JP2013014228A - Cover material for vehicle - Google Patents

Cover material for vehicle Download PDF

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JP2013014228A
JP2013014228A JP2011148423A JP2011148423A JP2013014228A JP 2013014228 A JP2013014228 A JP 2013014228A JP 2011148423 A JP2011148423 A JP 2011148423A JP 2011148423 A JP2011148423 A JP 2011148423A JP 2013014228 A JP2013014228 A JP 2013014228A
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engine
cover
base material
vehicle
cover material
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JP5686681B2 (en
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Fumiaki Takebayashi
文明 武林
Kuniaki Sasaki
邦明 佐々木
Hitoshi Kawahara
斎 河原
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Kasai Kogyo Co Ltd
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Abstract

PROBLEM TO BE SOLVED: To provide a lightweight cover material for vehicles which exhibits high performance of absorbing engine noise.SOLUTION: The cover material for vehicles is a material for an engine cover (30) covering an engine (21) in an engine room and comprises: a base material (36) formed of a fiber reinforced resin; an air impermeable skin material (37) which is made of an olefin resin such as olefin resin elastomer, and which is provided on the upper surface of the base material (36) to form a design surface (31); and a rear surface material (38) which is provided on the lower surface of the base material (36) and is made of an air permeable film or a nonwoven fabric having an air permeability set to be 5-50 cm/cm/sec.

Description

本発明は、エンジンルームの所定箇所を覆う車両用カバー材に関し、特に吸音性と意匠性を兼ね備える車両用カバー材に関する。   The present invention relates to a vehicle cover material that covers a predetermined portion of an engine room, and more particularly to a vehicle cover material that has both sound absorption and design properties.

車両のエンジンルームにおける防音性及び意匠性を高めるため、エンジンカバーに代表される各種のカバー材が実用に供されている。   In order to improve soundproofing and design in an engine room of a vehicle, various cover materials represented by an engine cover have been put to practical use.

従来の車両用カバー材を次図に基づいて説明する。
図7は、従来のエンジンカバーの基本構成を説明する図であり、図7(a)に示すように、エンジンカバー100は、射出成形により製造されるポリプロピレン製の基材101と、図7(b)に示すように、この基材101の裏面に超音波融着あるいはホットメルトで固定されるウレタン製などの吸音材102とからなり、エンジン103の上部(例えば、シリンダヘッドカバー、ハイブリッド車両のパワーユニット上部など)を上から覆うようにエンジンルーム内に配置される。
A conventional vehicle cover material will be described with reference to the following drawings.
FIG. 7 is a diagram for explaining the basic configuration of a conventional engine cover. As shown in FIG. 7A, the engine cover 100 includes a polypropylene base 101 manufactured by injection molding, and FIG. As shown in b), it is composed of a sound-absorbing material 102 made of urethane or the like fixed to the back surface of the base material 101 by ultrasonic fusion or hot melt. It is arranged in the engine room so as to cover the upper part etc. from above.

基材101の表面104は意匠面を形成し、一方、吸音材102はエンジン音を吸収する。すなわち、エンジンカバー100は、フードを開けた際のエンジンルームの見栄えを良くする意匠部品であると共に、エンジン103や電動モータ等の騒音を低減する吸音部品でもある。 The surface 104 of the substrate 101 forms a design surface, while the sound absorbing material 102 absorbs engine sound. That is, the engine cover 100 is a design part that improves the appearance of the engine room when the hood is opened, and is also a sound absorbing part that reduces noise such as the engine 103 and the electric motor.

ところで、車両の軽量化が求められる中、エンジンカバー100の更なる軽量化が期待される。しかしながら、エンジンカバー100においては、ポリプロピレン及びウレタン一定の質量によって、必要な強度及び吸音性能を得ているため、単なる軽量化は容易ではない。質量を例示すると、基材101の板厚tが2.5mm、面密度が2500g/m、吸音材102の質量が35gである場合、エンジンカバー100の総質量は、550gに及ぶ。 By the way, while the weight reduction of a vehicle is calculated | required, the further weight reduction of the engine cover 100 is anticipated. However, in the engine cover 100, since the required strength and sound absorbing performance are obtained by a certain mass of polypropylene and urethane, it is not easy to simply reduce the weight. For example, when the plate thickness t of the substrate 101 is 2.5 mm, the surface density is 2500 g / m 2 , and the mass of the sound absorbing material 102 is 35 g, the total mass of the engine cover 100 reaches 550 g.

