JP2013014032A - Method for manufacturing duct-integrated floor raising material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a duct-integrated floor raising material capable of being efficiently manufactured while maintaining the performance of duct sound insulation and gas permeability or quality, and securing favorable moldability.SOLUTION: The method for manufacturing the duct-integrated floor raising material has: a stage of forming a second sealed space corresponding to a large hollow section 18, a first sealed space corresponding to a small hollow part communicating with a third sealed space corresponding to a duct 22 in a recess, and a disposal bag 118; a stage of forming the large hollow section, the duct and further the small hollow part through the communication passage by sticking the outer surface of the portion of the tubular parison corresponding to the second sealed space and the disposal bag, respectively, with a blow pin 126, blowing a pressurizing fluid to expand the molten tubular parison and pushing it to the surface of the cavity of the corresponding separate mold to shape the tubular parison; and a stage of cutting off the disposal bag to form an intake port or a discharge port in the duct.

Description

  The present invention relates to a method for manufacturing a duct-integrated floor raising material, and more specifically, can efficiently manufacture while ensuring good formability while maintaining performance or quality including sound insulation and air permeability of the duct. The present invention relates to a method for manufacturing a duct-integrated floor raising material.

Conventionally, a resin vehicle floor raising material has been used to adjust the height of the floor surface of an automobile.
The resin vehicle floor raising material has a substantially rectangular panel shape with a predetermined thickness (height) according to the specifications, and is required to be lighter. Since the driver's feet are placed on the upper surface, rigidity, especially compression rigidity is required, so the rib that extends between the upper wall and the back wall and connects both walls is inside The integral hollow structure provided in the is adopted.

Since such a floor raising material is a resin-made integral hollow structure, blow molding is more technically advantageous than injection molding. For example, Patent Document 1 discloses blow molding. Disclosed is a method for producing an automotive floor raising material.
This method of manufacturing an automotive floor raising material is for blow-molding a molten parison in a split mold, and a step of opening the split mold between a mold opening stage and a split mold in which the melt parison is opened And a step of clamping the divided mold and blowing a pressurized fluid into the molten parison.

  More specifically, it is a method for manufacturing a vehicle floor raising material having a hollow double wall structure having a front wall and a back wall facing each other at an interval, and is formed in a groove shape on the front wall side of the vehicle floor raising material. One mold having a rib-forming portion protruding in a plate shape for forming a plurality of recessed groove-shaped ribs, and a plurality of conical ribs recessed in a substantially conical shape on the back wall side of the automotive floor raising material Forming a split mold including the other mold having a rib-forming portion projecting in a substantially conical shape for forming, and dripping a melted parison between the split molds to form a rib of one mold The tip of the part and the tip of the rib forming part of the other mold are clamped close to each other, and the parison is expanded along the cavity of the split mold by blowing pressurized fluid into the parison. At the same time, the grooved rib and the conical rib are welded together to Has a plurality of groove-shaped ribs that are recessed in a groove shape toward the back wall, and the back wall has a cone that is recessed in a substantially conical shape toward the front wall at a portion facing the groove-shaped rib. In this case, a floor raising material for automobiles is blow-molded, in which a rib is formed, and the top wall of each conical rib and the tip of the groove-shaped rib form a weld.

By the way, in the vicinity of the feet of the driver's seat, a resin vehicle floor in which an air duct is usually arranged at the feet of the driver's seat in order to flow air-conditioned air from an air conditioner installed at the front of the vehicle to the rear seat of the vehicle. It extends in the vehicle front-rear direction so as to cross adjacent edges or opposite edges of the raising material.
In this regard, for example, Patent Document 2 discloses a duct-integrated floor raising material in which an air duct and a floor raising material are integrated into a single module to reduce the number of parts. The duct-integrated floor raising material is made of resin, has a hollow double wall structure including an upper wall and a back wall, and has a first groove and a second groove that protrude from the back wall toward the hollow portion. The groove is integrated with the upper surface wall at the welded portion, and a duct portion having an air flow path isolated from the hollow portion of the floor raising material is provided between the first concave groove and the second concave groove. .

  If such a duct-integrated floor raising material is integrally formed by blow molding as in Patent Document 1, the blow pin must be stabbed into the molten parison, and the blowing pressure must be applied. This causes technical problems.

First, depending on the position where the blow pin is inserted, it becomes a defective product.
More specifically, as described above, the duct extends in the vehicle front-rear direction in a form crossing the adjacent edge of the duct-integrated floor raising material or the opposite edge, Three hollow parts partitioned from each other are formed, and the duct-integrated floor raising material is normally divided unevenly by the duct, so that one is a large hollow part and one is a small hollow part, and constitutes an air flow path The duct is formed between the large hollow portion and the small hollow portion.
In this case, the duct-integrated floor raising material is originally provided with a carpet on the top surface, even if the blow pin marks (holes) remain in the large hollow portion and small hollow portion other than the duct, and the sealing performance is not secured. The above aesthetic appearance is not required, and the strict sealing property is not required as long as the height of the hollow portion, that is, the thickness of the floor raising material is ensured and the predetermined rigidity is maintained.

However, because the duct part becomes a flow path for air conditioning air, if traces (holes) on the blow pin remain, air leaks from it, causing a reduction in ventilation efficiency. May occur.
In order to maintain the performance or quality of such a duct, only the duct part is separately molded (for example, blow molding) and prepared as a molded product, and the floor raising material is blow molded without the duct part. If the duct portion is incorporated, the production efficiency of the floor raising material is lowered.

Second, due to the large number of blow pins, the circulation of blow air is poor, and the moldability is adversely affected.
More specifically, when the blow pins are pierced and blow-molded into each of the three hollow portions partitioned from each other, it is necessary to increase the number of blow pins pierced from the viewpoint of molding efficiency, depending on the volume of the hollow portion. On the contrary, it may deteriorate the circulation of the blow air in the hollow part and deteriorate the moldability for the melted parison formed by the blowing pressure.

