JP2003326941A - Duct and its molding method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a duct for preventing dewing, absorbing a sound, and suitably fixing and holding various articles, and a method for inexpensively and suitably molding this duct. <P>SOLUTION: This duct D comprises a first duct member 10 for integrally arranging a duct wall part 16 and an article holding part 18, a second duct member 12 for integrally arranging a duct wall part 16 and an article holding part 18, a first urethane layer 20 formed by hardening a urethane material on the inside of the first duct member 10, and a second urethane layer 22 formed by hardening the urethane material on the inside of the second duct member 12. The first duct member 10 and the second duct member 12 are correspondingly joined in the lengthwise direction by adhesive strength when hardening the urethane material. A wire harness WH can be fixed in a sandwiching shape by the respective article holding parts 18 and 18 oppositely extended to the side. <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. 14 and 15 show a three-layer type instrument panel 60 which is composed of a base material 62, a foam material 64 and a skin material 66, and which is mounted in front of the passenger compartment.
FIG. 3 is a side cross-sectional view showing an example, but inside the instrument panel 60, an air conditioner unit 70 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 70 is blown into the passenger compartment from an air outlet 68 or the like provided at a required position of the instrument panel 60, so that the passenger compartment is air-conditioned. ing.

Therefore, the instrument panel 60
On the back side (inside) of the air conditioner unit 7 and the air outlet 68 provided in the instrument panel 60.
A duct D is provided which connects the air outlets 72 of 0 to each other and guides the temperature-controlled air sent from the air conditioner unit 70 to the air outlets 68. The duct D is made of polyethylene (PE) or polypropylene (P).
P) is formed by blow molding a resin material such as a cross-section, and the hollow body 82 is assembled to the back surface of the base material 62 of the instrument panel 60 with screws 84 or the like (FIG. 14). A trough-shaped member 86 formed by injection molding a resin material is provided.
86 is roughly classified into a type defining an air flow passage (FIG. 15) and the like.

Inside the instrument panel 60, various in-vehicle devices such as the air conditioner unit 70 and various in-vehicle electronic devices (instrument unit, air conditioning operation panel, audio and switch) arranged on the panel 60 are installed. Etc.) and a wire harness WH etc. for electrically connecting other in-vehicle electronic devices are arranged in a narrow space.
(However, in FIG. 14 and FIG. 15, the air conditioner unit 70
In-vehicle devices other than those are not shown). In the case of FIGS. 14 and 15, an example of arrangement in which the wire harness WH is attached to the reinforcement bar 74 for reinforcing the vehicle body extending in the vehicle width direction by using the band-shaped attachment member 94 is illustrated. There is. However, the wire harness WH can be attached to other components such as a steering hanger beam and pillars (pillar members) by using appropriate attachment members.

[0005]

The ducts D of the above-mentioned type and type have the following problems inherent therein. First, in the duct D of the type, since the hollow body 82 is made of PE, PP, or the like and is formed to be relatively thin, dew condensation easily occurs when the temperature difference between the inside and the outside of the hollow body 82 is large. was there. Further, when an in-vehicle device (not shown) arranged adjacent to the periphery of the duct D, the wire harness WH, or the like comes into contact with the outer surface of the hollow body 82 during vehicle body vibration, an unpleasant noise such as a collision sound or a rubbing sound is generated. There was also a problem. Furthermore, there is also a problem that the operating noise of the air conditioner unit 70 reverberates in the hollow body 82 and leaks into the passenger compartment. For this reason, a foam sheet 88 made of a resin such as rubber, plastic, or urethane having excellent heat insulation performance and sound insulation performance is attached to the outer surface or the inner surface of the hollow body 82 to prevent dew condensation and noise. Countermeasures are taken. However, since the material cost of the foam sheet 88 is separately added and the work of attaching the foam sheet 88 is required, there is a problem that the molding cost is further increased. In addition, since the inner surface and the outer surface of the hollow body 82 have a complicated three-dimensional shape composed of a curved surface and an uneven surface, there is a new problem that the foam sheet 88 cannot be properly attached. .

On the other hand, the type duct D has the same problems and problems as the type duct D because the air flow passage is formed from the base material 62 and the gutter-shaped member 86 formed of PP material or the like. is doing. For this reason, it becomes necessary to adhere the resin foam sheet 88 to the back surface of the base material 62 and the outer surface or the inner surface of the gutter-shaped member 86 to prevent dew condensation, noise, and the like. The material cost of the sheet 88 is separately added and the foam sheet 8 is added.
Since the attaching work of No. 8 is required, there is a problem that the molding cost is further increased. Moreover, since the back surface of the base material 62 and the inner and outer surfaces of the gutter-shaped member 86 each have a complicated three-dimensional shape composed of a curved surface and an uneven surface, the foam sheet 88 can be appropriately attached. There is also the problem of not being able to wear it. In addition, in the three-layer type instrument panel 60 illustrated in FIG. 15, since the foam material 64 has the same characteristics as the foam sheet 88, when considering only the heat insulating effect, the base material is used. Although it is not necessary to attach the foam sheet 88 to the back surface of 62 (shown by the chain double-dashed line in the figure), it is necessary to attach the foam sheet 88 to the gutter-shaped member 86, so Remains unresolved. However, if the sound absorbing effect is also taken into consideration, it is necessary to attach the foam sheet 88 to the back surface of the base material 62.

