. 3(a), showing the state in which the umbrella part 11 is elastically deformed. [Figure 4] It is a diagram showing a state in which the foamed resin product 1a with an axial insertion clip of the present invention is attached to an attachment object 40, and is a cross-sectional view cut axially along the first direction line L1. (a) shows the state during attachment, and (b) shows the attached state. [Figure 5] It is a cross-sectional view showing cross-section III-III in FIG. 4(b). [Figure 6] (a) shows cross-section IV-IV in FIG. 5, and (b) shows cross-section V-V in FIG. 6(a). [Figure 7]For FIG. 4(a), when the distance between the first clip 2a and the second clip 2b is shorter than the distance between the mounting holes 41a and 41b of the object 40 to be mounted in the first direction, the relationship between the first clip 2a and the mounting hole 41a is shown. (a) is a cross-sectional view corresponding to FIG. 4(a), and (b) is a cross-sectional view showing cross-section VI-VI in FIG. 7(a). [Figure 8] It is a partially enlarged perspective view of the shaft insertion clip 2, showing the state when the portion 6a forming the first outer diameter is elastically deformed. [Figure 9] It shows the foamed resin product 1b with a shaft insertion clip according to the second embodiment of the first aspect of the present invention, and is a diagram for explaining the state where the shaft insertion clip 12 embedded in the foamed resin body 3 is attached to the object 40 to be mounted, and is a cross-sectional view cut axially along the first direction line L1. [Figure 10] It is a cross-sectional view showing cross-section VII-VII in FIG. 9. [Figure 11] It shows cross-section VIII-VIII in FIG. 10 and is a cross-sectional view showing the shaft insertion clip 12. (a) shows the state when the shaft insertion clip 12 is being attached to the mounting hole 41, and (b) shows the state when the shaft insertion clip 12 is attached to the mounting hole 41. [Figure 12] It shows the foamed resin molding die 20 according to the second aspect of the present invention, showing the state where the first die 21 and the second die 22 are closed to each other. [Figure 13] It shows the state of opening the first die 21 after molding and detaching the foamed resin product 1a with a shaft insertion clip from the first die 21 from the state of FIG. 12. [Figure 14] (a) is an enlarged view of the main part of the foamed resin molding die 20 shown in FIG. 12, showing the case of molding the foamed resin product 1a with a shaft insertion clip of the first embodiment, and (b) shows cross-section IX-IX in FIG. 14(a). [Figure 15] (a) is an enlarged view of one of the main parts of the foamed resin molding die 20 shown in FIG. 12, showing the case of molding the foamed resin product 1b with a shaft insertion clip of the second embodiment, and (b) shows cross-section XI-XI in FIG. 15(a). [Figure 16]This figure shows in detail the insert 23 in the foamed resin mold 20 of the present invention. (a) shows the cross-section XX of Figure 14(b), which is a cross-sectional view of the insert 23a used in the foamed resin product 1a with an axial insert clip. (b) shows the cross-section XII-XII of Figure 15(b), which is a cross-sectional view of the insert 23b used in the foamed resin product 1b with an axial insert clip. [Figure 17] A conventional example is shown, illustrating the state in which the clip-attached foam resin product 51 is attached to the object 40, with (a) showing the state in the process of attachment and (b) showing the state after attachment. [Figure 18] Figure 17(b) is a view from above in the axial direction, showing the case where the clip-attached foamed resin product 51 is rotated relative to the object 40 to which it is attached. [Modes for carrying out the invention]

[0023] The foamed resin product 1 with a shaft-shaped insert clip and the foamed resin mold 20 embodying the present invention will be described below with reference to the drawings. The embodiments for carrying out the invention and the referenced drawings are used to explain the technical features that the present invention may adopt. The present invention is not limited to these. The configurations shown in the drawings are not intended to limit the invention to these configurations, but are merely illustrative examples.

[0024] <Common configuration for each embodiment of foamed resin product 1 with shaft-shaped insert clip> The common configuration of each embodiment of the foamed resin product 1 with a shaft-shaped insert clip according to the first aspect of the present invention will be described. Figures 1 to 11 show the foamed resin product 1 with a shaft-shaped insert clip according to the present invention. As shown in Figure 1, etc., the foamed resin product 1 with a shaft-shaped insert clip comprises a shaft-shaped insert clip 2, etc. and a foamed resin body 3. The shaft-shaped insert clip 2, etc. extends along the axial direction passing through the axis center C, with a base portion 4 formed on one side and an insertion portion 5 formed on the other side. The shaft-shaped insert clip 2, etc. includes a first clip 2a, etc. and a second clip 2b, etc., and the base portion 4 is embedded in the foamed resin body 3.