Third, the improvement in sound insulation of the duct portion through which ventilated air flows is limited.
More specifically, in order to improve the sound insulation of the duct part, it is necessary to increase the volume of the hollow part of the duct part. However, in the case of a duct-integrated floor raising material, the duct part is larger than the small hollow part. The duct portion is placed between the hollow portion and the spread is limited. On the other hand, the height of the duct portion is usually high because the upper surface of the duct portion may be stepped on by a driver. The volume of the hollow portion of the duct portion on the duct-integrated floor raising material is set so as to protect the duct portion between the small hollow portion and the large hollow portion that are set lower than each other and ensure rigidity. As a result, the air passing sound from the duct portion of the duct-integrated floor raising material installed at the foot of the driver's seat may be a concern.
Japanese Patent No. 4462924 JP 2010-30553 A

  In view of the above technical problems, an object of the present invention is a duct-integrated floor that can be efficiently manufactured while ensuring good formability while maintaining performance or quality including duct sound insulation and air permeability. It is providing the manufacturing method of a raising material.

In order to solve the above problems, a method for manufacturing a duct-integrated floor raising material according to the present invention is as follows.
A hollow double wall structure in which the height between the top wall and the back wall is used for raising the floor, and a small hollow part, a large hollow part, and a duct part is provided between these hollow parts, and the duct The part and the small hollow part are communicated by a communication passage, and the duct part and the large hollow part are partitioned between the duct-integrated floor raising material manufacturing method,
Providing a pair of split molds each provided with a pinch-off portion around each cavity, arranged to face each other's cavities, and relatively movable between a clamping position and an open position;
At least one of the split mold cavities has a first projecting portion for forming a first long groove on the back wall of the floor raising material that projects inward and partitions between the small hollow portion and the duct portion. A second projecting portion for forming a second long groove projecting inward and partitioning between the large hollow portion and the duct portion is provided between the pinch-off portions on the back wall of the floor raising material. A recess for forming a passage is provided at the tip of the first protrusion over the thickness of the first protrusion, and at least one of the mold cavities corresponds to the end of the duct part. A recess for forming a disposal bag communicating with the duct portion is provided outside the cavity portion to be
Furthermore, a stage of disposing a molten cylindrical parison between a pair of split molds in an open position;
By bringing the pair of split molds in the open position relatively close to the mold clamping position, the front ends of the first protrusion and the second protrusion of one mold and the cavity of the other mold The pair of split molds are moved to the clamping position so that they face each other up to a predetermined distance, and the molten cylindrical parison is flattened and protruded from the pinch-off portion, so that the molten cylinder A portion corresponding to the pinch-off portion of the pair of molds of the parison, and a second sealed space corresponding to the large hollow portion, a third sealed space corresponding to the duct portion, and a third sealed space corresponding to the duct portion; Forming a first sealed space corresponding to a small hollow portion communicating with the concave portion and a disposal bag;
A blow pin is inserted into the outer surface of the cylindrical parison corresponding to each of the second sealed space and the disposal bag, and a pressurized fluid is blown to expand the molten cylindrical parison, so that the corresponding mold part Shaping the cylindrical parison by pressing against the surface of the mold cavity to form a large hollow portion and a duct portion, and further a small hollow portion through the communication path;
Cutting the waste bag to form an intake port or an exhaust port in the duct portion.

According to the present invention, the duct-integrated floor raising material has a substantially rectangular panel shape having a predetermined thickness (height) because of functional requirements, while air from an air conditioner installed at the front of the vehicle is supplied to the vehicle. The air duct to be fed to the rear is devised to pierce the blow pin that acts on the floor raising material in the form of crossing the edge of the floor raising material to extend in the front-rear direction of the vehicle and to apply the blowing pressure to form the duct By doing so, a duct-integrated floor raising material is manufactured.

More specifically, according to the manufacturing method of the duct-integrated floor raising material having the above-described configuration, the large hollow portion is blown into the outer surface of the cylindrical parison corresponding to the large hollow portion and blown into the inside. On the other hand, a duct is formed on the duct end (air intake port side or air exhaust port side), and a blow pin is inserted into the discarded bag to blow into the duct. By forming the duct part, the duct part is molded, the inside of the divided mold or after taking out the molded product, the waste bag is cut like a burr, and the air intake port or the air exhaust port is formed. It does not leave a mark (hole) of the blow pin in the part that forms the flow path, thereby preventing a decrease in ventilation efficiency and also preventing the occurrence of abnormal noise from the mark of the blow pin. In addition, for the small hollow part, by blowing the blow air from the duct part through the communication path, the duct-integrated floor raising material as a whole reduces the number of blow pins to pierce, preventing the deterioration of the circulation of the blow air, It is possible to ensure good moldability, and the duct portion and the small hollow portion are communicated using this communication path to increase the hollow portion volume of the duct portion, thereby passing the duct portion. It is also possible to reduce the passing sound of ventilating air, so the floor raising material is integrated with the duct while ensuring good formability while maintaining the performance or quality including duct sound insulation and ventilation And can be manufactured efficiently.

Also, at each end of the duct part, a discard bag is formed,
It is preferable that the pressurized fluid is blown into the third sealed space corresponding to the duct portion by piercing each throwing bag with a blow pin.
Further, when the integral divided mold is clamped, it is preferable that a blow pin is pierced into a portion corresponding to the pinch-off portion in the discard bag.
Furthermore, the duct-integrated raising material has a top wall and a back wall, and a peripheral side wall between the top wall and the back wall, and the height of the peripheral side wall is by blow molding used for raising the floor. An integral hollow double wall structure,
The back wall is provided with the first long groove and the second long groove that protrude inward from the back wall and extend between adjacent or opposite peripheral side walls at a predetermined interval,
Each of the first long groove and the second long groove has an opposing side wall projecting inward and a bottom wall formed between lower edges of the opposing side walls,
The bottom wall of each of the first long groove and the second long groove is welded to the inner surface of the top wall, so that the second wall on the side adjacent to one of the opposing side walls of the first long groove and the one of the side walls. One of the opposing side walls of the long groove, the duct part forming an air flow path therein by the upper surface wall and the back surface wall, the other of the opposing side walls of the first long groove or the second long groove, the upper surface wall, the back surface It is preferable that the wall and the hollow portion constituted by the peripheral side wall are formed so as to be partitioned from each other.