On the other hand, the wire harness WH has the above-mentioned band-shaped mounting member 9 in a state in which a large number of electric wires are properly bundled by using a binding member 92 such as a tape or a belt.
Since it is fixed to the reinforce bar 74 and the vehicle body at appropriate intervals by using 4, the most of them are often exposed. That is, since the wire harness WH is apt to be partially pulled or loosened due to vibration of the vehicle body during traveling, and the wire harness WH may come into direct contact with the adjacent duct D or other on-vehicle equipment, it may be rubbed in some cases. Due to the abrasion of the electric wire coating material, the conductor wire may be exposed to cause a short circuit or malfunction of the in-vehicle electronic device. Further, since the work of binding and arranging the wire harness WH is unexpectedly troublesome and time-consuming, it has been desired to realize rationalization and simplification of these works. Furthermore,
The material cost of the bundling member 92 for bundling the wire harness WH and the material cost of the mounting member 94 for arranging the wire harness WH increase, and there is a problem that the cost increases.

[0008]

DISCLOSURE OF THE INVENTION The present invention has been proposed to suitably solve the above-mentioned problems, and is intended to prevent dew condensation, prevent abnormal noise generation, absorb noise, etc. while ensuring rigidity, and various articles such as wire harnesses. It is an object of the present invention to provide a duct capable of suitably holding and holding, and a method for suitably molding this duct at low cost.

[0009]

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 duct member integrally formed with a duct wall part forming a duct half and an article holding part extending from a side edge of the duct wall part by preforming a material having appropriate rigidity. A second duct member integrally provided with a duct wall portion forming a duct half body and an article holding portion extending from a side edge of the duct wall portion by preforming a material having appropriate rigidity; A first urethane layer formed to a required thickness by curing a urethane material inside the first duct member, and a second urethane layer formed to a required thickness by curing the urethane material inside the second duct member. Consisting of layers and said The first duct member and the second duct member are correspondingly joined in the longitudinal direction by the adhesive force when the retin material is hardened, and the duct is formed by the respective duct wall portions, and the lateral sides of the duct are formed. It is characterized in that the articles can be appropriately sandwiched and fixed by the respective article holding portions extending opposite to each other.

Another object of the present invention to solve the above problem and achieve the intended purpose is to provide 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, a first duct member integrally provided with a duct wall part forming a duct half and an article holding part extending from a side edge of the duct wall part is formed by preforming a material having appropriate rigidity. , A duct wall forming a duct half body and an article holding extending from a side edge of the duct wall, which is set at a required position on the molding surface of the first molding die and is preformed with a material having appropriate rigidity The second duct member integrally provided with the portion is set at a required position of the molding surface of the second molding die which is provided in the first molding die so as to be mold-closable, and the molding surface of the first molding die and the molding surface. The first duck set on the surface A urethane material is sprayed on the outer surface of the member to preform a first urethane layer having a required thickness, and a urethane material is sprayed on the molding surface of the second mold and the outer surface of the second duct member set on the molding surface. The second urethane layer having a required thickness is preformed, and at least one urethane material among the urethane materials sprayed on the respective molding dies is closed before the two dies are completely cured. , A part of the first urethane layer and the second urethane layer are correspondingly adhered to each other, and the first duct member and the second duct member are correspondingly arranged in the longitudinal direction by an adhesive force when the urethane material is cured. The ducts are joined to each other to form the ducts by the duct wall portions, and the article holding portions extending laterally of the ducts can appropriately fix the articles in a sandwiched manner. And wherein the door.

[0011]

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 60 shown in FIG. 14 or 15.
A temperature-controlled air that is sent from the air conditioner unit 70 by connecting the air outlet 68 provided in the instrument panel 60 and the air outlet 72 of the air conditioner unit 70 mounted on the vehicle in communication with each other. To guide the air to the air outlet 68, and as will be described later,
The article 90 can be appropriately clamped and fixed.

FIG. 1 is a schematic perspective view showing a duct according to a preferred embodiment of the present invention in a simplified and simple shape.
[Fig. 2] is a schematic perspective view showing each component of the duct illustrated in Fig. 1 in a separated state. The duct D of this embodiment is a first duct member 1 formed by preforming a material having appropriate rigidity.
0, a second duct member 12 similarly preformed of a material having an appropriate rigidity, and a first urethane layer 20 formed to a required thickness by curing the urethane material U inside the first duct member 10. , A second urethane layer 22 formed in a required thickness by curing the urethane material U inside the second duct member 12. And
The first duct member 10 and the second duct member 12, which are separately molded, are correspondingly joined in the longitudinal direction to define the air flow passage 14 to form the duct D, and An appropriate article 90 can be sandwiched and fixed by the article holding portions 18, 18 that extend laterally opposite to each other.

