JP2003306025A - Duct and molding method therefor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a duct preventing bedewing and generation of noise, absorbing noise and having appropriate rigidity; and a method for preferably molding this duct at low cost. <P>SOLUTION: The duct 10 comprises a first shape-retaining member 26 and a second shape-retaining member 28 having appropriate rigidity and a first urethane base material 12 and a second urethane base material 14 arranged on the inner side of these first shape-retaining member 26 and second shape- retaining member 28 and formed by curing the urethane material. These first urethane material 12 and second urethane material 14 are correspondingly joined in a longitudinal direction utilizing adhesion force of the urethane material in the curing process and the use of the adhesive or a pressure sensitive adhesive double coated tape are not required. The shape-retaining is realized by the first shape-retaining member 26 and the second shape-retaining member 28. <P>COPYRIGHT: (C)2004,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a duct and a method for forming the duct, and more particularly, to temperature control air sent from an air conditioner unit mounted on a vehicle, to an air outlet provided at a required position of a vehicle interior member. The present invention relates to a duct adapted to be guided and a method for suitably molding this duct.

[0002]

2. Description of the Related Art In a passenger compartment of a passenger car, there is an instrument panel on which various in-vehicle devices such as an instrument panel, an air conditioning operation panel and an audio system are installed, a floor console installed on a floor between a driver's seat and a passenger seat, and an occupant. Various vehicle interior members such as a roof panel attached to the room ceiling are installed. 12 and 13 show a three-layer type instrument panel 50 which is composed of a base material 58, a foam material 59, and a skin material 57 and which is mounted in front of the passenger compartment.
FIG. 3 is a side cross-sectional view showing an example of the above, but inside the instrument panel 50, an air conditioner unit 52 whose operation is controlled based on a required operation on the air conditioning operation panel is mounted. The temperature-controlled air adjusted to a predetermined temperature by the air conditioner unit 52 is blown into the passenger compartment from an air outlet 54 provided at a required position of the instrument panel 50,
Air conditioning of the passenger compartment is performed.

Therefore, the instrument panel 50
On the back side (inside) of the air conditioner unit 5 and the air outlet 54 provided in the instrument panel 50.
A duct 60 is provided which connects the two air outlets 56 to each other and guides the temperature-controlled air sent from the air conditioner unit 52 to the air outlet 54. Here, the duct 60 is made of polyethylene (PE) or polypropylene.
(PP) or the like is formed by blow molding a hollow body 62 having an irregular cross section, and the hollow body 62 is attached to the back surface of the base material 58 of the instrument panel 50 with screws 64 or the like (FIG. 12). There is a gutter-shaped member 66 formed by injection molding of the resin material, and the gutter-shaped member 66 is attached to the back surface of the base material 58 by vibration welding or the like to form both members 6
6, 58, the type that defines an air flow passage (FIG. 13) and the like.

[0004]

However, the ducts 60 of the above-mentioned type and type have the following problems, respectively. First, in the duct 60 of the type, since the hollow body 62 is made of PE, PP, or the like and is formed to have a relatively thin wall, dew condensation easily occurs when the temperature difference between the inside and the outside of the hollow body 62 is large. was there. Further, when an on-vehicle component, a wire harness, or the like (not shown) arranged around the duct 60 comes into contact with the outer surface of the hollow body 62 during vibration of the vehicle body, an unpleasant noise such as a collision sound or a rubbing sound is generated. There was also. Furthermore, the air conditioner unit 5
There is also a problem that the driving operation noise of No. 2 reverberates in the hollow body 62 and leaks into the passenger compartment. Therefore, the hollow body 62
A foam sheet 68 made of a resin such as rubber, plastic or urethane having excellent heat insulation and soundproofing is attached to the outer surface or the inner surface of the sheet to prevent dew condensation or noise generation. . However, the material cost of the foam sheet 68 is separately added, and the foam sheet 6 is also added.
Since the attaching work of No. 8 is required, there is a problem that the molding cost is further increased. Moreover, the hollow body 5
Since the inner surface and the outer surface of No. 2 have a complicated three-dimensional shape composed of a curved surface and an uneven surface, there is a new problem that the foam sheet 68 cannot be properly attached.

On the other hand, in the type duct 60, since the air flow passage is formed from the base material 58 and the gutter-shaped member 66 formed of PP material or the like, the type duct 6 is used.
It has the same problems and issues as 0. For this reason,
It is necessary to adhere the above-described resin foam sheet 68 to the back surface of the base material 58 and the outer surface or the inner surface of the gutter-shaped member 66 to prevent dew condensation, noise, and the like. Since the material cost is additionally added and the work of attaching the foam sheet 68 is required, there is a disadvantage that the molding cost is further increased. Moreover, the base material 5
Since the back surface of 8 and the inner and outer surfaces of the gutter-shaped member 52 each have a complicated three-dimensional shape composed of a curved surface and an uneven surface, there is also a problem that the foam sheet 68 cannot be properly attached. is there. In the three-layer type instrument panel 50 illustrated in FIG. 13, the foam material 5 is used.
Since 9 has the same characteristics as the foam sheet 68, it is not necessary to attach the foam sheet 68 to the back surface of the base material 58 (shown by the two-dot chain line in the figure), but the gutter-shaped member Since the attachment of the foam sheet 68 to 66 is required, the above mentioned problems still remain unsolved.

[0006]

DISCLOSURE OF THE INVENTION The present invention has been proposed in order to suitably solve the above-mentioned problems, and has a shape-retaining member having an appropriate rigidity and a urethane base material made of urethane formed inside or outside the shape-retaining member. It is an object of the present invention to provide a duct capable of preventing dew condensation, preventing generation of abnormal noise, absorbing noise, etc. while ensuring rigidity and a method of suitably molding this duct at low cost. .