そこで、繊維強化樹脂からなる基材と、通気性フィルム等の吸音材とで積層体を構成し、この積層体を用いてエンジンカバーの軽量化を図ることが考えられる。従来より、このような積層体を用いた車両用フロアアンダーカバーが提案されている(例えば、特許文献1(図2)参照。)。 In view of this, it is conceivable to form a laminate of a base material made of fiber reinforced resin and a sound absorbing material such as a breathable film, and to reduce the weight of the engine cover using this laminate. Conventionally, a vehicle floor undercover using such a laminate has been proposed (see, for example, Patent Document 1 (FIG. 2)).

図8は、従来のフロアアンダーカバーの基本構成を説明する図であり、フロアアンダーカバー110は、タイヤにより巻き上げられる石や砂から車体下部を保護する保護カバーであり、グラスファイバーとオレフィン系樹脂と発泡剤を混合し、加熱膨張させた芯材111と、オレフィン系樹脂製の補強層112と、通気性フィルム113及び不織布114で構成された路面側吸音材115とを積層させてなる。 FIG. 8 is a diagram for explaining the basic configuration of a conventional floor undercover. The floor undercover 110 is a protective cover that protects the lower part of the vehicle body from stones and sand that are rolled up by tires, and includes glass fiber, olefin resin, and the like. A core material 111 mixed with a foaming agent and heated and expanded, a reinforcing layer 112 made of olefin resin, and a road surface side sound absorbing material 115 composed of a breathable film 113 and a nonwoven fabric 114 are laminated.

このフロアアンダーカバー110では、芯材111及び路面側吸音材115の作用により、路面側から車室内へ伝わる音を低減する。また、芯材111をグラスファイバーで強化することで、芯材111の軽量化が可能となる。   In this floor under cover 110, the sound transmitted from the road surface side to the vehicle interior is reduced by the action of the core material 111 and the road surface sound absorbing material 115. Moreover, the core material 111 can be reduced in weight by reinforcing the core material 111 with glass fiber.

特開2009-298339号公報JP 2009-298339

仮に、この特許文献1に開示される技術をエンジンカバーに適用した場合を考える。フロアアンダーカバー110のような積層体をエンジンカバーに使用すると、エンジンカバーを軽量化することは可能である。   Consider a case where the technique disclosed in Patent Document 1 is applied to an engine cover. When a laminated body such as the floor under cover 110 is used for the engine cover, it is possible to reduce the weight of the engine cover.

しかしながら、フロアアンダーカバー110の路面側吸音材115は、芯材111に通気性フィルム113及び不織布114を貼ったものであり、意匠性部品としての品質確保が困難である。この問題点は、エンジンカバーに限られるものではなく、エンジンルームにおいてエンジン周辺の箇所を覆う各種のカバー材についても同様に生ずる。 However, the road surface side sound absorbing material 115 of the floor under cover 110 is obtained by pasting the air permeable film 113 and the nonwoven fabric 114 to the core material 111, and it is difficult to ensure the quality as a designable part. This problem is not limited to the engine cover, and similarly occurs in various cover materials that cover portions around the engine in the engine room.

そこで、本発明は、上記問題点を解決するために、高い意匠性と吸音性能の適正化が図れ、しかも軽量化が実現できる車両用カバー材を提供することにある。   SUMMARY OF THE INVENTION In order to solve the above problems, an object of the present invention is to provide a vehicular cover material that can be optimized for high designability and sound absorption performance and can be reduced in weight.

請求項1に係る発明は、エンジンルームの所定箇所を覆う車両用カバー材において、繊維強化樹脂で形成される基材と、この基材の上面に設けられて意匠面を形成する非通気性で且つオレフィン系樹脂製又はオレフィン系樹脂エラストマーの表皮材と、前記基材の裏面に設けられ、通気度が5〜50cm/cm/secに設定される通気性フィルム又は不織布の裏面材と、からなることを特徴とする。 The invention according to claim 1 is a vehicle cover material that covers a predetermined portion of an engine room, and is a non-breathable material that is formed on a top surface of the base material and is formed on a top surface of the base material to form a design surface. And an olefin-based resin or olefin-based resin elastomer skin material, a breathable film or non-woven fabric back material provided on the back surface of the base material and having a permeability of 5 to 50 cm 3 / cm 2 / sec, It is characterized by comprising.

請求項2に係る発明では、基材は、発泡剤で加熱発泡された繊維強化樹脂であることを特徴とする。 In the invention which concerns on Claim 2, a base material is the fiber reinforced resin heat-foamed with the foaming agent, It is characterized by the above-mentioned.