In addition, the hollow portion includes the other of the opposing side walls of the first long groove, the small hollow portion constituted by the top wall, the back wall, and the peripheral side wall, and the other of the opposing side walls of the second long groove, A large hollow portion constituted by the top wall, the back wall and the peripheral side wall, and the duct portion is disposed between the small hollow portion and the large hollow portion, and the first long groove The bottom wall may be formed with the communication path that communicates between the opposing side walls.
Furthermore, it is preferable that the recess for forming the communication path has a semicircular arc shape having a radius of 2 mm to 10 mm.
Furthermore, it is preferable that the concave portion for forming the communication path is formed in a groove shape in which a tip portion of the first projecting portion is cut out.

In addition, a third protrusion for forming a groove-like rib protruding from the upper surface wall toward the hollow portion is formed on the upper surface wall in the cavity of the mold part facing the at least one of the divided molds. Part is provided,
The bottom wall of each of the first long groove and the second long groove may be welded to the inner surface of the bottom portion of the groove-like rib.

Furthermore, the arrangement stage of the melted parison has a stage of extruding and dripping the melted parison from the extrusion slit arranged above the pair of split molds,
Each of the first protrusion and the second protrusion is provided so as to cross the pinch-off portion in a substantially vertical direction in the cavity of the at least one of the divided molds. Molded in the vertical direction,
The blow pin for the lower disposal bag is pierced upward or in the horizontal direction, and the blow pin for the upper disposal bag is pierced in the horizontal direction.
Furthermore, it is preferable that the blow pin for the hollow portion is pierced horizontally from the inside of the corresponding mold in a direction substantially orthogonal to the surface of the cavity.

An embodiment of a method for manufacturing a duct-integrated floor raising material 10 according to the present invention will be described below in detail with reference to the drawings. Hereinafter, the duct-integrated floor raising material 10 installed at the foot of the driver's seat of the automobile will be described as an example.

As shown in FIG. 1, the duct-integrated floor raising material 10 is installed between the floor pan F and the carpet C at the foot of the driver's seat S of the automobile V, and the carpet C regardless of the unevenness of the floor pan F. The thickness of the duct-integrated floor raising material 10 is determined so that the required floor surface satisfies the required level.
More specifically, the duct-integrated floor raising material 10 is disposed and used across the front wall surface below the dashboard of the automobile V and the concave portion of the floor surface connected thereto, and corresponds to the concave portion of the floor surface. The raised portion 2 and the footrest portion 3 corresponding to the front wall surface below the dashboard are integrally formed.

The duct-integrated floor raising material 10 is, for example, a member for making it possible to use an old model floor casing as it is in the case of a model change. Rigidity, particularly compression rigidity, is required in that it is installed at the foot of the driver's seat S and the driver's foot is placed on the upper surface.

As shown in FIG. 2, the duct-integrated floor raising material 10 has a substantially rectangular shape having a predetermined thickness (height) from the upper surface of the floor pan F on which the raising material is placed to a plane constituting the floor surface. The panel has a top wall 12, a back wall 14, and a peripheral side wall 16 between the top wall 12 and the back wall 14, and the height of the peripheral side wall 16 is used for raising the floor. It has a heavy wall structure. The back wall 14 is provided with an uneven portion for absorbing the unevenness of the floor pan F on which the back wall 14 is placed, and the top wall 12 is formed in a substantially flat shape.
The duct-integrated floor raising material 10 is composed of a thermoplastic resin such as ABS resin, modified polyphenylene oxide resin, polycarbonate resin, polyamide resin, polystyrene resin, polyethylene resin, polypropylene resin, etc. It is formed integrally.

The width of the duct-integrated floor raising member 10, that is, the size of the upper wall 12 or the rear wall 14 is determined as appropriate according to the place where the raising member 10 is installed. The thickness of each of the side walls 16 is determined by the relationship between the weight reduction of the raising material 10 and the required rigidity, particularly compression rigidity, and is formed in consideration of the blow pressure, blow ratio, etc. in blow molding described later. By determining the thickness of the molten cylindrical parison that is the material, the thickness of the raising material 10 that is the final molded product is determined.
The duct-integrated floor raising material 10 is provided with a large hollow portion 18, a small hollow portion 20, and a duct portion 22 disposed between the hollow portions 18, 20 so as to be partitioned from each other.
More specifically, as shown in FIG. 3, the first long groove 23 and the second long groove that protrude inward from the rear wall 14 and extend between the adjacent peripheral side walls 16 with a predetermined interval are provided on the rear wall 14. 24, each of the first long groove 23 and the second long groove 24 has an opposite side wall 26 protruding inward and a bottom wall 30 formed between the lower edges 28 of the opposite side walls 26. Each of the first long groove 23 and the second long groove 24 has a tapered shape toward the inside at a predetermined taper angle α, and the predetermined taper angle α corresponds to the blow ratio at the bottom of the first long groove 23 or the second long groove 24. Determined. The predetermined interval between the first long groove 23 and the second long groove 24 is determined according to the width of the duct portion 22 described later.