[0007]

SUMMARY OF THE INVENTION In order to solve the above problems and achieve a desired object, the present invention is to provide temperature-controlled air from an air conditioner unit mounted on a vehicle to an air outlet provided in a vehicle interior member. In the guiding duct, a first mold retaining member and a second mold retaining member, which are duct halves preliminarily molded of a material having appropriate rigidity, and a urethane material inside the first mold retaining member and the second mold retaining member. It is composed of a first urethane base material and a second urethane base material having a required thickness formed by curing the above, and the first urethane base material and the second urethane base material are lengthened by the adhesive force when the urethane material is cured. It is characterized in that it is configured by joining in a corresponding manner.

Similarly, in order to solve the above problems and achieve the intended purpose, another invention is a duct for guiding temperature-controlled air from an air conditioner unit mounted on a vehicle to an air outlet provided in a vehicle interior member. , A first mold-retaining member and a second duct half formed by preforming a material having appropriate rigidity
A mold holding member, and a first urethane base material and a second urethane base material having a required thickness formed by curing a urethane material outside the first mold holding member and the second mold holding member. It is characterized in that the first urethane base material and the second urethane base material are bonded correspondingly to each other in the longitudinal direction by the adhesive force at the time of curing.

Similarly, in order to solve the above problems and achieve the intended object, another invention is a duct for guiding temperature-controlled air from an air conditioner unit mounted on a vehicle to an air outlet provided in a vehicle interior member. , A first mold-retaining member and a second duct half formed by preforming a material having appropriate rigidity
A shape-retaining member, a first urethane base material having a required thickness formed by curing an urethane material outside the first shape-retaining member, and a requirement formed by curing the urethane material inside the second shape-retaining member. It is composed of a thick second urethane base material, and is configured by joining the first urethane base material and the second urethane base material correspondingly in the longitudinal direction by the adhesive force when the urethane material is cured. Characterize.

In order to solve the above-mentioned problems and achieve the intended object, still another invention is a duct for guiding temperature-controlled air from an air conditioner unit mounted on a vehicle to an air outlet provided in a vehicle interior member. In the molding method of (1), a first pre-molding member separately preformed is set at a required position on the molding surface of the first molding die, and the molding surface of the second molding die that is provided in the first molding die so as to be mold-closable. A second pre-molding member separately preformed is set at a required position, and a urethane material is sprayed on the molding surface of the first molding die and the outer surface of the first mold retaining member set on the molding surface to form a duct wall. Preforms a first urethane base material having an integral part and a collar part,
By spraying a urethane material on the molding surface of the second molding die and the outer surface of the second mold retaining member set on the molding surface, a second urethane base material integrally having a duct wall portion and a collar portion is spared. Of the urethane materials that have been molded and sprayed onto the respective molding dies, both molding dies are mutually closed before at least one urethane material is completely cured, and the first molding is performed.
The brim portion of the urethane base material and the brim portion of the second urethane base material are closely adhered to each other, and are formed inside the first mold retaining member and the second mold retaining member by an adhesive force when the urethane material is cured. The first urethane base material and the second urethane base material thus formed are bonded to each other in the longitudinal direction.

Further, in order to solve the above problems and achieve the intended purpose, still another invention is a duct for guiding temperature-controlled air from an air conditioner unit mounted on a vehicle to an air outlet provided in an interior member of the vehicle. In the molding method of 1., a urethane material is sprayed onto the molding surface of the first molding die to preform a first urethane base material integrally having a duct wall portion and a flange portion, and the die is closed to the first molding die. By spraying a urethane material on the molding surface of the second molding die which is provided as possible, the second urethane base material integrally having the duct wall portion and the collar portion is preformed, and preformed on the first molding die. A second pre-molded second mold is set with a pre-molded first mold holding member separately set on the duct wall of the first urethane base material.
A second pre-molding member separately set on the duct wall of the urethane base material is set, and at least one of the urethane materials sprayed onto the respective molds is completely cured before at least one urethane material is completely cured. The mold parts are mutually closed, the flange part of the first urethane base material and the flange part of the second urethane base material are brought into close contact with each other, and the first mold retention is achieved by the adhesive force when the urethane material is cured. It is characterized in that the first urethane base material and the second urethane base material formed outside the member and the second shape-retaining member are joined correspondingly in the longitudinal direction.

[0012]

BEST MODE FOR CARRYING OUT THE INVENTION Next, a duct and a method for molding the same according to the present invention will be described below with reference to the accompanying drawings with reference to the preferred embodiments. The duct of the present application is, for example, the instrument panel 50 shown in FIG. 12 or FIG.
The air outlet 54 provided in the instrument panel 50 and the air outlet 56 of the air conditioner unit 52 mounted on the vehicle are connected in communication with each other to control the temperature controlled air sent from the air conditioner unit 52. The air outlet 5
Served to guide you to 4.

[0013]

[First Embodiment] FIG. 1 is a schematic perspective view showing a duct according to a first embodiment of the present invention in a simplified and simple shape, and FIG. 2 is a view showing the duct constituent members illustrated in FIG. It is a schematic perspective view shown in the made state. Duct 10 of the first embodiment
Is a first mold-retaining member 26 and a second mold-retaining member 28 as duct halves preformed from a material having an appropriate rigidity.
And a first urethane base material 12 and a second urethane base material 14 which are formed by curing the urethane material U inside the first shape retention member 26 and the second shape retention member 28.

The first shape-retaining member 26 and the second shape-retaining member 28 are preformed in separate steps according to the outer shape and size of the duct 10 and are formed, for example, based on the injection molding technique. Examples of the material include synthetic resin, and metal formed based on press molding technology. Such a first shape-retaining member 26 and a second shape-retaining member 2
No. 8 has a thickness of about 0.5 to 1 mm, and since it has an appropriate rigidity, it functions as a shape maintaining member for the duct 10. In the duct 10 of the first embodiment, the first shape retention member 26 and the second shape retention member are entirely outside the duct wall portion 22 of the corresponding first urethane base material 12 and second urethane base material 14. The urethane base materials 12 and 14 are exposed to the outside.