[0025] The foamed resin body 3 is a so-called EA material, and its material is a foamed resin, such as rigid urethane. It can be used in a variety of applications, including automotive applications.

[0026] As shown in Figure 2, in a plan view from the side of the insertion portion 5, the direction of the line connecting the axial center Ca of the first clip 2a, etc., and the axial center Cb of the second clip 2b, etc., is defined as the first direction, and the direction of the line passing through the axial center C and perpendicular to the first direction is defined as the second direction. The line in the first direction is defined as the first direction line L1, and the line in the second direction is defined as the second direction line L2. In the insertion portions 5 of the first clip 2a, etc., and the second clip 2b, etc., at least in the portion attached to the object 40, the cross-sections of the axial insertion clips 2, etc., cut perpendicular to the axial direction, have a first outer diameter 6 in the first direction that is smaller than the second outer diameter 7 in the second direction.

[0027] Furthermore, the portion 7a of the first clip 2a and the second clip 2b that forms the second outer diameter 7 may be elastically deformable. In addition, the portion 6a of the first clip 2a and the second clip 2b that forms the first outer diameter 6 may be elastically deformable.

[0028] Furthermore, as shown in Figures 1 and 9, the shaft-shaped insertion clip 2 is provided with a first flange portion 8 at the boundary between the base portion 4 and the insertion portion 5, and a second flange portion 9 at the tip of the base portion 4. At least a portion of the first flange portion 8 is exposed from the surface of the foamed resin body 3, and the second flange portion 9 is embedded in the foamed resin body 3.

[0029] <Effects common to each embodiment of foamed resin product 1 with shaft-shaped insert clip> The above-described configuration common to the foamed resin product 1 with a shaft-shaped insert clip provides the following effects. As shown in Figure 2, the foamed resin product 1 with a shaft-shaped insert clip has a first outer diameter 6 in the first direction of the shaft-shaped insert clip 2, etc., which is smaller than the second outer diameter 7 in the second direction. As a result, when the shaft-shaped insert clip 2, etc. is attached to the mounting hole 41 of the object to be attached 40, the occurrence of play between it and the mounting hole 41 in the second direction is suppressed. Therefore, when the foamed resin product 1 with a shaft-shaped insert clip is attached to two mounting holes 41 of the object to be attached 40, the occurrence of vibration or runout can be suppressed.

[0030] Furthermore, in the shaft-shaped insert clip 2, at least a portion of the first flange 8 is exposed from the surface of the foamed resin body 3, and the second flange 9 is embedded in the foamed resin body 3. Therefore, the shaft-shaped insert clip 2, etc., has increased holding strength by gripping the foamed resin body 3 between the first flange 8 and the second flange 9, thus preventing it from falling off when attached to the object 40.

[0031] <Description of the foamed resin product 1a with a shaft-shaped insert clip according to the first embodiment> Next, each embodiment of the foamed resin product 1 with a shaft-shaped insert clip will be described. The difference between the foamed resin product 1a with a shaft-shaped insert clip of the first embodiment and the foamed resin product 1b with a shaft-shaped insert clip of the second embodiment lies in the difference between the shaft-shaped insert clip 2 and the shaft-shaped insert clip 12. Figures 1 to 8 show the foamed resin product 1a with a shaft-shaped insert clip of the first embodiment.

[0032] The shaft-shaped insertion clip 2 in the foamed resin product 1a with a shaft-shaped insertion clip will be described with reference to Figures 1, 2, 3, and 8. As shown in Figure 1, the foamed resin product 1 with a shaft-shaped insertion clip is provided with at least two shaft-shaped insertion clips 2, which are the first clip 2a and the second clip 2b. The first clip 2a and the second clip 2b have the same shape and are common parts. As shown in Figures 1 and 3, the upper part of the insertion portion 5 of the shaft-shaped insertion clip 2 is conical, and four ribs are formed in the axial direction.