The bottom wall 30 of each of the first long groove 23 and the second long groove 24 is welded to the inner surface 32 of the top wall 12, so that one side 26 a of the opposite side wall 26 and the other side 26 a of the side wall 26 are adjacent to each other. One side 26a of the opposing side wall 26 of the second long groove 24, the duct portion 22 forming an air flow path 27 therein by the upper surface wall 12 and the rear surface wall 14, and the other side 26b of the opposing side wall 26 of the first long groove 23, the upper surface The small hollow portion 20 constituted by the wall 12, the back wall 14 and the peripheral side wall 16, the other side 26 b of the opposite side wall 26 of the second long groove 24, the large hollow portion constituted by the top wall 12, the back wall 14 and the peripheral side wall 16. 18 are formed so as to be partitioned from each other.
The upper surface wall 12 is formed with concave grooves 34 corresponding to the first long groove 23 and the second long groove 24, the depth of the concave groove 34 is 10 mm or less, and the concave groove 34 has an opening width. The bottom wall 30 of each of the first long groove 23 and the second long groove 24 is welded to the inner surface of the bottom of the concave groove 34. In particular, the concave groove 34 provided in the upper surface wall 12 is concave when the height of the raising material 10 is low, the blow ratio by blow molding is not so high, and the upper wall 12 and the rear wall 14 are not thinned. The groove 34 may be omitted, and each of the first long groove 23 and the second long groove 24 may be extended to the inner surface 32 of the upper surface wall 12 and formed into a rib shape that connects the upper surface wall 12 and the rear wall 14. It is possible to reduce the unevenness of the top wall 12 that is felt through the carpet C.

As shown in FIG. 2, the large hollow portion 18 has a raised portion 2 and a footrest portion 3 corresponding to the front wall surface below the dashboard, and the corresponding upper surface wall 12 is provided with a concave groove 34. The top wall 12 is reinforced. In some cases, the groove 34 may be extended to the inner surface of the back wall 14 to form a rib that connects the top wall 12 and the back wall 14.
Similar to the large hollow portion 18, the small hollow portion 20 is provided with a concave groove 34 in the top wall 12 to reinforce the top wall 12. Since the small hollow portion 20 has a smaller volume than the large hollow portion 18, it is less necessary to provide a rib for connecting the top wall 12 and the back wall 14, but may be provided depending on circumstances.

The communication passage 50 that communicates the small hollow portion 20 and the duct portion 22 will be described with reference to FIG. 4 is a detail of the communication path 50, FIG. 4A is a partial cross-sectional view along the extending direction of the communication path 50, and FIG. 4B is a line CC in FIG. 4A. It is a fragmentary sectional view which follows.
As shown in FIG. 4, the communication passage 50 is provided in the bottom 30 of the first long groove 23 that partitions the small hollow portion 20 and the duct portion 22, and more specifically has a length corresponding to the width of the bottom 30. And one side 26a and the other side 26b of the opposing side wall of the 1st long groove 23 are connected.

As shown in FIG. 4 (B), the cross section of the communication path 50 is semicircular and preferably has a radius of 2 mm to 10 mm. If it is smaller than 2 mm, the communication passage 50 may be blocked due to the variation in the thickness of the cylindrical parison P during blow molding, which will be described later. The extension of the parison P may become excessive, and the portion of the communication path 50 may be broken.
The thickness of the cylindrical parison P is the basis of the thickness of the top wall 12, the back wall 14, and the peripheral side wall 16 of the duct-integrated floor raising material 10 that is a molded product. For example, the thickness is required for the raising material 10. The amount of raising is large, thereby increasing the height of the peripheral side wall 16, increasing the blow ratio at the time of molding, and in case the thickness of the bent portion of these housing walls is reduced, Since it is necessary to increase the thickness of the cylindrical parison P, the upper limit on the size of the cross-sectional shape of the communication passage 50 is relaxed, while the amount of raising required for the raising material 10 is small, thereby When the peripheral side wall 16 is low, the blow ratio is low at the time of molding, and the thickness of the bent portion of the housing wall is not reduced, the thickness of the cylindrical parison P is increased. Because there is no need to do, 5 The upper limit of the constraints on the size of the cross-sectional shape of the tend to become stricter.

In this regard, the installation position of the communication path 50 may be provided at an appropriate position of the first long groove 23. However, when the restriction on the cross-sectional shape of the communication path 50 from the molding is large, A plurality of communication paths 50 may be provided at predetermined intervals along the line.
Note that the cross-sectional shape of the communication passage 50 is not limited to a semicircular arc shape, and the pressurized fluid introduced from the disposal bag 118 formed in the duct portion 22 described later is small through the communication passage 50 during blow molding. Any shape may be used as long as it is blown into the hollow portion 20 and the small hollow portion 20 can be smoothly formed.

  The duct portion 22 extends in the front-rear direction of the vehicle so as to cross the adjacent peripheral side wall 16, and has a horizontal straight portion 36 located beside the duct-integrated floor raising material 10 and a vertical portion 38 connected to the horizontal straight portion 36. And a horizontal curved portion 40 connected to the vertical portion 38 and extending on the duct-integrated floor raising material 10. At one end of the horizontal straight portion 36, an intake port 42 is provided at a position protruding outward from the peripheral side wall 16. At one end of the horizontal curved portion 40, a position at which the exhaust port 44 protrudes outward from the peripheral side wall 16. The air flow path 27 is formed in the interior by the horizontal straight portion 36, the vertical portion 38, and the horizontal bending portion 40 so that the air-conditioned air of the air conditioner unit is sent from the exhaust port 44 to the rear seat. As shown in FIG. 2, the exhaust port 44 is divided into two channels by providing a compression portion 46.

The flow path cross-sectional area of the air flow path 27 may be appropriately determined in relation to the flow rate of the ventilation air, the passing sound of generated air, and the like. The height of the air flow path 27, that is, the height of the duct portion 22 is It is preferable that the height of the large hollow portion 18 and the small hollow portion 20 installed adjacent to each side of the duct portion 22 is set to be lower than the upper surface of the large hollow portion 18 and the small hollow portion 20. The duct portion 22 is prevented from projecting so as not to be stepped directly on by the driver D, for example, and the duct portion 22 is protected by the large hollow portion 18 and the small hollow portion 20.
A concave groove 34 is formed in the portion of the top wall 12 constituting the air flow path 27 of the duct portion 22, similarly to the large and small hollow portions 18 and 20.