請求項3に係る発明は、意匠面にシボ加工を施したことを特徴とする。 The invention according to claim 3 is characterized in that the design surface is textured.

請求項4に係る発明は、車両用カバー材がエンジンを上から覆うエンジンカバーであることを特徴とする。 The invention according to claim 4 is an engine cover in which the vehicle cover material covers the engine from above.

請求項1の発明では、裏面材の通気度を、エンジン音を吸音する上で好適な範囲(5〜50cm/cm/sec)から適宜設定し、表皮材を非通気性で且つオレフィン系樹脂製とした。 In the first aspect of the present invention, the air permeability of the back surface material is appropriately set from a range (5 to 50 cm 3 / cm 2 / sec) suitable for absorbing engine sound, and the skin material is non-breathable and olefinic. Made of resin.

本発明では、裏面材の通気度を5〜50cm/cm/secから設定することにより、低周波数域から高周波数域に至る広範囲において、適正な吸音性能が得られる。
更に、本発明では、表皮材を非通気性としたので、裏面材や基材の吸音作用に加え、表皮材の膜振動による吸音作用も得られる。結果、吸音性能を一層高めることができる。
In the present invention, by setting the air permeability of the back material from 5 to 50 cm 3 / cm 2 / sec, appropriate sound absorbing performance can be obtained in a wide range from the low frequency range to the high frequency range.
Furthermore, in the present invention, since the skin material is made non-breathable, in addition to the sound absorbing effect of the back material and the base material, the sound absorbing effect by the membrane vibration of the skin material can be obtained. As a result, the sound absorption performance can be further enhanced.

したがって、本発明によれば、エンジンルームにおいて、吸音性能の適正化が図れ、繊維強化樹脂による軽量化も実現できる車両用カバー材を提供することができる。   Therefore, according to the present invention, it is possible to provide a vehicular cover material that can optimize sound absorption performance in an engine room and can be reduced in weight by a fiber reinforced resin.

請求項2の発明では、基材を発泡剤で加熱発泡された繊維強化樹脂とした。
基材が板厚の厚い多孔質体となるため、更に吸音性能を高めることができる。
In the invention of claim 2, the base material is a fiber reinforced resin heated and foamed with a foaming agent.
Since the substrate is a porous body having a large plate thickness, the sound absorbing performance can be further improved.

請求項3の発明では、表皮材の材質をオレフィン系樹脂製、例えば、オレフィン系樹脂エラストマーとし、意匠面にシボ加工を施した。
シボ転写性の高い材料で表皮材を形成するため、意匠面に模様が鮮明に形成される。結果、車両用カバー材の意匠性を高めることができる。
In the invention of claim 3, the material of the skin material is made of an olefin resin, for example, an olefin resin elastomer, and the design surface is subjected to embossing.
Since the skin material is formed of a material having high texture transferability, a pattern is clearly formed on the design surface. As a result, the design of the vehicle cover material can be improved.

請求項4に係る発明では、車両用カバー材を、エンジンを上から覆うエンジンカバーとした。
本発明によれば、高い吸音性能が得られ、軽量化が実現できるエンジンカバーを提供することができる。
In the invention according to claim 4, the vehicle cover material is an engine cover that covers the engine from above.
According to the present invention, it is possible to provide an engine cover that can achieve high sound absorption performance and can be reduced in weight.

車両前部の斜視図であり、フードを開けた形態を示す図である。It is a perspective view of the front part of a vehicle, and is a figure showing the form which opened the hood. 本発明に係るエンジンカバーを説明する図であり、(a)は平面図、(b)は(a)のb−b線断面図である。It is a figure explaining the engine cover which concerns on this invention, (a) is a top view, (b) is the bb sectional view taken on the line of (a). 図2(b)の3部拡大図である。FIG. 3 is an enlarged view of a part 3 in FIG. 通気度を変化させたときの裏面材面側からの吸音特性を示すグラフである。It is a graph which shows the sound absorption characteristic from the back material surface side when changing an air permeability. エンジンカバーの製造方法を説明する図であり、(a)は加熱工程、(b)は素材セット工程、(c)は成形工程を説明する図である。It is a figure explaining the manufacturing method of an engine cover, (a) is a heating process, (b) is a raw material setting process, (c) is a figure explaining a shaping | molding process. エンジンカバーの作用を説明する図である。It is a figure explaining the effect | action of an engine cover. 従来のエンジンカバーを説明する図であり、(a)は平面図、(b)は(a)のb−b線断面図である。It is a figure explaining the conventional engine cover, (a) is a top view, (b) is the bb sectional view taken on the line of (a). 従来のフロアアンダーカバーの断面図である。It is sectional drawing of the conventional floor undercover.