The first duct member 10 and the second duct member 12 are formed in a required shape in separate steps according to the outer shape and size of the duct D and the outer shape and size of the article 90 to be fixed. Preformed. For example, those made of synthetic resin molded based on the injection molding technology, those made of metal molded based on the press molding technology, etc. can be suitably implemented, and the average thickness is set to 0.
By setting the thickness to about 5 to 1 mm, it has appropriate rigidity as a whole. The first duct member 10 integrally includes a duct wall portion 16 forming a lower half body (duct half body) of the duct D and an article holding portion 18 extending from one side edge of the duct wall portion 16. It is formed on the duct wall part 1
6 has a substantially U-shaped cross section based on the outer shape of the duct D, and the article holder 18 has a substantially semi-circular cross section. Further, the second duct member 12 integrally includes a duct wall portion 16 forming an upper half body (duct half body) of the duct D and an article holding portion 18 extending from one side edge of the duct wall portion 16. It is formed on the duct wall part 1
6 has a substantially U-shaped cross section based on the outer shape of the duct D, and the article holder 18 has a substantially semi-circular cross section. In addition, each of the article holders 18, 18
Is capable of bending elastic deformation with the joint portion with the corresponding duct wall portions 16, 16 as a base end, and bending elastic deformation of itself.

The first urethane layer 20 and the second urethane layer 22 will be described later and as shown in FIGS.
It is molded from the urethane material U based on the urethane spray molding technology using the duct molding die 40. That is, the first urethane layer 20 is such that the first duct member 10 is set on the molding surface 42a of the first molding die 42 of the duct molding die 40, and then the outer surface of the first duct member 10 is removed from the molding surface 42a. By spraying the urethane material U over the entire length, the required thickness is formed from the duct wall portion 16 to the article holding portion 18. Such a first urethane layer 20 is formed inside the duct wall portion 16 of the first duct member 10 and faces the air flow passage 14, and a duct surface portion 24 in the lateral direction of the duct surface portion 24. The flange portions 26, 26 integrally formed with the duct surface portion 24 along both side edges and the article holding surface portion 28 formed inside the article holding portion 18 have an average although there are partial differences. The thickness is about 2 to 5 mm.

The second urethane layer 22 has the second duct member 12 set on the molding surface 44a of the second molding die 44 of the duct molding die 40, and then the molding surface 44 is formed.
By spraying the urethane material U from a to the outer surface of the second duct member 12, a required thickness is formed from the duct wall portion 16 to the article holding portion 18. The second urethane layer 22 is formed inside the duct wall portion 16 of the second duct member 12 and faces the air flow passage 14, and the duct surface portion 24.
The flange portions 26, 26 integrally formed with the duct surface portion 24 along both side edges in the lateral direction of the article, and the article holding surface portion 28 formed inside the article holding portion 18 are partially different. However, the average thickness is about 2 to 5 mm.

Here, the urethane material U for molding the first urethane layer 20 and the second urethane layer 22.
For example, a soft foam type is preferably used. Therefore, the first urethane layer 20 and the second urethane layer 2
No. 2 has the physical properties of the molded urethane foam as it is, is lightweight and has appropriate elasticity and flexibility, and further has high heat insulation performance and 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 D of the embodiment composed of such constituent members, the urethane material U sprayed on the inside of the first duct member 10 or the urethane material U sprayed on the inside of the second duct member 12. By the adhesive force at the time of hardening, the respective flange portions 26, 26 of the first urethane layer 20 and the second urethane layer 22 are correspondingly adhered, so that the first duct member 10 and the second duct member 12 are Correspondingly joined in the longitudinal direction. Then, the duct D is formed by the respective duct wall portions 16 and 16, and
Various article 90 can be sandwiched by the article holders 18, 18 extending opposite to the side of the duct. Further, the duct surface portions 24, 24 of the first urethane layer 20 and the second urethane layer 22 come to face the air flow passage 14 inside the duct D, and the article holding surface portions 28, 28 are formed.
Comes to face the inside of the article holders 18, 18.

On the other hand, in each of the article holding portions 18, 18 provided on the side of the duct D, the length equal to or substantially the same as the entire length of the duct wall portion 16 along the edge of the duct wall portion 16 is provided. Is formed. And the first duct member 1
By correspondingly joining the 0 and the second duct member 12 in the longitudinal direction, an elongated article accommodating space 30 is defined between the two 18, 18. These article holders 18, 18
As described above, the positive elastic deformation and the flexible elastic deformation with the joint portion integrally formed with the duct wall portion 16 as the base end are allowed, and are joined to the duct wall portion 16. Since the edge portions 18a, 18a on the side opposite to the side are separated from each other, a gap S having a required width can be defined between the edge portions 18a, 18a. Therefore, when both or one of the respective article holding portions 18, 18 is elastically deformed so that both end edge portions 18a, 18a are separated from each other, the gap S is widened, so that the gap S is reduced. The article 90 can be attached to and detached from the article storage space 30 (FIG. 9).

Further, when an article 90 having a cross-sectional size that is appropriately larger than the interval between the article holding portions 18, 18 in the non-deformed state (normal state) is housed in the article housing space 30, each of the article The holding portions 18 and 18 can elastically clamp the article 90 in a state of being elastically deformed as appropriate. Further, since the article holding surface portions 28, 28 formed inside the article holding portions 18, 18 can also be elastically deformed in a compressive manner, the article 90 can also be deformed by the compression deformation of the article holding surface portions 28, 28. Can be held elastically. In addition, in the embodiment, in the non-deformed state of both article holding portions 18, 18, the mode in which an appropriate gap S is defined between both end edge portions 18a, 18a is illustrated, but on the assumption that they are not joined, It is also possible to adopt a mode in which the gaps S are always defined by the contact between the both edge portions 18a, 18a. In addition, each article holding unit 18,
The cross-sectional shape of 18 is not limited to the semi-arcuate shape illustrated in the embodiment, and various cross-sectional shapes can be implemented based on the shape and size of the article 90.