As shown in FIG. 5, the molding device 100 for the duct-integrated floor raising material 10 includes a molten resin extrusion device 102 and a mold clamping device 104 disposed below the extrusion device 102. A cylindrical parison of a molten thermoplastic resin extruded from the extrusion apparatus 102 is sent to the mold clamping apparatus 104, and the molten cylindrical parison is blow-molded by the mold clamping apparatus 104. 5 to 7 show the molding apparatus with reference to a cross section taken along line BB of the duct-integrated floor raising material 10 shown in FIG. 2, and the dotted line portion shown in FIG. 2 is omitted. Yes.
Although the extruding device 102 is conventionally known and detailed description thereof is omitted, the molten cylindrical parison P is pushed downward and suspended between the divided molds 106A and 106B of the mold clamping device 104. Yes.

The mold clamping device 104 includes a pair of split molds 106A and 106B and a mold driving device (not shown).
The two divided molds 106A and 106B are arranged with the cavities 108 facing each other, and the cavities 108 are arranged along the substantially vertical direction.

In each of the two divided molds 106A and 106B, a pinch-off portion 114 is formed around the cavity 108. The pinch-off portion 114 is formed in an annular shape around the cavity 108, and the opposite molds 106A and 106B are opposed to each other. Protrusively toward. As a result, when the two divided molds 106A and 106B are clamped, the tip portions of the respective pinch-off portions 114 come into contact with each other so that the parting line PL is formed at the peripheral edge of the cylindrical parison P. It is welded and a hollow part is formed inside.
The surface of one cavity 108A has a complementary shape depending on the shape to be molded on the surface of the upper surface wall 12. The surface of the other cavity 108B has a complementary shape depending on the shape to be molded on the surface of the back wall 14.
More specifically, the first long groove that projects inwardly on the back wall 14 of the floor raising material 10 and partitions between the small hollow portion 20 and the duct portion 22 is formed in the cavity 108B of one split mold 106B. 1st protrusion part 110 (not shown) for forming 23, and the 2nd long groove which protrudes toward the inside on the back wall 14 of the floor raising material 10, and partitions off between the large hollow part 18 and the duct part 22 And a second projecting portion 112 for forming a portion 24 is provided so as to substantially traverse the annular pinch-off portion 114B. Thus, as will be described later, when blow molding is performed, one of the split molds 106B is clamped. Thus, the sealed space formed by the annular pinch-off portions 114A and 114B is divided into three (the large hollow portion 18, the small hollow portion 20, and the duct portion 22) by the first projecting portion 110 and the second projecting portion 112. As doing. Strictly speaking, the small hollow portion 20 and the duct portion 22 communicate with each other through a communication path 50.

In the cavity 108A of the mold part 106A facing the split mold 106B, a third projecting part for forming a groove-like rib projecting from the upper surface wall 12 toward the hollow part side is further formed on the upper surface wall 12. 116 is provided so that the bottom wall 30 of each of the first long groove 23 and the second long groove 24 is welded to the inner surface of the bottom of the groove-like rib.

As shown in FIG. 8, a recess 113 for forming the communication path 50 is provided in the distal end portion 111 of the first protrusion 110 across the thickness direction of the first protrusion 110. The recess 113 is preferably formed in a groove shape in which the tip end portion 111 of the first protrusion 110 is notched, and the width d and the cross-sectional shape of the recess 113 respectively constitute the length and the cross-sectional shape of the communication path 50. .
In each of the cavities 108A, B of the split molds 106A, B, a disposal bag 118 communicating with the duct portion 22 is formed near the pinch-off portion 114 outside the portion of the cavity 108 corresponding to the end portion of the duct portion 22. Recesses 120A and B are provided.

  Further, the cavity 108B of one split mold 106B is further provided with a projection 122 on the back wall 14 of the floor raising material 10 for forming a concave groove 34 projecting toward the inside. The cavity 108A of the other split mold 106A is provided with a projection 117 at the position corresponding to the projection 122 to form a concave groove 36 projecting inward on the upper surface wall 12, Thereby, the rib which connects the back surface wall 14 and the upper surface wall 12 is formed in a hollow part.

The mold driving device (not shown) is the same as the conventional one, and the description thereof is omitted. However, the two divided molds 106A and 106B are respectively formed by a mold driving device (not shown). In the open position, the molten cylindrical parison P can be suspended between the two split molds 106A, B, while the pinch-off portion of the two split molds 106A, B is closed in the closed position. 114 abuts and the annular pinch-off portions 114 abut each other so that a sealed space is formed in the two divided molds 106A and 106B.
A conventionally known blow pin 126 is applied to the divided dies 106A, B so that when the dies 106A, B are clamped, a blowing pressure can be applied to the sealed space formed by both the dies 106A, B. The blow pin 126 is configured to be capable of reciprocating linear movement between the piercing position and the standby position by, for example, a piston / cylinder mechanism.
The blow pin 126 is provided in accordance with each of the large hollow portion 18, the small hollow portion 20 and the duct portion 22 that are partitioned from each other. In particular, the duct portion 22 is not the main body portion that constitutes the air flow path 27 but the both ends of the main body portion. It is provided with respect to the disposal bag 118 formed. In FIG. 5, only the blow pins 126 for the large hollow portion 18 and the lower disposal bag 118 are shown.