[0033] As shown in Figure 3(a), the lower part of the insertion portion 5 has a portion 6a that forms the first outer diameter 6 and a portion 7a that forms the second outer shape. The first clip 2a and the second clip 2b have a shaft portion 5a and an umbrella portion 11 that protrudes from the shaft portion 5a in the insertion portion 5, and the umbrella portion 11 forms the first outer diameter 6 and the second outer diameter 7. Furthermore, the insertion portion 5 has multiple umbrella portions 11 in the axial direction. As shown in Figure 3(b), the umbrella portion 11 is formed in a substantially triangular shape extending radially outward from the shaft portion 5a, and the lower surface 11a is inclined so that the outer diameter portion 11b hangs down in the axial direction. The umbrella portion 11 is elastically deformable when an external force is applied in the direction indicated by the arrow in Figure 3(b). Polyacetal resin is used as an example for the shaft-shaped insertion clip 2, but other materials may be used.

[0034] As shown in Figures 2 and 3, clip-side engaging portions 10 are formed in the portion 6a that forms the first outer diameter 6. Two clip-side engaging portions 10 are formed opposite each other, straddling the axis center Ca and axis center Cb, and are formed in a line along the first direction line L1 that passes through the axis center Ca and axis center Cb. In the case of the shaft-shaped insert clip 2, the clip-side engaging portions 10 are groove-shaped recesses formed symmetrically on either side of the first direction line L1 that passes through the axis center Ca and axis center Cb, as shown in Figures 2 and 3. As will be described later, when using the shaft-shaped insert clip 2 to mold a foamed resin product 1a with a shaft-shaped insert clip, the foamed resin mold 20 has a nest-side engaging portion 28 that engages with the clip-side engaging portion 10, which is a convex portion formed along the first direction.

[0035] As shown in Figure 2, in a plan view from the insertion part 5 side, the umbrella portion 11 of the shaft-shaped insertion clip 2 has a basic circular shape, and a part of it is cut out by the clip-side engagement portion 10, which is a groove-shaped recess. Therefore, the first outer diameter 6, which is the maximum outer diameter in the first direction, is shorter than the second outer diameter 7, which is the maximum outer diameter in the second direction.

[0036] Next, with reference to Figures 4 to 8, the state in which the foamed resin product 1a with a shaft-shaped insert clip is attached to the object 40 will be described. The example shown in Figure 4 shows the case in the first direction where the distance between the mounting holes 41a and 41b of the object 40 matches the distance between the axial centers C of the first clip 2a and the second clip 2b. Figure 4(a) shows the state in which the foamed resin product 1a with a shaft-shaped insert clip is being attached to the object 40, and Figure 4(b) shows the state after it has been attached. In the example shown in Figure 5, the mounting hole 41a is circular, and the mounting hole 41b is an elongated hole that is longer in the first direction. The elongated hole has a minor axis dimension similar to the diameter of the mounting hole 41a, and a major axis dimension larger than the diameter of the mounting hole 41a.

[0037] In this case, as shown in Figure 4(a), the foamed resin product 1a with a shaft-shaped insert clip is smoothly attached to the object 40 in the first direction. As shown in Figure 6, in the second direction, the shaft-shaped insert clip 2 is formed such that the diameter of the umbrella portion 11 in the portion 7a forming the second outer diameter 7 is larger than the diameter of the mounting hole 41, and the umbrella portion 11 is inserted while deforming. The umbrella portion 11 included in the portion 7a forming the second outer diameter 7 of the first clip 2a is inserted into the mounting hole 41a while deforming evenly in the second direction. Similarly, the portion 7b forming the second outer diameter 7 of the second clip 2b is inserted into the mounting hole 41b while deforming evenly in the second direction.

[0038] As shown in Figure 6(a), in the second direction, the portion of the umbrella 11 attached to the mounting hole 41 is in an elastically deformed state. As shown in Figure 6(b), the portion of the umbrella 11 corresponding to the upper surface 42 of the object to be attached 40 is in an open state and is attached by being sandwiched between it and the first flange 8.

[0039] Next, the example shown in Figure 7 illustrates the case where, in the first direction, the distance between the mounting holes 41a and 41b of the object to be mounted 40 is longer by a distance M than the distance between the first clip 2a and the second clip 2b. In this case, since the first outer diameter 6 is smaller than the second outer diameter 7, if the diameter of the mounting hole 41 is larger than the first outer diameter 6, the shaft-shaped insertion clip 2 will be mounted closer together by the diameter difference in the first direction.