Here, the article 90 is, for example, a wire harness (signal / power transmission electric wire) WH for electrically connecting various in-vehicle electronic devices mounted on the instrument panel 60. Further, the article 90 is not limited to this wire harness WH, and is, for example, of a tube type in which a pressure transmission medium such as oil is enclosed, or of a pipe type in which various fluids (oil, water, etc.) are circulated. In addition, all of the long mode are included.

As described above, in the duct D of the embodiment, the first urethane layer 20 and the second urethane layer 22 having the physical properties (characteristics) of urethane foam are formed by foaming and curing the urethane material U. First duct member 10 and second
Since it is provided inside the duct member 12, the following beneficial effects are obtained. First, the first urethane layer 20 and the second urethane layer 22 that entirely cover the inside of the duct D.
Has excellent heat insulation performance, so that even if the temperature difference between the inside and the outside of the duct D is large, it is difficult for dew condensation to occur.
Further, since the first urethane layer 20 and the second urethane layer 22 are also excellent in sound absorbing performance, it is suitable for the abnormal noise generated by the contact of the vehicle-mounted device or the wire harness (not shown) arranged around the duct D. Don't absorb it and propagate it. Furthermore,
Since the operating noise of the air conditioner unit 70 is also absorbed, it is possible to prevent the operating noise from leaking into the passenger compartment. Therefore, it is not necessary to separately attach the foam sheet or the like made of a resin such as rubber, plastic, or urethane, which has excellent heat insulation performance and sound insulation performance, to the outer surface or the inner surface of the duct D. Costs do not increase because measures are taken to ensure

Further, since the first duct member 10 and the second duct member 12 which entirely cover the outside of the duct D have appropriate rigidity themselves, the duct D itself has an appropriate strength. It is hard to be deformed with the ingredients. Therefore,
Even if there is a pressure difference between the inside of the duct D (inside the air flow passage 14) and the outside, the deformation caused by the pressure difference is preferably prevented. Further, since the article holders 18, 18 also have appropriate rigidity, the article 90 such as the wire harness WH can be suitably held and fixed. Moreover, the article holder 18,
A first urethane layer 20 and a second urethane layer formed inside 18
Since the respective article holding surface portions 28, 28 of the urethane layer 22 come into close contact with each other while being appropriately deformed to the outer surface shape of the held article 90, the article 90 can be held more stably.

Next, a molding method for molding the duct D of the embodiment constructed as described above will be described with reference to FIGS.

The first urethane layer 20 and the second urethane layer 22 constituting the duct D of the embodiment are molded based on the urethane spray molding technique using the duct molding die 40 shown in FIG. 3 as described above. It Duct mold 4 here
0 sets the first duct member 10 and sets the second duct member 12 and the first molding die 42 provided with a concave molding surface 42a for molding a part of the first urethane layer 20. And a second molding die 44 provided with a concave molding surface 44a for molding a part of the second urethane layer 22. Then, the first molding die 42 and the second
A hinge 46 is openably and closably joined to the molding die 44 by a hinge 46 so that the second molding die 44 can be closed with respect to the first molding die 42 (FIGS. 3, 6, and 7). Further, on the back side of the molding surfaces 42a, 44a of both the molding dies 42, 44,
For example, a heating pipe 48 through which a heat medium such as water or oil flows is laid in a meandering shape, and the corresponding molding surfaces 42a and 44a are formed.
Is the optimum temperature for curing the urethane material U.
It can be heated to (for example, about 65 ° C.).

The first mold 42 and the second mold 44
Is formed of a synthetic resin, aluminum, steel or the like based on a known technique. Further, the molding surface 42a of the first molding die 42 is a portion obtained by combining the uneven surface portion on which the first duct member 10 is set and the flat surface portions located on both sides of the uneven surface portion, and the molding surface 42a of the second molding die 44 is formed. The molding surface 44a is
It is a portion in which the uneven surface portion on which the second duct member 12 is set and the flat surface portions located on both sides of the uneven surface portion are combined. However, the illustrated first molding die 42 and second molding die 44
In the above, the uneven surface portions of the respective molding surfaces 42a and 44a are formed in such a shape that they are in intimate contact with the entire outer surfaces of the first duct member 10 and the second duct member 12 to be set. The shape may be such that it partially contacts the first duct member 10 and the second duct member 12.
(Because the urethane material U is sprayed on the outer surfaces of the first duct member 10 and the second duct member 12).

In the duct forming method using the duct forming die 40 as described above, in the forming preparation step, the first forming die 42 and the second forming die 44 are opened and the heat is applied to the heating pipe 48. A medium is supplied to heat and hold the respective molding surfaces 42a, 44a of the first molding die 42 and the second molding die 44 at a required temperature, and an appropriate release agent is applied to the molding surfaces 42a, 44a (Fig. 3).