Regarding the number of blow pins 126 installed and the direction of piercing, the large hollow portion 18 and the small hollow portion 20 are in a horizontal direction in a direction substantially orthogonal to the cavities 108 of the molds 106A and B, while the duct portion 22 is The upper disposal bag 118 is disposed horizontally in a direction substantially orthogonal to the cavities 108 of the molds 106A and 106B (in FIG. 5, on the drawing, from the back to the front or from the front to the back), while the lower disposal bag is disposed. The bag 118 is directed upward. Since the volume of the small hollow portion 20 is smaller than that of the large hollow portion 18, the number of blow pins 126 pierced to form the small hollow portion 20 is larger than the number of blow pins 126 pierced to form the large hollow portion 18. Few.
Accordingly, the blow pin 126 can be smoothly stabbed in a state where the cylindrical parison P is suspended between the divided molds 106A and 106B.

The manufacturing method of this floor raising material 10 for automobiles is to blow the molten parison P in the divided molds 106A, B, and the mold opening stage of the divided molds 106A, B and the molten parison P are opened. This is roughly composed of a step of hanging between the divided molds 106A and 106B, and a step of clamping the divided molds 106A and B and blowing a pressurized fluid into the molten parison P.
More specifically, as shown in FIG. 5, first, the molten cylindrical parison P is placed between the pair of split molds 106A, B at the open position. Specifically, the parison P in a molten state is extruded from the extrusion device 102 disposed above the pair of split molds 106A and 106B and is suspended. The diameter and thickness of the cylindrical parison P may be determined on the basis of the thickness required for the automotive floor raising material 10 after blow molding, particularly considering the blow ratio at the time of blow molding.

Next, as shown in FIG. 6, the pair of split molds 106A and B in the open position are relatively brought close to the mold clamping position, whereby the first protrusion 110 and the second protrusion of the one mold 106B. 112. The pair of split molds 106A and B are moved to the clamping position so that the respective tip end portions and the cavity 108A of the other mold 106A face each other and come close to a predetermined distance, and a molten cylindrical parison is obtained. P is flatly crushed and protrudes from the pinch-off portion 114, and the tips of the first protrusion 110 and the second protrusion 112 of one mold 106A, B and the cavity 108 of the other mold 106A, B are used. The pair of split molds 106A and 106B are moved to the mold clamping position so that the tip of the third protrusion 116 is opposed to and close to a predetermined distance. When the mold is clamped, the predetermined distance is such that the first long groove is formed in the molten cylindrical parison P by the distal ends of the first projecting portion 110 and the second projecting portion 112 and the distal end portion of the third projecting portion 116. 23, the groove | channel which becomes the foundation of each of the 2nd long groove 24 and the concave groove 34 is formed, and when the bottom part of each groove | channel is welded, it sets so that this welding may be performed reliably. That is, a molten resin corresponding to twice the thickness of the molten parison P is formed between the opposing front ends of the first protrusion 110 and the second protrusion 112 and the corresponding front end of the third protrusion 116. However, if the predetermined distance is too small, welding is possible, but the molten cylindrical parison P is crushed, and the cylindrical parison P protrudes from each tip, while the predetermined distance is too large, Insufficient welding.

Further, by clamping the divided molds 106A and 106B, the portions corresponding to the pinch-off portions 114 of the pair of molds 106A and 106 of the molten cylindrical parison P are welded, so that the peripheral side wall 16 is formed. On the other hand, a sealed hollow portion is formed inside the cylindrical parison P. On the other hand, the first long groove 23, the second long groove 24, and the concave groove 34 are formed by the first protrusion 110 to the third protrusion 116. Are formed, and the bottoms of the first long groove 23 and the second long groove 24 are welded to the bottoms of the corresponding concave grooves 34 except for a portion corresponding to the concave portion 113 provided at the tip portion 111 of the first projecting portion 110. Thus, the first sealed space corresponding to the large hollow portion 18 by the tip 111 of the first projecting portion 110, the third sealed space corresponding to the duct portion 22 communicating with the small hollow portion 20 via the communication path 50, and Throwing bag 11 There is formed.

In this case, each of the first projecting portion 110 and the second projecting portion 112 is provided so as to cross the pinch-off portion 114 substantially vertically in the cavity 108 of one of the split molds 106A and 106B. The part 22 is formed in a substantially vertical direction.
Next, as shown in FIG. 6, the blown pin 126 is pierced into the outer surface of the portion of the cylindrical parison P corresponding to each of the first sealed space and the disposal bag 118, and the pressurized fluid is blown into the molten cylinder. The cylindrical parison P is inflated and pressed against the surface of the cavity 108 of the corresponding mold part 106A, B, thereby forming the cylindrical parison P and molding the large hollow part 18 and the duct part 22 respectively. At the same time, the pressurized fluid introduced into the duct portion 22 through the communication passage 50 is blown into the small hollow portion 20, and the small hollow portion 20 is also formed.

More specifically, a disposal bag 118 is formed at each end of the duct portion 22, and a blow pin 126 is pierced into each disposal bag 118, thereby adding to the third sealed space corresponding to the duct portion 22. Inject pressurized fluid. In this case, when the integrated divided molds 106A and 106B are clamped, the blow pin 126 is pierced into a portion corresponding to the pinch-off portion 114 in each disposal bag 118. As a result, the portion corresponding to the pinch-off portion 114 is firmly sandwiched between the pair of molds 106A and 106B, so that the blow pin 126 can be securely connected without, for example, the portion of the parison P being pierced escaping in the piercing direction. It is possible to stab.

As shown in FIG. 6, the blow pin 126 with respect to the lower disposal bag 118 stabs upward, and the blow pin 126 with respect to the upper disposal bag 118 is in the horizontal direction (the direction from the back to the front or from the front to the back in the drawing). ) On the other hand, the blow pin 126 for the large hollow portion 18 is pierced in the horizontal direction from the inside of the corresponding mold 106A, B in a direction substantially orthogonal to the surface of the cavity 108.

  As a result, air leakage without leaving blow pin marks (holes) in the body of the duct portion 22 constituting the air-conditioning air flow path without reducing molding efficiency due to smooth piercing of the blow pins 126. It is possible to suppress the decrease in ventilation efficiency due to the airflow and to prevent the generation of abnormal noise from the floor surface.