[0040] When the shaft insertion clip 2 cannot be adjusted only by the diameter difference in the first direction, as shown in FIGS. 7(b) and 8, the umbrella portion 11 included in the portion 6a forming the first outer diameter 6 is attached to the mounting hole 41 while being deformed. As shown in FIG. 8, the umbrella portion 11 of the portion 6a forming the first outer diameter 6 is easily deformed because the notch-shaped clip-side engaging portion 10 is formed. That is, the shaft insertion clip 2 is more likely to be deformed in the portion 6a forming the first outer diameter 6 than in the portion 7a forming the second outer diameter 7 where the clip-side engaging portion 10 is not formed. Therefore, in the example shown in FIG. 7, it may be possible to attach it to the mounting hole 41.

[0041] When the foamed resin product 1a with the shaft insertion clip is attached to the attachment object 40, in the second direction, the shaft insertion clip 2 follows the mounting hole 41 and thus does not deviate.

[0042] Next, the shaft insertion clip 2 will be described in more detail. As shown in FIG. 2, since the umbrella portion 11 of the shaft insertion clip 2 is cut out, in the cross section perpendicular to the axial direction of the insertion portion 5, the portion overlapping the first direction line L1 has no umbrella portion 11 and only the shaft portion 5a. That is, the length of the shaft portion 5a, which is the portion overlapping the first direction line L1, is S1. The portion overlapping the second direction line L2 is the second outer diameter 7, which is the outer diameter of the umbrella portion 11 shown in FIG. 2, and the length of the second outer diameter 7 is S2. That is, the relationship S1 < S2 is satisfied.

[0043] Next, the configurations satisfying the relationship of S1 < S2 described above will be listed. A foamed resin product 1 with an axial insertion clip including a first clip 2a, a second clip 2b, and a foamed resin body 3, wherein the first clip 2a and the second clip 2b have a base 4 embedded in the foamed resin body 3 and an insertion portion 5 extending from the base 4, a first direction line L1 passes through the axial center Ca of the first clip 2a and the axial center Cb of the second clip 2b, and a second direction line L2 passes through the axial center Ca and the axial center Cb, respectively. When the second direction line L2 is perpendicular to the first direction line L1, in a plan view, in at least a portion of the insertion portion 5 of the foamed resin product 1 with an axial insertion clip that is attached to the attachment object 40, in a cross section perpendicular to the axial direction of the insertion portion 5, a portion overlapping the first direction line L1 is shorter than a portion overlapping the second direction line L2.

[0044] <Effect of the foamed resin product 1a with an axial insertion clip of the first embodiment> The foamed resin product 1a with an axial insertion clip of the first embodiment described above has the following effects. As shown in FIGS. 1 to 6, since the umbrella portion 11 of the axial insertion clip 2 forms the first outer diameter 6 and the second outer diameter 7, the foamed resin product 1 with an axial insertion clip can be fastened to the attachment object 40 in a state where play in the axial direction is suppressed.

[0045] [[ID=IO]]As shown in FIG. 6(a), when the foamed resin product 1a with an axial insertion clip is attached to the attachment hole 41 of the attachment object 40, the upper surface 42 holds the attachment object with the umbrella portion 11 spreading in the radial direction, and the lower surface 43 is held by the first flange portion 8 with respect to the plate thickness of the portion to be attached. Therefore, the foamed resin product 1a with an axial insertion clip is attached to the attachment object 40 in a state where axial play is reduced.

[0046] In addition, since the axial insertion clip 2 has a plurality of umbrella portions 11 in the axial direction, it can be attached even when the plate thickness in the attachment hole 41 of the attachment object 40 is different: More specifically, as shown in FIG. 3(a), the axial insertion clip 2 of the foamed resin product 1a with an axial insertion clip can be attached to an attachment object having different plate thicknesses in units of the pitch interval P between adjacent umbrella portions 11 in the axial direction.

[0047] Furthermore, as shown in Figure 6(a), when the shaft-shaped insert clip 2 is attached to the mounting hole 41 of the object to be attached 40, the multiple umbrella-shaped portions 11 are elastically deformed in the axial direction relative to the mounting hole 41 in the second direction. Therefore, the foamed resin product 1a with the shaft-shaped insert clip can be firmly fixed to the mounting hole 41.

[0048] Furthermore, as shown in Figure 2, the umbrella portion 11 of the shaft-shaped insertion clip 2 has a constant outer diameter over a wide area, except for the groove-shaped recess that forms the clip-side engaging portion 10. Even if the direction in which the clip-side engaging portion 10 of the first clip 2a and the clip-side engaging portion 10 of the second clip 2b are aligned is tilted with respect to the first direction, the relative size relationship between the first outer diameter 6 and the second outer diameter 7 can be maintained. Therefore, even if a certain degree of manufacturing error occurs, the foamed resin product 1a with a shaft-shaped insertion clip can suppress the runout that occurs when it is attached to the object 40.