The first urethane base material 12 and the second urethane base material 14 are molded from a urethane material U by utilizing a urethane spray molding technique as will be described later and shown in FIGS. 3 to 8. . Specifically, the first urethane base material 12 is the first molding die 3 in the duct molding die 30.
After the first mold holding member 26 is set on the second molding surface 32a, the urethane material U is molded on the molding surface 32a and the outer surface of the first mold holding member 26 by spraying. Similarly, in the second urethane base material 14, the second mold holding member 28 is set on the molding surface 34a of the second molding die 34 of the duct molding die 30, and then the molding surface 34
It is formed by spraying the urethane material U on the outer surface of the a and the second shape-retaining member 28. Then, the first urethane base material 12 and the second urethane base material 14 are correspondingly joined in the longitudinal direction by utilizing the adhesive force when the urethane material U is cured, and the air flow passage 16 is defined inside. It has an air inlet 18 and an air outlet 20 at both ends. The molding surface 32a and the molding surface 34a
Is a surface in which a concave surface portion for setting the first shape-retaining member 26 and the second shape-retaining member 28 and flat surface portions located on both sides of the concave surface portion are combined.

The first urethane substrate 12 has a duct wall portion 22 that substantially defines the air flow passage 16, and the duct wall portion 22 along both lateral edges of the duct wall portion 22. It is composed of the collar portions 24, 24 integrally formed with 22, and has a thickness of about 2 to 5 mm and a so-called hat shape in cross section. In addition, the second urethane base material 14 is formed on the duct wall portion 22 that substantially defines the air flow passage 16 and the duct wall portion 22 along both lateral edges of the duct wall portion 22 in the lateral direction. It consists of integrally molded collars 24, 24,
It has a thickness of about 2 to 5 mm and its transverse cross section has a so-called inverted hat shape. Then, the first urethane base material 12 and the second urethane base material 14 are correspondingly joined in the longitudinal direction by aligning and adhering the collar portions 24, 24 of the respective base materials 12, 14 to each other. ing.

Here, as the urethane material U for molding the first urethane base material 12 and the second urethane base material 14, for example, a soft foam type is preferably used. Therefore, the first urethane base material 12 and the second urethane base material 14 have the same physical properties of the molded urethane foam as they are, are light in weight and have appropriate elasticity and flexibility, and further have high heat insulation performance. It also has sound absorption performance. However, the urethane material U is not limited to the foamed soft type, and for example, a non-foamed soft type or the like can also be used.

In the duct 10 of the first embodiment as described above,
Since the first urethane base material 12 and the second urethane base material 14 as the duct halves are made of urethane foam obtained by foaming and curing the urethane material U, it has the same physical properties (characteristics) of the urethane foam as it is. There is. Since the first urethane base material 12 and the second urethane base material 14 have appropriate thicknesses, they also have excellent heat insulation performance.
Condensation is less likely to occur even if the temperature difference between the inside and outside is large. Further, since the first urethane base material 12 and the second urethane base material 14 also have excellent sound absorbing performance, the duct 10
Even if an in-vehicle component or a wire harness (not shown) disposed around the vehicle comes into contact with the duct 10 when the vehicle body vibrates and an unpleasant noise is generated, it can be appropriately absorbed and propagated. Absent. Furthermore, since the operation sound of the air conditioner unit 52 is absorbed in the duct 10, it is possible to prevent the operation sound from leaking into the passenger compartment. Therefore,
Since it is not necessary to separately attach the foam sheet or the like made of a resin such as rubber, plastic, or urethane having excellent heat insulation performance and sound insulation performance to the outer surface or the inner surface of the duct 10, it is possible to prevent dew condensation and noise. The cost does not increase due to the measures to be taken.

Further, in the duct 10 of the first embodiment, the first mold-retaining member 26 and the second mold-retaining member 26 are provided outside the duct wall portion 22 of the first urethane base material 12 and the second urethane base material 14.
A shape-retaining member 28 is provided, and substantially the entire outer surface of the duct 10 is composed of these shape-retaining members 26 and 28.
Therefore, since the duct 10 has an appropriate rigidity and is hard to be deformed, even if a pressure difference is generated between the inside and the outside of the duct 10, the deformation due to the pressure difference is preferably prevented. It is like this.

Next, a molding method for molding the duct 10 of the first embodiment constructed as described above will be described with reference to FIGS.
Description will be made with reference to FIG.

As described above, the first urethane base material 12 and the second urethane base material 14 constituting the duct 10 of the first embodiment can be applied to the urethane spray molding technique by using the duct molding die 30 shown in FIG. It is molded based on. Here, the duct molding die 30 includes a first molding die 32 provided with a concave molding surface 32a for molding the first urethane base material 12 while setting the first molding die member 26, and the second molding die 32. The mold member 28 is set and the second urethane base material 14 is set.
And a second molding die 34 provided with a concave molding surface 34a for molding, and the first molding die 32 and the second molding die 34 are hinge-joined by a hinge 36 so as to be openable and closable.
The second molding die 34 can be closed with respect to the first molding die 32 (FIGS. 3 and 6). Further, a heating pipe 38 through which a heat medium such as water or oil flows is laid in a meandering shape on the back side of the molding surfaces 32a and 34a of both molding dies 32 and 24, and the surface temperature of the corresponding molding surfaces 32a and 34a is increased. At the optimum temperature for curing the urethane material U (eg 65 ° C.
It can be heated to a certain degree). The first mold 32 and the second mold 34 are made of synthetic resin, aluminum, steel or the like based on a known technique.

In the duct forming method using the duct forming die 30 as described above, as a forming preparation step, the first forming die 32 and the second forming die 34 are opened, and then the heating pipe 38 is heated. A medium is supplied to heat and maintain the respective molding surfaces 32a, 34a of the first molding die 32 and the second molding die 34 at a required temperature, and an appropriate release agent is applied to the molding surfaces 32a, 34a (Fig. 3).