Next, the disposal bag 118 is cut to form an air inlet 42 at one end of the duct portion 22 and an air outlet 44 at the other end. By forming the intake port 42 and the exhaust port 44 at positions projecting outward from the peripheral side wall 16 where the parting line PL (see FIG. 2) is formed, the intake port 42 and the exhaust port 44 can be easily provided. External ducts can be connected.
Next, as shown in FIG. 7, the pair of split molds 106A, B are opened, the molded duct-integrated floor raising material 10 is taken out of the pair of split molds 106A, B, and burrs are removed. The duct-integrated floor raising material 10 is completed.

  According to the manufacturing method of the duct-integrated floor raising material 10 having the above-described configuration, the large hollow portion 18 is blown into the outer surface of the cylindrical parison P corresponding to the large hollow portion 18 with the blow pin 126 pierced inside. While forming by applying pressure, the duct portion 22 is formed with a discard bag 118 at the duct end (air intake port side or air exhaust port side), and a blow pin 126 is pierced into the discard bag 118, The duct portion 22 is formed by shaping by applying blowing pressure to the inside, and the waste bag 118 is cut like a burr in the divided mold 106 or after taking out the molded product, and the air inlet 42 or the air exhaust is cut. By forming the opening 44, no trace (hole) of the blow pin 126 is left in the portion where the air flow path 27 is formed, thereby preventing a reduction in ventilation efficiency. Further, it is possible to prevent the generation of abnormal noise from the mark of the blow pin 126. Further, for the small hollow portion 20, the blow air from the duct portion 22 is sent through the communication passage 50, so that the duct-integrated floor raising material 10 is provided. As a whole, by reducing the number of blow pins 126 to be pierced, it is possible to prevent deterioration of the circulation of blow air and ensure good moldability. By communicating with the small hollow portion 20, the volume of the hollow portion of the duct portion 22 is increased, so that it is possible to reduce the passing sound of the ventilation air passing through the duct portion 22, and thus the sound insulation of the duct. The floor raising material can be efficiently manufactured integrally with the duct while ensuring good moldability while maintaining performance or quality including air permeability.

The embodiments of the present invention have been described in detail above, but various modifications or changes can be made by those skilled in the art without departing from the scope of the present invention.
For example, in the present embodiment, the case where the duct-integrated floor raising material 10 is installed at the foot of the driver's seat S of the automobile V has been described, but the present invention is not limited to this and is used for adjusting the height of the floor surface. As long as it is installed, it may be installed at the foot of the auxiliary seat or rear seat of the car V.
Further, in the present embodiment, the duct integrated floor raising material 10 has been described as a case where the duct portion 22 crosses the adjacent side surface of the raising material 10 in the front-rear direction of the vehicle, but the duct portion 22 is not limited thereto. As long as the route overlaps with the installation position of the floor raising material 10 and the duct portion 22 is integrally formed, for example, the duct portion 22 may cross the opposite side surfaces of the raising material 10 in the longitudinal direction of the vehicle.

Furthermore, in the present embodiment, in the duct-integrated floor raising material 10, the first long groove 23 and the second long groove 24 that partition the duct portion 22 and the hollow portion protrude inward from the back wall 14, and inward from the top wall 12. Although the description has been given of the case in which the groove 34 protruding in the direction and the distal ends of the raised material 10 are welded to each other inside the raising material 10, the first long groove 23 and the second long groove 24 are not limited to the upper wall 12. The groove 34 may be provided on the back wall 14 side. In addition, the height required for raising the floor raising material 10 is not so high, so that the blow ratio of the top wall 12 and the back wall 14 is not so high at the time of blow molding, and the thinning of the thickness of both walls is a problem. If not, the concave groove 34 is omitted, and the tip of the first long groove 23 or the second long groove 24 provided in the back wall 14 or the top wall 12 is directly welded to the top wall 12 or the inner surface 32 of the back wall 14. You may comprise.
In addition, in the present embodiment, a case has been described in which the discarded bag is cut before the split mold 106 is opened.

FIG. 3 is a schematic view showing a situation where a duct-integrated raising member according to an embodiment of the present invention is installed at the foot of a driver's seat of an automobile V. It is a perspective view of the duct-integrated raising member according to the embodiment of the present invention. FIG. 3 is a cross-sectional view taken along line AA in FIG. 2. FIG. 2 is a partial cross-sectional view of a communication passage 50 provided in a first long groove 23 in the duct-integrated raising member forming apparatus 100 according to the embodiment of the present invention. FIG. 6 is a schematic view showing a state in which a cylindrical parison P is disposed between a pair of split molds 106A and B in the duct-integrated raising member forming apparatus 100 according to the embodiment of the present invention. FIG. 5 is a schematic view showing a state where a pair of split molds 106A and 106B are clamped in the duct-integrated raising member forming apparatus 100 according to the embodiment of the present invention. FIG. 6 is a schematic view showing a state in which a pair of split molds 106A and B are opened in the duct-integrated raising member forming apparatus 100 according to the embodiment of the present invention. FIG. 5 is a partial perspective view showing details of a concave portion 113 provided at a distal end portion 111 of a first projecting portion 110 in the duct-integrated raising member forming apparatus 100 according to the embodiment of the present invention.