[0049] <Description of the foamed resin product 1b with shaft-shaped insert clip according to the second embodiment> Next, the foamed resin product 1b with a shaft-shaped insert clip of the second embodiment will be described with reference to Figures 9 to 11. As already explained, the difference from the foamed resin product 1a with a shaft-shaped insert clip of the first embodiment is the difference in the shape of the shaft-shaped insert clip 12. As shown in Figure 11, the shaft-shaped insert clip 12 has a shaft portion 15 that extends in the axial direction, and a claw portion 14 that extends downward in a U-shape, connected to the upper end of the shaft portion 15. As shown in Figure 10, the shaft portion 15 and the claw portion 14 are formed in pairs, facing each other on a first direction line L1 passing through the axis center C. The claw portion 14 elastically deforms along the second direction. The two shaft-shaped insert clips 12, the first clip 12a and the second clip 12b, have the same shape and are common parts.

[0050] As shown in Figures 10 and 11(b), the portion of the claw portion 14 corresponding to the mounting hole 41 has an arc-shaped outer circumference 14a so as to be in contact with the inner wall of the mounting hole 41 in the second direction. As shown in Figure 10, the shaft-shaped insertion clip 12 has a first outer diameter 6, which is the maximum outer diameter in the first direction, and this is the width dimension of the claw portion 14. As shown in Figure 11(b), the second outer diameter 7, which is the maximum outer diameter in the second direction, is the arc-shaped portion 14a. The first outer diameter 6 is shorter than the second outer diameter 7. The claw portion 14 also includes a portion other than the arc-shaped portion 14a whose outer diameter is even larger than the second outer diameter 7.

[0051] As shown in Figure 10, in each axial insertion clip 12, there is a gap 16 in the second direction between the two shaft portions 15, with a first direction line L1 passing through the axial center C. As shown in Figure 11(a), the axial insertion clip 12 is inserted into the mounting hole 41 of the object to be attached 40 while the claw portion 14 is elastically deformed, and as shown in Figure 11(b), when attached, the claw portion 14 spreads in the second direction, and the lower end comes into contact with the upper surface 42 of the object to be attached 40.

[0052] As will be described later, when the foamed resin product 1b with a shaft-shaped insert clip is molded, the clip-side engaging portion 10 that engages with the insert-side engaging portion 28b in the foamed resin mold 20 corresponds to the portion 6a that forms the first outer diameter 6 parallel to the second direction.

[0053] <Effects of the foamed resin product 1b with shaft-shaped insert clip according to the second embodiment> The foamed resin product 1b with a shaft-shaped insert clip of the second embodiment described above provides the following effects. The shaft-shaped insert clip 12 has opposing claw portions 14 that are elastically deformable around the shaft center C. As shown in Figure 11(a), when it is attached to the mounting hole 41 of the object to be attached 40, the claw portions 14 are inserted while elastically deforming. As shown in Figure 11(b), when attached, the claw portions 14 return to their natural state after elastic deformation, and the lower end engages with the upper surface 42 of the periphery of the mounting hole 41. Therefore, the shaft-shaped insert clip 12 does not elastically deform when attached to the object to be attached 40, thus preventing permanent deformation and a reduction in holding force. In addition, since the elastic force of the claw portions 14 can be adjusted by the thickness in the second direction, a shaft-shaped insert clip 12 with an appropriate elastic force can be selected depending on the application.

[0054] Furthermore, as shown in Figure 10, the clip-side engaging portion 10 can be a plane in which the portion 6a forming the first outer diameter 6 is formed parallel to the second direction. As will be described later, as shown in Figure 15(b), when the shaft-shaped insertion clip 12 is attached to the insert 23b, the clip-side engaging portion 10 and the insert-side engaging portion 28b are brought into contact surface-to-surface, so that play between them is suppressed. Therefore, the foamed resin product 1b with the shaft-shaped insertion clip is molded in an appropriate state.