When the preparation for molding is completed, first, as shown in FIG. 4, in the concave portion of the molding surface 32a of the first molding die 32,
The first mold retaining member 26, which has been separately preformed, is set, and at the same time, the recess is formed in the molding surface 34a of the second molding die 34.
The second pre-molding member 28, which is separately preformed, is set.
The back surfaces of the first shape-retaining member 26 and the second shape-retaining member 28 (the first urethane base material 12 and the second urethane base material 1
Before being set in the molding dies 32, 34, it is desirable that the surface (contacting surface 4) be appropriately treated with a primer if necessary. Further, depending on the material of the urethane material U used to mold the first urethane base material 12 and the second urethane base material 14, the first shape-retaining member 26 and the second shape-retaining member 28 are preheated to a predetermined temperature. First response
Molding surface 32 of each of molding die 32 and second molding die 34
It is desirable to set to a, 34a.

The first molding die 32 and the second molding die 34.
To the first shape-retaining member 26 and the second shape-retaining member 28
When the setting of is completed, then the first urethane base material 1
The second and second urethane base materials 14 are molded. That is, as shown in FIG. 5, the spray gun 40 is brought above the molding surface 32a of the first molding die 32, and the molding surface 32a
And the first shape-retaining member 2 set on the molding surface 32a
By spraying the urethane material U on the outer surface (inner surface of the molded duct 10) of 6, the first urethane base material 12 integrally having the duct wall portion 22 and the collar portions 24, 24 is preformed. On the other hand, the spray gun 40 is brought above the molding surface 34a of the second molding die 34, and the molding surface 34a
And the second shape-retaining member 2 set on the molding surface 34a
By spraying the urethane material U on the outer surface (inner surface of the molded duct 10) of 8, the second urethane base material 14 integrally having the duct wall portion 22 and the collar portions 24, 24 is preformed. As a result, the first shape-retaining member 26 and the second shape-retaining member 28 are attached to the duct wall portions 22 of the corresponding first urethane base material 12 and second urethane base material 14, respectively.
It comes to adhere closely. If two spray guns 40 are prepared and the urethane material U is simultaneously sprayed on each of the molding surface 32a of the first molding die 32 and the molding surface 34a of the second molding die 34, the molding cycle time can be reduced. Can be shortened.

When the spraying of the urethane material U onto the first mold 32 and the second mold 34 is completed, as shown in FIG.
Before at least one of the urethane materials U is completely cured, the second molding die 34 is closed with respect to the first molding die 32 to close the molding dies 32, 34 to each other. As a result, the first urethane base material 1 preformed on the first molding die 32 is formed.
The flange portions 24, 24 of the second urethane base material 14 preformed in the second molding die 34 are brought into close contact with the respective flange portions 24, 24 of No. 2 correspondingly. Here, since the urethane material U has adhesiveness before being completely cured, at least one of the urethane materials U, U sprayed on the two molds 32, 34 is cured. Before
By bringing the flange portions 24, 24 of the first urethane base material 12 and the flange portions 24, 24 of the second urethane base material 14 into close contact with each other, the respective flange portions 24, 24/24, 24 are adhered to each other to form a urethane material. The first urethane base material 12 and the second urethane base material 14 can be bonded correspondingly in the longitudinal direction by utilizing the adhesive force when U is cured.

In the closed state of the duct molding die 30, the urethane material U is on standby until it is completely foamed and cured. Then, the first formed inside the first shape-retaining member 26.
When the molding of the urethane base material 12 and the second urethane base material 14 formed inside the second shape retention member 28 is completed, FIG.
As shown in (1), the molded duct 10 is removed from the mold after the second mold 34 is opened from the first mold 32 and the mold is opened.

Further, after removing the mold, unnecessary portions of the collar portions 24, 24 and other unnecessary portions are cut off with a cutter or the like as needed (FIG. 8). Here, the first urethane base material 12
Also, the edges of the first shape-retaining member 26 and the second shape-retaining member 28 attached to the outer side of the second urethane base material 14 are the flange portions 24,
Since it faces 24, unnecessary portions of the collar portions 24, 24 can be peeled off with a fingertip.

As described above, in the molding method for molding the duct 10 of the first embodiment, the preformed first mold retaining member 2 is used.
The urethane material U is sprayed on the molding surface 32a of the first molding die 32 in which 6 is set to preform the first urethane base material 12, and the second molding die 34 in which the preformed second mold holding member 28 is set. After the urethane material U is sprayed onto the molding surface 34a of the above to pre-form the second urethane base material 14, before the at least one of the urethane materials U, U is completely cured, the molding dies 32, 34 are By mutually closing the molds, the first urethane base material 12 and the second urethane base material 14 can be correspondingly joined in the longitudinal direction by utilizing the adhesive force when the urethane material U is cured. Therefore, the molding operation of the first urethane base material 12 and the second urethane base material 14, the adhesion between the first urethane base material 12 and the first shape retention member 26, and the second urethane base material 14 and the second shape retention member 28. Since the bonding work of 1) and the joining work of the formed first urethane base material 12 and the second urethane base material 14 can be performed as a continuous series of steps, respectively, the molding work of the duct 10 can be simplified and rationalized. As a result, the molding cost can be reduced. In addition, since no separate adhesive or the like is used for joining the first urethane base material 12 and the second urethane base material 14, it is possible to further reduce the molding cost.

In the duct 10 of the first embodiment, the duct 10 is provided at a required position on the back side of the instrument panel 50, such as at the edge of the first mold retaining member 26 and / or the second mold retaining member 28. It is also possible to integrally provide a mounting bracket (mounting portion) 42 that is used when mounting. In such an embodiment, the first shape-retaining member 26 and / or
Alternatively, it can be easily carried out by preforming the second shape-retaining member 28 so that its end edge portion is extended.