When the preparation for molding is completed, first, as shown in FIG. 4, a material having an appropriate rigidity is preformed to extend from the duct wall portion 16 forming the duct half and the side edge of the duct wall portion 16. The first duct member 10 integrally provided with the article holding portion 18 is provided with the molding surface 4 of the first molding die 42.
Set it to the required position of 2a. In addition, a duct wall portion 1 forming a duct half body by preforming a material having appropriate rigidity
6 and the second duct member 12 integrally provided with the article holding portion 18 extending from the side edge of the duct wall portion 16 in the second molding die 44 provided in the first molding die 42 so as to be mold-closeable. It is set at a required position on the molding surface 44a. The back surfaces of the first duct member 10 and the second duct member 12
(The surface where the first urethane layer 20 and the second urethane layer 22 contact each other) has an appropriate primer before setting the first duct member 10 and the second duct member 12 in the molding dies 42 and 44. It is desirable to process it. In addition, the first urethane layer 20 and the second urethane layer 2
Depending on the material of the urethane material U for molding 2, the first duct member 10 and the second duct member 12
The corresponding first molding die 4 under the preheating to a predetermined temperature.
Molding surfaces 42a and 44a of the second molding die 44 and the second molding die 44, respectively.
It is desirable to set

The first molding die 42 and the second molding die 44.
When the setting of the first duct member 10 and the second duct member 12 to the above is completed, then the first urethane layer 20 and the second urethane layer 22 are molded. That is, as shown in FIG. 5, the spray gun 50 is brought above the molding surface 42a of the first molding die 42, and the molding surface 42a
And by spraying the urethane material U on the outer surface (inner surface in the duct D to be molded) of the first duct member 10 set on the molding surface 42a, the required thickness is extended from the duct wall portion 16 to the article holding portion 18. The first urethane layer 20 is preformed. That is, the urethane material U is entirely sprayed from the outer surface of the duct wall portion 16 to the outer surface of the article holding portion 18, so that the preformed first urethane layer 20 is formed.
Is the duct surface portion 2 formed inside the duct wall portion 16.
4, the collar portions 26, 26 formed along both side edges of the duct surface portion 24, and the article holding surface portion 28 formed inside the article holding portion 18.

On the other hand, the spray gun 50 is brought above the molding surface 44a of the second molding die 44, and the molding surface 44a and the second duct member 1 set on the molding surface 44a.
By spraying the urethane material U onto the outer surface of 2 (inner surface of the molded duct D), the second urethane layer 22 having a required thickness is preformed from the duct wall portion 16 to the article holding portion 18. That is, the second urethane layer 22 preformed by spraying the urethane material U entirely from the outer surface of the duct wall portion 16 to the outer surface of the article holding portion 18,
Duct surface portion 24 formed inside the duct wall portion 16
And the collar portions 26, 26 formed along both side edges of the duct surface portion 24, and the article holding surface portion 28 formed inside the article holding portion 18.

Two spray guns 50 are prepared, and the molding surface 42a of the first molding die 42 and the second molding die 4 are prepared.
If the urethane material U is simultaneously sprayed onto each of the four molding surfaces 44a, the shortening of the molding cycle time can be expected.

When the spraying of the urethane material U onto the first molding die 42 and the second molding die 44 is completed, as shown in FIG.
Before at least one of the urethane materials U is completely cured, the second molding die 44 is closed with respect to the first molding die 42 so that the molding dies 42, 44 are closed to each other. As a result, the first urethane layer 20 preformed on the first mold 42 is formed.
The respective flange portions 26, 26 of the second urethane layer 22 preformed in the second molding die 44 come into close contact with the respective flange portions 26, 26 of the corresponding. Here, the urethane material U is
As is well known, since it has adhesiveness before being completely cured, at least one of the urethane materials U, U sprayed on the two molds 42, 44 is cured before it is cured. By bringing the flange portions 26, 26 of the first urethane layer 20 and the flange portions 26, 26 of the second urethane layer 22 into close contact, the respective flange portions 26, 26/26, 26 are adhered to each other,
The first urethane layer 20 and the second urethane layer 22 can be correspondingly joined in the longitudinal direction by utilizing the adhesive force when the urethane material U is cured.

In the closed state of the duct molding die 40, the urethane material U is on standby until it is completely foamed and cured. Then, when the molding of the first urethane layer 20 formed inside the first duct member 10 and the second urethane layer 22 formed inside the second duct member 12 is completed, FIG.
As shown in (1), the molded duct D is removed from the mold after the second mold 44 is opened from the first mold 42 and the mold is opened.

Further, after removing the mold, unnecessary portions of the collar portions 26, 26 and other unnecessary portions are cut off by a cutter or the like as needed (FIG. 8). Here, the first urethane layer 20 and the second urethane layer 22 are coated on the outside of the first urethane layer 20.
Since the edges of the duct member 10 and the second duct member 12 face the collar portions 26, 26, unnecessary portions of the collar portions 26, 26 can be peeled off with a fingertip.

In the duct D of the embodiment molded in this way, after the molding is completed as shown in FIG. 9, the article holding portions 18, 18 are elastically deformed to expand the gap S, and the article storage space is expanded. Wire harness W for 30
If articles 90 such as H are stored, each article holder 18,
Since the article 18 elastically clamps the article 90, the article 90 can be stably held.

As described above, in the molding method for molding the duct D according to the embodiment, the molding surface 42a of the first molding die 42 is used.
The urethane material U is entirely sprayed on the outer surface of the preformed first duct member 10 set to the first urethane layer 20.
And the molding surface 42a of the second molding die 44
The urethane material U is entirely sprayed on the outer surface of the second duct member 12 after the preforming which is set to the second urethane layer 22.
Of the respective urethane materials U, U after the pre-molding, before the two molds 42, 4 are completely cured.
By closing the molds 4 with each other, the first urethane layer 20 and the second urethane layer 22 are adhered to each other by using the adhesive force when the urethane material U is cured, and the first duct member 10 and the second duct member 10 The duct members 12 can be correspondingly joined in the longitudinal direction.