[0055] <Description of Foamed Resin Molding Die 20> Next, with reference to Figures 12 to 16, a foam resin mold 20 according to a second aspect of the present invention will be described. The foam resin mold 20 is a mold for molding a foam resin product 1 with an axial insert clip, and comprises a first mold 21 and a second mold 22, with one being the upper mold and the other the lower mold. The first mold 21 comprises a plurality of inserts 23 capable of holding the axial insert clip 2, etc. Each insert 23 is provided with a recess 25 into which the axial insert clip 2, etc. is inserted. The recess 25 is provided with an insert-side engaging portion 28 that extends in the depth direction of the recess 25. The insert-side engaging portions 28 are arranged along the direction of alignment of adjacent recesses 25. As shown in Figure 16, a part of the recess 25 is formed with an inclined surface 29 that extends toward the insertion opening 26. The inclined surface 29 is formed by a tapered surface with an angle θ with respect to the axial direction over its entire circumference.

[0056] As shown in Figures 12 and 14, the recess 25 is formed along the first direction, and the position of the recess 25 determines the position of the axial insertion clip 2, etc. As shown in Figure 13, the first mold 21 is rotatable relative to the second mold 22 about the pivot axis 30. When the first mold 21 is closed relative to the second mold 22, a cavity 35 is formed inside.

[0057] Next, the insert 23 will be described with reference to Figures 14 to 16. Figure 14 shows the insert 23a used for the foamed resin product 1a with a shaft-shaped insert clip. Figure 15 shows the insert 23b used for the foamed resin product 1b with a shaft-shaped insert clip, and only one of the two inserts 23b is shown. The insert 23 is interchangeable depending on the form of the foamed resin product 1 with a shaft-shaped insert clip to be molded.

[0058] <Explanation of nested 23a> The insert 23a will be described with reference to Figures 14 and 16(a). The insert 23a is detachable from the first type 21 by bolts 31. The insert 23a comprises an upper insert 35a and a lower insert 36a, which are connected by bolts or the like (not shown). The insert-side engaging portion 28a is a convex portion that extends in the depth direction of the recess 25. As shown in Figure 14(b), the insert-side engaging portion 28a is arranged along the direction of alignment of adjacent recesses 25a. Specifically, the insert-side engaging portion 28a is arranged along a first direction line L1 that passes through the center of the recess 25a. The clip-side engaging portion 10 of the axial insertion clip 2 is formed by a groove-shaped recess recessed from the outer circumference, and when it engages with the convex portion which is the insert-side engaging portion 28a, it becomes aligned along the first direction line L1.

[0059] As shown in Figure 14(b), the nesting element 23a has a nesting projection 32 formed on a part of its outer circumference, and the first mold 21 has a nesting mounting recess 33 that corresponds to the shape of the nesting projection 32. The nesting mounting recess 33 is formed on the first direction line L1, and the mounting direction of the nesting element 23a is restricted by the first mold 21. This configuration is the same for the nesting element 23b, which will be described later.

[0060] The foamed resin product 1a with a shaft-shaped insert clip has the following configuration because the clip-side engaging portion 10 of the shaft-shaped insert clip 2 is aligned along the first direction due to the configuration of the insert-side engaging portion 28a of the insert 23a. Specifically, in the portion of the insertion portion 5 of the first clip 2a and the second clip 2b that is attached to the object to be attached 40, the cross-sections of the shaft-shaped insert clip 2 cut perpendicular to the axial direction are formed such that the first outer diameter 6, which is the maximum outer diameter in the first direction, is smaller than the second outer diameter 7, which is the maximum outer diameter in the second direction.

[0061] Next, the inclined surface 29 on the insert 23a will be described. As shown in Figure 16(a), the inclined surface 29 is formed on the lower insert 36a. Of the axial length N1 of the lower insert 36a, the inclined surface 29 is formed in the range of axial length N2 on the side of the insertion opening 26. The insert-side engaging portion 28a, which has already been described, is formed in the lower insert 36a in the range of axial length N3. The insert projection 32 is formed in the range of axial length N1 of the lower insert 36a. In the lower insert 36a, the range of axial length N1 is the range in which the umbrella portion 11 of the axial insertion clip 2 is formed, and the axial length N2 is preferably approximately half of the axial length N1.

[0062] Furthermore, as shown in Figure 16(a), the first flange portion 8 of the shaft-shaped insert clip 2 has a curved surface that extends radially from the axis center C and is directed upward in the axial direction. The lower surface 37 of the lower insert 36a is formed with a curved surface that matches the shape of the first flange portion 8. If the shape of the first flange portion 8 changes, the lower insert 36a will also be changed to a corresponding shape. Also, as shown in Figure 16(b), the relationship between the insert 23b, which will be described later, and the lower surface 37 of the shaft-shaped insert clip 12 is similar.