[0030]

[Second Embodiment] FIG. 10 is a schematic sectional view showing a duct according to a second embodiment of the present invention in a simplified and simple shape.
The duct 10 of the second embodiment has a first mold-retaining member 26 and a second mold-retaining member 28 as duct halves preformed from a material having an appropriate rigidity, and these first mold-retaining member 2
6 and the first urethane base material 12 and the second urethane base material 14 which are formed by curing the urethane material U outside the second shape retention member 28. That is, although the duct 10 of the first embodiment described above has a structure in which the first mold-retaining member 26 and the second mold-retaining member 28 are attached to the outside of the first urethane base material 12 and the second urethane base material 14, respectively. On the other hand, the duct 10 of the second embodiment has a structure in which the first mold retaining member 26 and the second mold retaining member 28 are attached to the inside of the first urethane base material 12 and the second urethane base material 14.

In the duct 10 of the second embodiment as described above,
Since the first urethane base material 12 and the second urethane base material 14 as the duct halves are made of urethane foam obtained by foaming and curing the urethane material U, the heat insulation performance is excellent and the temperature inside and outside the duct 10 is high. Condensation is less likely to occur even if the difference is large. Further, since the first urethane base material 12 and the second urethane base material 14 are also excellent in sound absorbing performance, vehicle-mounted parts and wire harnesses arranged around the duct 10 and the like.
Even if an unpleasant noise is generated by contacting the duct 10 when the vehicle body vibrates (not shown), it does not appropriately absorb and propagate it. Therefore, it is not necessary to separately attach the foam sheet or the like made of a resin such as rubber, plastic, or urethane having excellent heat insulation performance and sound insulation performance to the outer surface or the inner surface of the duct 10 to prevent dew condensation or noise generation. Costs do not increase because measures are taken to take measures such as the above.

Further, in the duct 10 of the second embodiment, the first mold-retaining member 26 and the second mold-retaining member 26 are provided inside the duct wall portion 22 of the first urethane base material 12 and the second urethane base material 14.
A shape-retaining member 28 is provided, and substantially the entire duct 10 is composed of these shape-retaining members 26 and 28. Therefore, since the duct 10 has an appropriate rigidity and is hard to be deformed, even if a pressure difference is generated between the inside and the outside of the duct 10, the deformation due to the pressure difference is preferably prevented. .

The molding method for molding the duct 10 of the second embodiment is the same as the molding method for molding the duct 10 of the first embodiment described above, except that the first mold holding member 26 and the first mold holding member 26 shown in FIG. Second step of setting the shape-retaining member 28, and the first urethane base material 12 and the second urethane base material 14 shown in FIG.
It can be carried out simply by changing the order of the molding process. That is, although not specifically shown, the first molding die 3
Second molding surface 32a and second molding die 34 molding surface 34a
When the mold release agent is applied to and the molding preparation is completed, first, the first
The spray gun 40 is brought to above the molding surface 32a of the molding die 32, and the urethane material U is sprayed onto the molding surface 32a, whereby the first urethane group integrally having the duct wall portion 22 and the collar portions 24, 24 is formed. The material 12 is preformed. On the other hand, the spray gun 40 is brought to above the molding surface 34a of the second molding die 34, and the urethane material U is sprayed onto the molding surface 34a, whereby the duct wall portion 22 and the collar portion 2 are formed.
The second urethane base material 14 integrally having 4, 24 is preformed.

When the spraying of the urethane material U onto the first molding die 32 and the second molding die 34 is completed, the first molding die 32 is preformed on the molding surface 32a of the first molding die 32.
On the outer surface (inner surface in the duct 10 to be molded) of the duct wall portion 22 of the urethane base material 12, which is separately preformed
The shape-retaining member 26 is set. Similarly, the second urethane base material 14 preformed on the molding surface 34 a of the second molding die 34.
On the outer surface (inner surface of the molded duct 10) of the duct wall portion 22, the second pre-molding member 28 separately preformed is set. The outer surfaces of the first mold retaining member 26 and the second mold retaining member 28 that come into contact with the first urethane base material 12 and the second urethane base material 14 are preferably subjected to a primer treatment in advance, if necessary.

The first shape-retaining member 26 and the second urethane base material 12 and the second urethane base material 14 with respect to the second urethane base material 14 and the second urethane base material 14, respectively.
After the setting of the mold holding member 28 is completed, the second molding die 34 is closed with respect to the first molding die 32 before the urethane material U of at least one of the urethane materials U is completely cured. Then, the two molds 32 and 34 are closed. As a result, with respect to the collar portions 24, 24 of the first urethane base material 12 preformed on the first molding die 32, the collar portions 2 of the second urethane base material 14 preformed on the second molding die 34 are formed.
Since 4 and 24 adhere correspondingly, the first urethane base material 12 and the second urethane base material 14 can be bonded correspondingly in the longitudinal direction by utilizing the adhesive force when the urethane material U is cured.

The urethane material U is completely foamed and cured,
When the molding of the first urethane base material 12 formed on the outer side of the first shape retention member 26 and the second urethane base material 14 formed on the outer side of the second shape retention member 28 is completed, the molded duct 10 is removed. Mold. Then, after demolding, the collar portions 24, 24
Molding is completed by cutting off the unnecessary portions of and other unnecessary portions with a cutter or the like.

As described above, the molding method for molding the duct 10 of the second embodiment is also the same as the molding work of the first urethane base material 12 and the second urethane base material 14, the first urethane base material 12
Between the first shape-retaining member 26 and the second urethane base material 1
4 and the second shape-retaining member 28, and the joining operation of the first urethane base material 12 and the second urethane base material 14 that have been formed can be performed as a continuous series of steps, respectively. The molding work can be simplified and rationalized to reduce the molding cost. In addition, since no separate adhesive or the like is used for joining the first urethane base material 12 and the second urethane base material 14, it is possible to further reduce the molding cost.

[0038]

[Modification] The duct 10 may have a configuration other than those illustrated in the first and second embodiments.
For example, FIG. 11 is a schematic cross-sectional view showing the duct according to the modified example in a simplified and simple shape, and the duct 10 according to the modified example is a duct half body preformed from a material having appropriate rigidity. The first shape-retaining member 26 and the second shape-retaining member 28, and the urethane material U on the outside of the first shape-retaining member 26.
And a second urethane base material 14 formed by curing the urethane material U inside the second shape-retaining member 28. That is, in the duct 10 according to the modified example, the first urethane base material 1 is provided in a substantially half region of the entire outer surface of the duct 10.
2 is exposed, and the second urethane base material 14 is exposed in an approximately half region of the entire inner surface of the duct 10.