以下、添付図面を参照して、本発明を実施するための形態(以下、実施形態)について詳細に説明する。なお、実施形態の説明の全体を通して同じ要素には同じ番号を付している。   DESCRIPTION OF EMBODIMENTS Hereinafter, embodiments for carrying out the present invention (hereinafter referred to as embodiments) will be described in detail with reference to the accompanying drawings. Note that the same number is assigned to the same element throughout the description of the embodiment.

図1に示すように、車両10は、フロントボディ11を備える。フロントボディ11は、車体12の側面前部を形成するフロントフェンダ13と、これらフロントフェンダ13を繋ぐフロントマスク14と、これらフロントフェンダ13及びフロントマスク14に被せるフード16とを備える。   As shown in FIG. 1, the vehicle 10 includes a front body 11. The front body 11 includes a front fender 13 that forms a front side surface of the vehicle body 12, a front mask 14 that connects the front fender 13, and a hood 16 that covers the front fender 13 and the front mask 14.

また、フロントマスク14にラジエータグリル17及びヘッドライト18、18が設けられる。フロントフェンダ13、フロントマスク14、フード16によって、エンジン21を収納するエンジンルーム22が形成される。エンジンルーム22には、エンジン21の他、動力伝達装置、吸気装置、排気装置、電装品等の各種の収納体が所定箇所に配置される。なお、エンジン21には、内燃機関の動力源の他、電動モータと内燃機関とを組み合わせた動力源(例えば、ハイブリッド車両のパワーユニット)も含まれる。   The front mask 14 is provided with a radiator grille 17 and headlights 18 and 18. An engine room 22 that houses the engine 21 is formed by the front fender 13, the front mask 14, and the hood 16. In the engine room 22, in addition to the engine 21, various storage bodies such as a power transmission device, an intake device, an exhaust device, and electrical components are arranged at predetermined positions. The engine 21 includes a power source (for example, a power unit of a hybrid vehicle) that combines an electric motor and an internal combustion engine in addition to the power source of the internal combustion engine.

エンジンルーム22には、エンジン21を上から覆うエンジンカバー30と、エンジンカバー30の車両幅方向の両側に隣接するルームサイドカバー60と、エンジンカバー30とフロントマスク14との間に配置されるルームフロントカバー70とが設けられる。   The engine room 22 includes an engine cover 30 that covers the engine 21 from above, a room side cover 60 that is adjacent to both sides of the engine cover 30 in the vehicle width direction, and a room that is disposed between the engine cover 30 and the front mask 14. A front cover 70 is provided.

これらのエンジンカバー30、ルームサイドカバー60、ルームフロントカバー70は、本発明の車両用カバー材に相当するものであり、それぞれの上面は、シボ加工が施された意匠面31、61、71として形成される。シボ加工による模様31a、31bは、梨地やサンドブラスト、皮状模様、幾何学模様など、各種のパターンから選択可能である。   The engine cover 30, the room side cover 60, and the room front cover 70 are equivalent to the vehicle cover material of the present invention, and the upper surfaces of the engine cover 30, the room side cover 60, and the room front cover 70 are the design surfaces 31, 61, 71 that are subjected to the texture processing. It is formed. The patterns 31a and 31b by the texture processing can be selected from various patterns such as satin, sandblast, skin pattern, and geometric pattern.

このように、エンジンカバー30、ルームサイドカバー60、ルームフロントカバー70をエンジンルーム22に配置することで、エンジンルーム22の上部全体が意匠面31、61、71で覆われるため、装飾性の高いエンジンルーム22の外観が得られる。   As described above, the engine cover 30, the room side cover 60, and the room front cover 70 are arranged in the engine room 22 so that the entire upper part of the engine room 22 is covered with the design surfaces 31, 61, 71. The appearance of the engine room 22 is obtained.

次に、エンジンカバー30の基本構成を図2、図3に基づいて説明する。
図2(a)に示すように、エンジンカバー30は、平面視で略長方形形状である。また、図2(b)に示すように、エンジンカバー30は、平板状の本体部32と、この本体部32の車両幅方向の両端部から下がる側壁部33とを備える。
Next, the basic configuration of the engine cover 30 will be described with reference to FIGS.
As shown in FIG. 2A, the engine cover 30 has a substantially rectangular shape in plan view. As shown in FIG. 2B, the engine cover 30 includes a flat plate-like main body portion 32 and side wall portions 33 that are lowered from both ends of the main body portion 32 in the vehicle width direction.