[0063] <Explanation of nested 23b> Next, the insert 23b will be described with reference to Figures 15 and 16(b). The insert 23b is detachable from the first mold 21 by a configuration similar to that of the insert 23a. The insert 23b comprises an upper insert 35b and a lower insert 36b, which are connected by bolts or the like (not shown). The insert-side engaging portion 28b extends in the depth direction of the recess 25 and is formed by a convex shape or a surface parallel to the second direction. The example shown in Figure 15(b) shows the case where the insert-side engaging portion 28b is formed in a convex shape. In addition, although not shown, the insert-side engaging portion 28b may not have a convex shape and may simply be formed by a surface parallel to the second direction, corresponding to the portion 6a that forms the first outer diameter 6 parallel to the second direction in the claw portion 14.

[0064] Although not shown in the diagram, the insert-side engaging portion 28b is arranged along the direction of alignment of adjacent recesses 25b, similar to the insert 23a. Specifically, the insert-side engaging portion 28b is arranged along a first direction line L1 passing through the center of the recess 25b. The foamed resin product 1b with an axial insert clip can achieve the same configuration as the insert 23a because the clip-side engaging portion 10 of the axial insert clip 12 is aligned along the first direction due to the configuration of the insert-side engaging portion 28b in the insert 23b. That is, in at least the portion of the insertion portion 5 of the first clip 12a and the second clip 12b that is attached to the object to be attached 40, the cross-sections cut perpendicular to the axial direction of the axial insert clip 2 are formed such that the first outer diameter 6, which is the maximum outer diameter in the first direction, is smaller than the second outer diameter 7, which is the maximum outer diameter in the second direction.

[0065] Next, the inclined surface 29 in the insert 23b will be described. As shown in Figure 16(b), the inclined surface 29 is formed on the lower insert 36b. Of the axial length N1 of the lower insert 36b, the inclined surface 29 is formed in the range of axial length N2 on the side of the insertion opening 26. The insert-side engaging portion 28b is formed in the lower insert 36b in the range of axial length N3. In the lower insert 36b, the range of axial length N1 is the range in which the claw portion 14 of the axial insertion clip 12 is formed, and the axial length N2 is preferably approximately half of the axial length N1.

[0066] <Effects of Foamed Resin Molding Die 20> The foam resin mold 20 described above provides the following effects. As shown in Figure 14, the foam resin mold 20 has a recess 25 into which an axial insert clip 2 or the like can be inserted, and an insert-side engaging portion 28 is formed along the direction of alignment of the recess 25. When the axial insert clip 2 or the like has a clip-side engaging portion 10 that can engage with the insert-side engaging portion 28, the clip-side engaging portion 10 is molded in a state where it is aligned along the direction of alignment of the recess 25. Therefore, the foam resin mold 20 can mold a foam resin product 1 with an axial insert clip that can be stably attached to an object 40 to be attached.

[0067] Furthermore, a portion of the recess 25 of the foamed resin mold 20 forms an inclined surface 29 that widens towards the insertion opening 26, thereby reducing the release resistance with the shaft-shaped insertion clip 2, etc. As shown in Figure 16(a), when the shaft-shaped insertion clip 2 of the foamed resin product 1a with a shaft-shaped insertion clip is released from the insert 23a, the elastically deformable umbrella portion 11 comes into contact with the inner surface of the lower insert 36a. Also, as shown in Figure 16(b), when the shaft-shaped insertion clip 12 of the foamed resin product 1b with a shaft-shaped insertion clip is released from the insert 23b, the elastically deformable claw portion 14 comes into contact with the inner surface of the lower insert 36b.

[0068] The foamed resin body 3 can be molded into various shapes, but when demolding from the first mold 21, it may be necessary to tilt it depending on the shape. In this case, since an inclined surface 29 is formed that extends towards the insertion opening 26, the resistance when demolding the foamed resin product 1 with the shaft-shaped insertion clip from the insert 23 is reduced. Therefore, the foamed resin molding die 20 can easily demold the foamed resin product 1 with the shaft-shaped insertion clip.