In the duct 10 of such a modified example, since the first urethane base material 12 and the second urethane base material 14 as the duct halves are made of urethane foam obtained by foaming and curing the urethane material U, the heat insulation performance is improved. Even if the temperature difference between the inside and the outside of the duct 10 is large, it is difficult for dew condensation to occur. Further, due to the sound absorbing performance of the first urethane base material 12, an in-vehicle component or a wire harness (not shown) arranged around the duct 10 comes into contact with the first urethane base material 12 when the vehicle body vibrates and is uncomfortable. Even if an abnormal sound is generated, it is not properly absorbed and propagated. Further, the sound absorbing performance of the second urethane base material 14 can prevent the operating noise of the air conditioner unit 52 from being absorbed in the duct 10 and leaking into the passenger compartment. Therefore, the duct 10
Since it is not necessary to separately attach the foam sheet etc. made of resin such as rubber, plastic or urethane, which has excellent heat insulation and soundproofing, to the outside or inside of the, it is possible to prevent condensation and noise. Costs do not increase due to the measures taken.

In the duct 10 of the modified example, the first shape-retaining member 26 is disposed inside the duct wall portion 22 of the first urethane base material 12, and the duct wall portion of the second urethane base material 14 is provided. Since the second shape-retaining member 28 is disposed on the outer side of 22, the duct 10 is substantially entirely composed of these shape-retaining members 26 and 28. Therefore, since the duct 10 has an appropriate rigidity and is difficult to be deformed, even if a pressure difference occurs between the inside and the outside of the duct 10, the deformation caused by the pressure difference is preferably prevented.

The molding method for molding the duct 10 of the modified example is the molding method for molding the duct 10 of the first embodiment and the molding method for molding the duct 10 of the second embodiment. It can be implemented simply by merging and applying. That is, although not specifically shown, the first molding die 3
When the mold release agent is applied to the second molding surface 32a and the preparation for molding is completed, in the first molding die 32, the urethane material U is sprayed onto the molding surface 32a by the spray gun 40, and the duct wall portion 22 and The first urethane base material 12 integrally having the collar portions 24, 24 is preformed. Meanwhile, the second
In the molding die 34, the second pre-molding member 28 separately preformed is set in the concave portion of the molding surface 34a.

Next, in the first molding die 32, its molding surface 3
The outer surface of the duct wall portion 22 of the first urethane base material 12 preformed in 2a (inner surface in the molded duct 10)
Then, the first pre-molding member 26 separately preformed is set.
On the other hand, in the second mold 34, the spray gun 40
By blowing the urethane material U onto the molding surface 34a and the outer surface (the inner surface in the duct 10 to be molded) of the second shape-retaining member 28 set on the molding surface 34a, the duct wall portion 22 and the collar portion 24, Second having 24 integrally
The urethane base material 14 is preformed.

When the respective operations for the first molding die 32 and the second molding die 34 are completed, at least one urethane material U among the urethane materials U, U
Before the resin completely cures, the second mold 34 is closed with respect to the first mold 32 to close the molds 32, 34 to each other. As a result, the first mold preformed on the first mold 32
Since the brim portions 24, 24 of the second urethane base material 14 preformed in the second molding die 34 adhere to the brim portions 24, 24 of the urethane base material 12 correspondingly, the urethane material U is cured. The first urethane base material 12 and the second urethane base material 14 can be correspondingly joined in the longitudinal direction by utilizing the adhesive force at the time of performing.

The urethane material U is completely foamed and cured, and the first urethane base material 12 formed on the outer side of the first mold retaining member 26 and the second urethane formed on the inner side of the second mold retaining member 28. When the molding of the base material 14 is completed, the molded duct 10 is demolded. Then, after demolding, the collar portion 24,
The molding is completed by cutting off unnecessary portions of 24 and other unnecessary portions with a cutter or the like.

Further, although the concrete illustration of the duct 10 is omitted, the first mold-retaining member 26 and the second mold-retaining member 2 as duct halves preformed from a material having an appropriate rigidity.
8, a first urethane base material 12 formed by curing the urethane material U inside the first mold retaining member 26, and a first urethane base material 12 formed by curing the urethane material U outside the second mold retaining member 28. It may be composed of two urethane base materials 14. In such a duct 10, the first urethane base material 12 is exposed in a substantially half region of the entire inner surface of the duct 10, and the second urethane substrate 12 is exposed in a substantially half region of the entire outer surface of the duct 10.
The urethane base material 14 is exposed.

Here, the duct 10 arranged in a narrow space on the back side of the instrument panel 50 on which a large number of devices and parts are mounted rarely has the simple shape shown in FIG. It often has a complicated outer surface having a curved surface or an uneven surface. However, in the urethane spray molding technique described above, the molding surfaces 3 of the first molding die 32 and the second molding die 34, which have a curved shape or an uneven shape, are formed.
2a, 34a and the outer surface of the first mold retaining member 26 and the second mold retaining member 28 which are preformed in a similar shape,
Since the urethane material U can be appropriately sprayed by the spray gun 40, the first urethane base material 12 and the second urethane base material 14 having a complicated outer surface shape having a curved surface or an uneven surface can be molded, while First urethane base material 1
2 and the first mold-retaining member 26, and the second urethane base material 14 and the second mold-retaining member 28 can be molded in a state of being in close contact with each other. That is, since it is not necessary to attach a foam sheet made of a resin such as rubber, plastic, or urethane having excellent heat insulation performance and sound insulation performance, it is inconvenient for the conventional duct 60 shown in FIGS. 12 and 13. Is preferably solved.

The duct 10 of the present application is not limited to the one provided on the back side of the instrument panel 50, but other than this, it is provided on the back side of various vehicle interior members such as a floor console and a roof panel. What is done is also targeted.