Therefore, the forming work of the first urethane layer 20 inside the first duct member 10 and the forming work of the second urethane layer 22 inside the second duct member 12, the first urethane layer 20 and the first duct member 10 are performed. With the second urethane layer 22 and the second duct member 12, and the formed first urethane layer 20 and the second urethane layer 2
Since the joining work of the first duct member 10 and the second duct member 12 by adhesion with 2 can be performed as a continuous series of processes, the forming work of the duct D can be simplified and rationalized. The cost can be reduced. Further, since no separate adhesive or the like is used for joining the first urethane layer 20 and the second urethane layer 22, it is possible to further reduce the molding cost.

On the other hand, at the same time when the duct D is molded by the duct molding die 40, it is possible to provide the article holding portions 18, 18 for fixing and holding the article 90 such as the wire harness WH. Simplification and rationalization.

In the duct D illustrated in the above embodiment, the first
Both the article holding portion 18 provided on the duct member 10 and the article holding portion 18 provided on the second duct member 12 are bent and elastically deformed with the joint portion with the corresponding duct wall portions 16, 16 as the base end. In addition, the flexible elastic deformation of itself was possible. However, when it is premised that the article 90 can be attached to and detached from the article storage space 30 via the gap S, and the article 90 stored in the article storage space 30 can be elastically held, Both article holders 18,
It is not necessary for any of the articles 18 to be elastically deformed, and it is sufficient that at least one of the article holding portions 18 is elastically deformable.

Further, the article holding unit 1 exemplified in the above embodiment.
8 and 18 illustrate the case where the duct wall portions 16 and 16 are formed to have the same or substantially the same length as the duct wall portion 16 along the edges thereof. However, in order to fix and hold a long-length article 90 such as a wire harness, as shown in FIG. 10 or 11, the article holders 18, 18 are set to have a short length (for example, 5
(About 0 to 100 mm), and the duct wall 1
A plurality may be formed at required intervals along the edge of 6.

Here, FIG. 10 shows a mode in which the article holding portions 18 provided on the first duct member 10 and the article holding portions 18 provided on the second duct member 12 are formed corresponding to the positions facing each other. Is an example. Further, FIG. 11 shows the article holding portions 18 provided on the first duct member 10 and the article holding portions 18 provided on the second duct member 12, respectively.
It is an example of a mode in which each is formed in a staggered manner. In addition, in the mode of each of the article holding portions 18 and 18 shown in FIGS.
Not only 0, but also an article 90 having a relatively short overall length can be clamped.

FIG. 12 is a schematic cross-sectional view illustrating the structure of the duct D according to the modification. In this duct D, the first urethane layer 20 and the second urethane layer 2 formed inside the first duct member 10 and the second duct member 12, respectively.
2 is composed of a duct surface portion 24 formed inside the duct wall portion 16 and collar portions 26, 26 formed along side edges of the duct surface portion 24. And
The first duct member 10 and the second duct member 12 are formed by adhering the flange portions 26, 26 to each other so as to face each other.
Are designed to be joined together. The duct D of such a modified example is suitable when the article holding surface portions 28, 28 are not required inside the article holding portions 18, 18, and the heat insulating performance and the sound absorbing performance required for the duct D are described above. It is equivalent to that of the embodiment.

In order to mold the duct D of such a modified example, when molding the first urethane layer 20 inside the first duct member 10 set in the first molding die 42 (FIG. 5), Outer surface of the duct wall portion 16 of the duct member 10
By spraying the urethane material U on (inside) and its peripheral portion, only the duct surface portion 24 and the flange portions 26, 26 can be molded. Similarly, when molding the second urethane layer 22 inside the second duct member 12 set in the second molding die 44, the outer surface (inner side) of the duct wall portion 16 and its peripheral portion in the second duct member 12 By spraying the urethane material U onto the duct surface portion 24 and the collar portion 2
Only 6,26 can be molded.

Further, in each of the ducts D of the embodiment and the modification, as shown in FIG. 13, the instrument is provided at the other end of the first duct member 10 and / or the second duct member 12. It is also possible to integrally provide a mounting bracket 32, which is provided when the duct D is mounted, at a required position on the back side of the panel 60 (FIG. 13).
Then, the mounting bracket 3 is attached to the edge of the second duct member 12.
2 is provided as an example). Such an aspect
This can be easily carried out by preforming the first duct member 10 and / or the second duct member 12 in a shape in which the edge portion is extended.

Here, the actual duct arranged in a narrow space on the back side of the instrument panel 60 on which a large number of devices and parts are mounted rarely has the simple shape shown in FIG. Often has a complicated outer surface shape having a curved surface or an uneven surface. However, in the urethane spray molding technique described above, the first duct member 10 and the second duct member 12 formed into a curved surface shape or an uneven shape.
Since the urethane material U can be appropriately sprayed onto the outer surface (inner side) of the above, the first urethane layer 20 and the second urethane layer having a complicated outer surface shape having a curved surface or an uneven surface. 22 can be suitably shaped. Therefore, the first urethane layer 20 and the first duct member 10
Can be molded in a state where they are in close contact with each other, and can be formed in a state in which the second urethane layer 22 and the second duct member 12 are 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, which has excellent heat insulation performance and sound insulation performance, it is inconvenient for the conventional duct D shown in FIGS. 14 and 15. Is preferably solved.