[0069] <Explanation of the molding method for foamed resin products with shaft-shaped insert clips> Next, a method for molding a foamed resin product 1 with a shaft-shaped insert clip using a foamed resin molding die 20 will be described. The description will be given with reference to Figures 12 and 13. The foamed resin molding method comprises the steps of inserting and holding the embedded shaft-shaped insert clip 2, etc., into the recess 25, injecting foamed resin raw material into the second mold 22 which will be the lower mold, and closing the first mold 21 and the second mold 22. Furthermore, the method includes the steps of opening the first mold 21 and the second mold 22 and removing the embedded shaft-shaped insert clip 2, etc., from the recess 25. The above steps constitute a foamed resin molding method for molding a foamed resin product 1 with a shaft-shaped insert clip, in which a portion of the shaft-shaped insert clip 2, etc., is exposed from the foamed resin body 3.

[0070] The process will be explained in detail with reference to Figures 12 to 16. First, the insert 23 is attached to the first mold 21 of the foam resin molding die 20. At this time, the insert 23 is fastened from the upper side of the first mold 21 with bolts 31. Next, the shaft-shaped insertion clip 2, etc., is attached to the recess 25 of the insert 23. At this time, the clip-side engaging portion 10 is attached in alignment with the position of the insert-side engaging portion 28. The above steps are performed with the first mold 21 open from the second mold 22, as shown in Figure 13.

[0071] Next, the foaming resin material is poured into the second mold 22. The first mold 21 and the second mold 22 are closed, and the foaming resin material is foamed and molded in the cavity 35 formed inside. A detailed explanation of the foaming process is omitted. Once the foaming is complete, the first mold 21 is opened from the second mold 22 as shown in Figure 13, and the foamed resin product 1 with the shaft-shaped insert clip is released from the first mold 21.

[0072] When demolding the foamed resin product 1 with an axial insert clip from the first mold 21, depending on the shape of the product, it may be necessary to pull it out while tilting it with respect to the axial direction in which the axial insert clip 2 etc. is inserted. At this time, a part of the recess 25 in the insert 23 has an inclined surface 29 that widens on the side of the insertion opening 26, so the resistance to pulling out between the axial insert clip 2 etc. and the recess 25 is reduced, making demolding easier. By the above process, the foamed resin product 1 with an axial insert clip can be molded. [Explanation of symbols]

[0073] 1, 1a, 1b Foamed resin product with shaft-shaped insert clip 2. Shaft-shaped insert clip 2a First clip 2b Second clip 3. Foamed resin body 4 base 5. Insertion part 5a Shaft 6 First outer diameter 7 Second outer diameter 8. First guard section 9. Second guard section 11 Umbrella section 12 Shaft-shaped insert clips 12a First clip 12b Second clip 15 Shaft 20 Foam resin molding molds 21 Type 1 22 Type 2 23, 23a, 23b nested 25, 25a, 25b recess 26 Insertion opening 28, 28a, 28b Nesting side engaging portion 29 Slope 40. Objects to be installed C, Ca, Cb axis center

Claims

1. A shaft-shaped insert clip and Equipped with a foamed resin body, The aforementioned shaft-shaped insert clip extends along the axial direction passing through the center of the shaft, with a base formed on one side and an insert portion formed on the other side. The shaft-shaped insert clip includes a first clip and a second clip, and the base is embedded in the foamed resin body. In a plan view from the side of the insertion portion, the direction of the line connecting the axis center of the first clip and the axis center of the second clip is defined as the first direction, and the direction of the line passing through the axis centers and perpendicular to the first direction is defined as the second direction. A foamed resin product with an axial insert clip, wherein, in the insertion portions of the first clip and the second clip, at least the portion attached to the object to be attached, the cross-sections cut perpendicular to the axial direction of the axial insert clip have a first outer diameter, which is the maximum outer diameter in the first direction, smaller than the second outer diameter, which is the maximum outer diameter in the second direction.

2. The shaft-shaped insertion clip is provided with a first flange at the boundary between the base and the insertion portion, and a second flange at the tip of the base. The foamed resin product with a shaft-shaped insert clip according to claim 1, wherein at least a portion of the first flange is exposed from the surface of the foamed resin body, and the second flange is embedded in the foamed resin body.

3. The foamed resin product with a shaft-shaped insert clip according to claim 1 or 2, wherein the first clip and the second clip have a shaft portion and an umbrella portion protruding from the shaft portion in the insertion portion, and the umbrella portion forms the first outer diameter and the second outer diameter.

4. The foamed resin product with an axial insert clip according to claim 3, wherein the umbrella portion has a plurality of axial portions.

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