V car
C carpet
F floor pan
S Driver's seat
D driver
P tubular parison
PL parting line 10 duct-integrated raising member 12 upper surface wall 14 rear surface wall 16 peripheral side wall 18 large hollow portion 20 small hollow portion 22 duct portion 23 first long groove 24 second long groove 26 opposite side wall 28 lower edge 30 bottom wall 32 inner surface 34 Concave groove 36 Horizontal straight part 38 Vertical part 40 Horizontal curved part 42 Inlet port 44 Exhaust port 50 Communication path 100 Molding device 102 Extruding device 104 Clamping device 106 Split mold 108 Cavity 110 First protrusion 111 Front end 113 Recess 112 Second protrusion 114 Pinch-off part 116 Third protrusion 117 Protrusion 118 Disposal bag 120 Recess 122 Protrusion 126 Blow pin

Claims (10)

A hollow double wall structure in which the height between the top wall and the back wall is used for raising the floor, and a small hollow part, a large hollow part, and a duct part is provided between these hollow parts, and the duct The part and the small hollow part are communicated by a communication passage, and the duct part and the large hollow part are partitioned between the duct-integrated floor raising material manufacturing method,
Providing a pair of split molds each provided with a pinch-off portion around each cavity, arranged to face each other's cavities, and relatively movable between a clamping position and an open position;
At least one of the split mold cavities has a first projecting portion for forming a first long groove on the back wall of the floor raising material that projects inward and partitions between the small hollow portion and the duct portion. A second projecting portion for forming a second long groove projecting inward and partitioning between the large hollow portion and the duct portion is provided between the pinch-off portions on the back wall of the floor raising material. A recess for forming a passage is provided at the tip of the first protrusion over the thickness of the first protrusion, and at least one of the mold cavities corresponds to the end of the duct part. A recess for forming a disposal bag communicating with the duct portion is provided outside the cavity portion to be
Furthermore, a stage of disposing a molten cylindrical parison between a pair of split molds in an open position;
By bringing the pair of split molds in the open position relatively close to the mold clamping position, the front ends of the first protrusion and the second protrusion of one mold and the cavity of the other mold The pair of split molds are moved to the clamping position so that they face each other up to a predetermined distance, and the molten cylindrical parison is flattened and protruded from the pinch-off portion, so that the molten cylinder A portion corresponding to the pinch-off portion of the pair of molds of the parison, and a second sealed space corresponding to the large hollow portion, a third sealed space corresponding to the duct portion, and a third sealed space corresponding to the duct portion; Forming a first sealed space corresponding to a small hollow portion communicating with the concave portion and a disposal bag;
A blow pin is inserted into the outer surface of the cylindrical parison corresponding to each of the second sealed space and the disposal bag, and a pressurized fluid is blown to expand the molten cylindrical parison, so that the corresponding mold part Shaping the cylindrical parison by pressing against the surface of the mold cavity to form a large hollow portion and a duct portion, and further a small hollow portion through the communication path;
Cutting the waste bag and forming an air inlet or an air outlet in the duct portion. At each end of the duct part, a throwaway bag is formed,
The method for producing a duct-integrated hoist according to claim 1, wherein a pressurized fluid is blown into the third sealed space corresponding to the duct portion by piercing each blow bag with a blow pin. 3. The method for producing a duct-integrated raising material according to claim 1, wherein when the integral split mold is clamped, a blow pin is inserted into a portion corresponding to the pinch-off portion in the discard bag. The duct-integrated raising material has an upper surface wall, a rear surface wall, and a peripheral side wall between the upper surface wall and the rear surface wall, and the height of the peripheral side wall is an integral hollow two by blow molding used for raising the floor. A heavy wall structure,
The back wall is provided with the first long groove and the second long groove that protrude inward from the back wall and extend between adjacent or opposite peripheral side walls at a predetermined interval,
Each of the first long groove and the second long groove has an opposing side wall projecting inward and a bottom wall formed between lower edges of the opposing side walls,
The bottom wall of each of the first long groove and the second long groove is welded to the inner surface of the top wall, so that the second wall on the side adjacent to one of the opposing side walls of the first long groove and the one of the side walls. One of the opposing side walls of the long groove, the duct part forming an air flow path therein by the upper surface wall and the back surface wall, the other of the opposing side walls of the first long groove or the second long groove, the upper surface wall, the back surface The method for producing a duct-integrated hoisting material according to any one of claims 1 to 3, wherein the wall and the hollow portion formed by the peripheral side wall are formed in a manner of being partitioned from each other. The hollow portion includes the other of the opposing side walls of the first long groove, the small hollow portion constituted by the upper surface wall, the back wall and the peripheral side wall, the other of the opposing side walls of the second long groove, and the upper surface wall. A large hollow portion constituted by the back wall and the peripheral side wall, and the duct portion is disposed between the small hollow portion and the large hollow portion, and is formed on the bottom wall of the first long groove. 5. The duct-integrated floor raising material according to claim 4, wherein the communication path that communicates between the opposite side walls is formed. The method for manufacturing a duct-integrated hoist according to claim 5, wherein the recess for forming the communication path has a semicircular shape with a radius of 2 mm to 10 mm. The said recessed part for forming the said communicating path is a manufacturing method of the duct integral raising material of Claim 5 formed in the groove shape which notched the front-end | tip part of the said 1st protrusion part. A cavity of the mold part that faces at least one of the divided molds is provided with a third projecting part on the upper surface wall for forming a groove-like rib projecting from the upper surface wall to the hollow part side. And
The duct-integrated floor raising material according to claim 1, wherein the bottom wall of each of the first long groove and the second long groove is welded to the inner surface of the bottom portion of the groove-shaped rib. The molten parison arrangement step includes a step of extruding and dripping the molten parison from an extrusion slit disposed above the pair of split molds,
Each of the first protrusion and the second protrusion is provided so as to cross the pinch-off portion in a substantially vertical direction in the cavity of the at least one of the divided molds. Molded in the vertical direction,
9. The duct according to claim 1, wherein the blow pin for the lower disposal bag pierces upward or in a horizontal direction, and the blow pin for the upper disposal bag pierces in a horizontal direction. A method for producing a body-raising material.         The method for producing a duct-integrated hoist according to claim 9, wherein the blow pin for the hollow portion is pierced horizontally from the inside of the corresponding mold in a direction substantially orthogonal to the surface of the cavity.

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