[0048]

As described above, according to the duct of the present invention, the duct is composed of the first urethane base material and the second urethane base material formed by curing the urethane material. Is excellent. Therefore, even if the temperature difference between the inside and the outside of the duct is large, it is difficult for dew to condense, and even if a noise such as a collision noise or a rubbing noise caused by the on-vehicle components arranged around the duct comes into contact, it is preferably absorbed. On the other hand, there is an advantage that the operating noise of the air conditioner unit and the like can be absorbed to prevent the air conditioner unit from leaking into the passenger compartment.
That is, since it is not necessary to attach a foam sheet or the like having excellent heat insulation and sound absorption performance to the outer surface or the inner surface of the duct, the cost is increased to take measures to prevent dew condensation and abnormal noise. There is no. In addition, since the first shape-retaining member and the second shape-retaining member are disposed on the outer sides of the first urethane base material and the second urethane base material, respectively, appropriate rigidity is secured and deformation is less likely to occur. There is. The first
Even if the first shape-retaining member and the second shape-retaining member are provided inside the urethane base material and the second urethane base material, respectively, it is possible to ensure appropriate rigidity and prevent deformation. Further, even if the first shape-retaining member is arranged outside the first urethane base material and the second shape-retaining member is arranged inside the second urethane base material, appropriate rigidity is ensured and deformation occurs. It can be difficult.

Similarly, according to the method of forming a duct according to another invention, the first mold holding member in which the preformed first mold retaining member is set is set.
The urethane material is sprayed onto the molding surface of the molding die to preform the first urethane base material, and the urethane material is sprayed onto the molding surface of the second molding die in which the preformed second mold holding member is set to the second surface. After preforming the urethane base material, by closing both molds before at least one urethane material is completely cured, the first urethane is used by utilizing the adhesive force when the urethane material is cured. The base material and the second urethane base material can be correspondingly joined in the longitudinal direction. Therefore,
Molding work of the first urethane base material and the second urethane base material,
Adhesion between the first urethane base material and the first shape retention member, adhesion between the second urethane base material and the second shape retention member, and bonding work between the formed first urethane base material and the second urethane base material Since each can be performed as a continuous series of steps,
There is an advantage that the molding work of the duct can be simplified and rationalized to reduce the molding cost. In addition, since no separate adhesive or the like is used for joining the first urethane base material and the second urethane base material, it is possible to further reduce the molding cost.

Further, according to the duct molding method of another invention, the urethane material is sprayed onto the molding surface of the first molding die to preform the first urethane base material, and the molding surface of the second molding die is formed. A urethane material was sprayed onto the first urethane base material to preform the second urethane base material, and then the first urethane base material was preformed to the first base material.
By setting the shape-retaining member and setting the second shape-retaining member preformed on the second urethane base material, and closing the two molds with each other before at least one urethane material is completely cured, The first urethane base material and the second urethane base material can be correspondingly bonded in the longitudinal direction by utilizing the adhesive force when the urethane material is cured. Therefore, the first
Molding work of urethane base material and second urethane base material, first
Adhesion between the urethane base material and the first shape retention member, adhesion between the second urethane base material and the second shape retention member, and bonding work between the formed first urethane base material and the second urethane base material, respectively. Since it can be carried out as a continuous series of steps, there is an advantage that the molding work of the duct can be simplified and rationalized, and the molding cost can be reduced. In addition, since no separate adhesive or the like is used for joining the first urethane base material and the second urethane base material, it is possible to further reduce the molding cost.

[Brief description of drawings]

FIG. 1 is a schematic perspective view showing a duct according to a first embodiment of the present invention in a simplified and simple shape.

FIG. 2 is a schematic perspective view showing the duct shown in FIG. 1 with its constituent members separated.

FIG. 3 is an explanatory cross-sectional view showing a duct molding die for molding the duct shown in FIG. 1 in a state in which a first molding die and a second molding die are opened.

FIG. 4 is an explanatory cross-sectional view showing a state in which a preformed first mold holding member is set on a molding surface of a first molding die and a preformed second mold holding member is set on a molding surface of a second molding die. Is.

FIG. 5: After the setting of the first mold retaining member and the second mold retaining member to the first mold and the second mold is completed, a urethane material is sprayed on the molding surface of each mold and the outer surface of the mold retaining member. By this, it is an explanatory sectional view showing a state in which the first urethane base material and the second urethane base material are preformed.

FIG. 6 is a diagram illustrating a first urethane base material and a second urethane group obtained by closing the second mold to the first mold before curing at least one of the urethane materials sprayed on both molds. It is an explanatory cross-sectional view showing a state in which the flange portions of the material are brought into close contact with each other and the first urethane base material and the second urethane base material are correspondingly bonded by the adhesive force when the urethane material is cured.

FIG. 7 is an explanatory cross-sectional view showing a state in which the second molding die is opened from the first molding die and the molded duct is released from the mold after completion of molding of the first urethane base material and the second urethane base material.

FIG. 8 is an explanatory cross-sectional view showing a state in which molding of the duct is completed by appropriately cutting off unnecessary portions of the brim portions adhered to each other after demolding.

FIG. 9 is a view showing that the first mold retaining member and the second mold retaining member have edge portions,
FIG. 4 is an explanatory cross-sectional view showing a duct integrally provided with a mounting bracket that is provided when mounting a vehicle interior member.

FIG. 10 is a schematic cross-sectional view showing a duct according to a second embodiment of the present invention in a simplified and simple shape.

FIG. 11 is a schematic cross-sectional view showing a duct according to a modification with a simplified and simple shape.

FIG. 12 is a cross-sectional view showing a state in which a blow-molded duct is assembled inside an instrument panel that is a vehicle interior member.

FIG. 13 is a cross-sectional view showing a state in which a duct formed by a base material of the instrument panel and a gutter-shaped member joined to the base material is provided inside an instrument panel which is a vehicle interior member.