The duct D of the present application is not limited to the one provided on the back side of the instrument panel 60, 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.

[0046]

As described above, according to the duct of the present invention, since the urethane layer that entirely covers the inside of the duct is excellent in the heat insulating performance, the temperature inside and outside the duct is high. Condensation is less likely to occur even if the difference is large. Also, since the urethane layer has excellent sound absorbing performance,
Abnormal noise generated by the contact of in-vehicle devices or articles arranged around the duct is preferably absorbed and not propagated. Furthermore,
Since the operating noise of the air conditioner unit is also absorbed, it is possible to prevent the operating noise from leaking into the passenger compartment. Therefore, it is not necessary to separately attach a foam sheet or the like having excellent heat insulating performance and soundproofing performance to the outer surface or the inner surface of the duct, and the cost is not increased because measures are taken to prevent dew condensation and enhance the sound absorbing effect. Further, since the duct member which entirely covers the outside of the duct itself has an appropriate rigidity, the duct itself has an appropriate strength and is difficult to be deformed. Further, there is also an advantage that an article such as a wire harness can be suitably held by the article holding portion integrally provided on the duct member.

According to another aspect of the duct molding method of the present invention, the first urethane layer is formed inside the first duct member and the second urethane layer is formed inside the second duct member. Adhesion work between the duct member and the first urethane layer and between the second duct member and the second urethane layer, and joining work between the first duct member and the second duct member,
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, and the molding cost can be reduced. Further, since no separate adhesive or the like is used for joining the first duct member and the second duct member, it is possible to further reduce the molding cost. On the other hand, since it is possible to provide an article holding portion capable of fixedly holding an article such as a wire harness simultaneously with the duct forming operation, the forming operation can be further simplified and rationalized.

[Brief description of drawings]

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

FIG. 2 is a schematic perspective view showing the duct shown in FIG. 1 in a state where each constituent member is 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 the preformed first duct member is set on the molding surface of the first molding die and the preformed second duct member is set on the molding surface of the second molding die. .

FIG. 5 is an outer surface of the first duct member set in the first mold.
The urethane material is sprayed on the inner side to preform the first urethane layer, and the urethane material is sprayed on the outer surface (inner side) of the second duct member set in the second mold to preform the second urethane layer. It is explanatory sectional drawing which shows the state which is doing.

FIG. 6 is a first urethane layer and a second urethane layer obtained by closing the second mold to the first mold before curing at least one of the urethane materials sprayed on both molds. FIG. 4 is an explanatory cross-sectional view showing a state in which the flange portions are brought into close contact with each other and the first duct member and the second duct member are correspondingly joined by an 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 layer and the second urethane layer.

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 an explanatory cross-sectional view showing a state in which an article such as a wire harness is clamped and fixed by an article holding portion integrally provided on the side of the duct.

FIG. 10 is a view showing that the plurality of article holding portions whose lengths are set to be short are formed at predetermined intervals along the edge of the duct wall portion, and the article holding portions and the second article holding portions provided on the first duct member are provided. FIG. 6 is a schematic perspective view illustrating a mode in which the respective article holding portions provided on the duct member are correspondingly formed at positions facing each other.

FIG. 11 is a view showing that the plurality of article holders whose lengths are set to be short are formed at predetermined intervals along the end edge of the duct wall portion, and the article holders and the second article holders provided on the first duct member. It is a schematic perspective view which illustrated the aspect which formed each article holding part provided in the duct member so that each might stagger.

FIG. 12 is a duct of a modified example in which the first urethane layer formed inside the first duct member and the second urethane layer formed inside the second duct member are provided only on the duct wall portion and its peripheral portion. FIG.

FIG. 13 is an explanatory cross-sectional view showing a duct in which a mounting bracket used when mounting to a vehicle interior member is integrally provided at an edge portion of a second duct member.

FIG. 14 is a cross-sectional view showing a state in which a duct formed of a blow-molded hollow body is assembled inside an instrument panel that is an interior member of a vehicle.

FIG. 15 is a cross-sectional view showing a state in which a duct formed by a base material of an instrument panel and a gutter-shaped member joined to the base material is provided inside an instrument panel that is a vehicle interior member.

[Explanation of symbols]

10 1st duct member, 12 2nd duct member, 16
Duct wall part, 18 article holding part, 18a edge part, 20
1st urethane layer, 22 2nd urethane layer, 24 duct surface part, 26 collar part, 28 article holding surface part, 42 1st
Mold, 42a Molding surface, 44 Second mold, 44a
Molding surface, 60 instrument panel (vehicle interior member), 68 air outlet, 70 air conditioner unit, 9
0 article, S gap, U urethane material, WH wire harness

Claims (13)