[Explanation of symbols]

12 First urethane base material 14 Second urethane base material 22 Duct wall 24 collar part 26 First shape retention member 28 Second shape retention member 32 First Mold 32a molding surface 34 Second Mold 34a molding surface 42 Mounting bracket (mounting part) 50 Instrument panel (vehicle interior material) 52 Air conditioner unit 54 Air outlet U Urethane material

Claims (9)

[Claims] 1. An air blowout port (54) provided in a vehicle interior member (50) for controlling temperature air from an air conditioner unit (52) mounted on a vehicle.
In the duct for guiding to, the first mold retaining member (26) and the second mold retaining member (28), which are duct halves preliminarily molded of a material having appropriate rigidity, and the first mold retaining member (26) and The second shape-retaining member (28) comprises a first urethane base material (12) and a second urethane base material (14) having a required thickness formed by curing the urethane material (U). A duct formed by correspondingly joining the first urethane base material (12) and the second urethane base material (14) in a longitudinal direction by an adhesive force when the (U) is cured. 2. An air outlet (54) provided in a vehicle interior member (50) for adjusting temperature of air from an air conditioner unit (52) mounted on a vehicle.
In the duct for guiding to, the first mold retaining member (26) and the second mold retaining member (28), which are duct halves preliminarily molded of a material having appropriate rigidity, and the first mold retaining member (26) and The urethane material (U) is formed on the outside of the second shape-retaining member (28) by hardening to form a first urethane base material (12) and a second urethane base material (14) having a required thickness. A duct formed by correspondingly joining the first urethane base material (12) and the second urethane base material (14) in a longitudinal direction by an adhesive force when the (U) is cured. 3. An air outlet (54) provided on an interior member (50) of a vehicle for adjusting temperature of air from an air conditioner unit (52) mounted on the vehicle.
In the duct for guiding to, the first mold-retaining member (26) and the second mold-retaining member (28), which are duct halves formed by preforming a material having appropriate rigidity, and the first mold-retaining member (26). The first urethane base material (12) having a required thickness formed by curing the urethane material (U) on the outer side, and the required urethane resin (U) formed by curing the urethane material (U) on the inner side of the second shape-retaining member (28). It consists of a thick second urethane base material (14), and due to the adhesive force when the urethane material (U, U) cures,
The first urethane base material (12) and the second urethane base material (14)
The duct is characterized in that it is configured by joining in a longitudinal direction correspondingly. 4. The first urethane base material (12) and the second urethane base material (14) include a duct wall portion (22) and the duct wall portion.
(22) is integrally formed with the collar part (24), and each collar part
The duct according to any one of claims 1 to 3, wherein the (24, 24) are bonded to each other so as to be correspondingly bonded in the longitudinal direction. 5. A mounting portion (42) provided when mounting to a vehicle interior member (50) or the like is provided at a required position of the first mold retaining member (26) and / or the second mold retaining member (28). The duct according to any one of claims 1 to 4, which is integrally provided. 6. The duct according to claim 1, wherein the urethane material (U) is a soft foam type. 7. An air outlet (54) provided in a vehicle interior member (50) for controlling temperature air from an air conditioner unit (52) mounted on a vehicle.
In the method of forming a duct to be guided to the first forming die (32), a first pre-molding member (26) separately preformed is set at a required position on the forming surface (32a) of the first forming die (32), )) Second mold (34) that can be closed
In the molding surface (34a), a second pre-molding member (28) separately preformed is set, and the molding surface (32a) of the first molding die (32) and the molding surface (32a)
The urethane material (U) is sprayed on the outer surface of the first shape-retaining member (26) set on the duct wall (22) and the collar (2).
The first urethane base material (12) integrally having 4) is preformed, and the molding surface (34a) of the second molding die (34) and the molding surface (34a).
The urethane material (U) is sprayed on the outer surface of the second shape-retaining member (28) set to the duct wall portion (22) and the collar portion (2).
The urethane material (U, U) obtained by preforming the second urethane base material (14) integrally having 4) and spraying it onto the respective molding dies (32, 34).
Among these, at least one of the urethane materials (U) is completely closed before both molds (32, 34) are closed, and the flange portion (24) of the first urethane base material (12) and The brim portion (24) of the second urethane base material (14) is correspondingly adhered, and the adhesive force when the urethane material (U) is cured causes the first mold retaining member (26) and the second mold retainer. A method for forming a duct, characterized in that the first urethane base material (12) and the second urethane base material (14) formed inside the member (28) are joined correspondingly in the longitudinal direction. 8. An air outlet (54) provided in a vehicle interior member (50) for adjusting temperature of air from an air conditioner unit (52) mounted on a vehicle.
In the method of forming a duct for guiding to, the duct wall part (22) and the flange part (24) are integrally formed by spraying the urethane material (U) on the forming surface (32a) of the first forming die (32). The first urethane base material (12) having the same is preformed, and the second molding die (3) provided in the first molding die (32) so as to be mold-closeable.
By spraying the urethane material (U) on the molding surface (34a) of 4),
The second urethane base material (14) integrally having the duct wall portion (22) and the flange portion (24) is preformed, and the first urethane base material (12) preformed on the first molding die (32). ) And the duct wall of the second urethane base material (14) preliminarily molded in the second molding die (34) while the separately molded first mold retaining member (26) is set in the duct wall portion (22). A second pre-molding member (28) separately set in the part (22) is set, and the urethane material (U, U) sprayed onto the respective molding dies (32, 34).
Among these, at least one of the urethane materials (U) is completely closed before both molds (32, 34) are closed, and the flange portion (24) of the first urethane base material (12) and The brim portion (24) of the second urethane base material (14) is correspondingly adhered, and the adhesive force when the urethane material (U) is cured causes the first mold retaining member (26) and the second mold retainer. A method for forming a duct, characterized in that the first urethane base material (12) and the second urethane base material (14) formed on the outside of the member (28) are correspondingly joined in the longitudinal direction. 9. The collar portion, if necessary, after the joining of the first urethane base material (12) and the second urethane base material (14) is completed.
The method for forming a duct according to claim 7 or 8, wherein (24, 24) is partially cut off.