[Claims] 1. An air outlet (68) provided on a vehicle interior member (60) for adjusting temperature of air from an air conditioner unit (70) mounted on a vehicle.
In the duct for guiding to, the duct wall portion (16) forming the duct half body and the article holding portion (18) extending from the side edge of the duct wall portion (16) are formed by preforming a material having appropriate rigidity. From the side edge of the duct wall (16) and the duct wall (16) forming a duct half by preforming a first duct member (10) integrally provided with The second duct member (12) integrally provided with the extended article holding portion (18) and the urethane material (U) inside the first duct member (10) are cured to have a required thickness. First urethane layer (20)
And a second urethane layer (22) formed to a required thickness by curing the urethane material (U) inside the second duct member (12).
The first duct member (10) and the second duct member (12) are correspondingly joined in the longitudinal direction by an adhesive force when the urethane material (U) is cured, and the respective duct walls are formed. Division (16/16)
While forming the duct by, the article (90) can be appropriately pinched and fixed by each of the article holding portions (18/18) extending sideways of the duct. duct. 2. The first urethane layer (20) and the second urethane layer (22) include a duct surface portion (24) formed inside the duct wall portion (16/16) and the duct surface portion (24). ) And a flange portion (26) formed along the side edge of the first urethane layer (2
The flange portion (26) of (0) and the flange portion (26) of the second urethane layer (22) are adhered to each other so that the first duct member (10) and the second duct member (12) are joined together. The duct according to claim 1, which is formed. 3. The first urethane layer (20) and the second urethane layer (22) include a duct surface portion (24) formed inside the duct wall portion (16/16) and the duct surface portion (24). ) Of the first urethane layer (20), and a collar portion (26) formed along the side edge of (1) and an article holding surface portion (28) formed inside the article holding portion (18). (26) and the flange portion (2) of the second urethane layer (22)
The first duct member (10) is formed by adhering 6) oppositely.
The duct according to claim 1, wherein the second duct member (12) is joined. 4. The article holding portion (18/18) is elastically deformable, at least one of which is allowed to elastically deform at a base end of a joint portion with a corresponding duct wall portion (16/16). Gap defined between the edge parts (18a / 18a) of both article holders (18/18)
The article (90) can be attached and detached via (S).
The duct according to any one of 3 above. 5. The article holder (18/18) is provided with the article (9).
The duct according to claim 4, wherein the duct (0) can be elastically clamped. 6. The article holder (18/18) has the same or substantially the same length as the entire length of the duct wall (16/16) along the edge of the duct wall (16/16). Claims 1-5 formed
The duct according to any one of 1. 7. The article holding part (18/18) according to claim 1, wherein a plurality of the article holding parts (18/18) are formed at required intervals along an edge of the duct wall part (16/16). The listed duct. 8. The duct according to claim 1, wherein the article (90) is a wire harness (WH) or the like for electrically connecting various in-vehicle electronic devices. 9. The duct according to claim 1, wherein the urethane material (U) is a soft foam type. 10. An air outlet (6) provided on a vehicle interior member (60) for adjusting temperature of air from an air conditioner unit (70) mounted on a vehicle.
In the method of forming a duct for guiding to 8), a material having appropriate rigidity is preformed, and the duct wall portion (16) forming the duct half and the article extended from the side edge of the duct wall portion (16). The first duct member (10) integrally provided with the holding portion (18) is set at a required position on the molding surface (42a) of the first molding die (42), and a material having appropriate rigidity is preformed. And a second duct member (12) integrally provided with a duct wall portion (16) forming a duct half and an article holding portion (18) extending from a side edge of the duct wall portion (16), The molding surface (44a) of the second molding die (44), which is provided in the first molding die (42) so as to be capable of closing the mold, is set to a required position, The molding surface (42a)
The urethane material (U) is sprayed on the outer surface of the first duct member (10) set to the above to preform the first urethane layer (20) having a required thickness, and the molding surface of the second molding die (44). (44a) and the molding surface (44a)
The urethane material (U) is sprayed onto the outer surface of the second duct member (12) set in the above to preform the second urethane layer (22) having a required thickness, and the second urethane layer (22) is sprayed onto the respective molding dies (42, 44). Attached urethane material (U, U)
Among them, at least one of the urethane materials (U) is completely closed before the two molding dies (42, 44) are closed, and the first urethane layer (20) and the second urethane layer (22) are closed. Corresponding to each other, and the first duct member (10) and the second duct member (12) are joined to each other in the longitudinal direction by the adhesive force when the urethane material (U) is cured. , Each of the duct walls (16/1
The duct is formed by 6), and the articles (90) can be appropriately clamped and fixed by the article holding portions (18/18) that extend sideways of the duct. A method for forming a duct, which is characterized in that 11. The first urethane layer (20) and the second urethane layer (22) by spraying the urethane material (U) on the inner side of the duct wall portion (16/16) and its peripheral portion.
The duct surface portion formed inside the duct wall portion (16)
The duct molding method according to claim 10, wherein the duct (26) and the flange (26) are formed along the side edge of the duct surface (24). 12. The urethane material extends from the inside of the duct wall portion (16/16) to the inside of the article holding portion (18/18).
By spraying (U) all over, the first urethane layer (2
0) and the second urethane layer (22), the duct surface portion (24) formed inside the duct wall portion (16), and the duct surface portion (2
The duct according to claim 10, wherein the duct portion (26) is formed along the side edge of (4) and the article holding surface portion (28) formed inside the article holding portion (18). Molding method. 13. The first molding die (42) and the second molding die
When the molds (44) are closed, the first urethane layer (20)
The flange part (26) of the second urethane layer (22) and the flange part (26) of the second urethane layer (22) are adhered to each other so that the first duct member (10) and the second duct member (12) are joined. Claim 11 or 1
2. The method for forming a duct according to 2.