本体部32は、要求される強度や吸音性能、あるいは、エンジン21上部の位置や形状に応じて、各部の厚みが設定される。結果、本体部32には、厚肉部34と薄肉部35が形成される。   The thickness of each part of the main body 32 is set according to the required strength and sound absorption performance, or the position and shape of the upper part of the engine 21. As a result, a thick part 34 and a thin part 35 are formed in the main body part 32.

図3に示すように、エンジンカバー30は、三層構造で構成されており、繊維強化樹脂で形成される基材36と、この基材36の上面に設けられて意匠面31を形成する非通気性で且つオレフィン系樹脂製、例えば、オレフィン系樹脂エラストマーの表皮材37と、基材36の下面に設けられ、通気性を有する通気性フィルム又は不織布の裏面材38とからなる。   As shown in FIG. 3, the engine cover 30 has a three-layer structure, and includes a base material 36 formed of fiber reinforced resin and a non-surface that is provided on the upper surface of the base material 36 and forms a design surface 31. It consists of a breathable and olefin-based resin, for example, an olefin-based resin elastomer skin 37, and a breathable film or non-woven fabric back material 38 provided on the lower surface of the substrate 36.

基材36の材質は、グラスファイバーとポリプロピレンとからなる繊維強化樹脂、又は、グラスファイバーとポリプロピレンと発泡剤からなる発泡繊維強化樹脂が望ましい。基材36の板厚は、1〜30mmであり、基材36の面密度は、400〜2000g/mである。 The material of the base material 36 is desirably a fiber reinforced resin made of glass fiber and polypropylene, or a foamed fiber reinforced resin made of glass fiber, polypropylene and a foaming agent. The plate | board thickness of the base material 36 is 1-30 mm, and the surface density of the base material 36 is 400-2000 g / m < 2 >.

表皮材37の材質は、シボ加工における転写性や成形性を考慮すると、エチレン−プロピレンゴムに代表されるオレフィン系樹脂エラストマー製のシートが望ましい。しかし、用途に応じて、ポリプロピレンなどのオレフィン系樹脂製のフィルム又はシートから任意に選定可能である。表皮材37の板厚は、0.3〜1.0mmである。表皮材37の面密度は、300〜1000g/mである。 The material of the skin material 37 is preferably a sheet made of an olefin resin elastomer typified by ethylene-propylene rubber in consideration of transferability and moldability in embossing. However, it can be arbitrarily selected from a film or sheet made of an olefin resin such as polypropylene according to the application. The plate thickness of the skin material 37 is 0.3 to 1.0 mm. The surface density of the skin material 37 is 300 to 1000 g / m 2 .

裏面材38は、通気性のフィルム又は不織布からなる。裏面材38の面密度は、10〜200g/mである。裏面材38の板厚は、フィルムの場合、0.04〜0.2mm、不織布の場合、0.2〜1.2mmである。裏面材の通気度は、エンジンカバー30に要求される吸気性能に応じて、エンジン音に対して好適な範囲(5〜50cm/cm/sec)から設定される。なお、この通気度は、フラジール法により求めた数値である。 The back material 38 is made of a breathable film or a nonwoven fabric. The surface density of the back material 38 is 10 to 200 g / m 2 . The plate | board thickness of the back surface material 38 is 0.04-0.2 mm in the case of a film, and is 0.2-1.2 mm in the case of a nonwoven fabric. The air permeability of the back surface material is set from a range (5 to 50 cm 3 / cm 2 / sec) suitable for the engine sound according to the intake performance required for the engine cover 30. This air permeability is a numerical value obtained by the Frazier method.

この好適な範囲(5〜50cm/cm/sec)を定めるための実験例を以下に述べる。なお、本発明は実験例に限定されるものではない。 An experimental example for determining this preferable range (5 to 50 cm 3 / cm 2 / sec) will be described below. Note that the present invention is not limited to experimental examples.

(実験例)
・試料
裏面材、グラスウール、シートからなる3層の積層体を想定
裏面材:面密度50g/m 板厚0.15mm
グラスウール:面密度1000g/m 板厚10mm
表皮材:面密度350g/m 板厚0.5mm
・方法
裏面材の通気度を変化させ、以下の実験1〜8を設定し、各実験において、1/3オクターブバンド中心周波数(Hz)に対する垂直入射吸音率を調べる。
(Experimental example)
-Sample Assume a three-layer laminate consisting of a back material, glass wool, and a sheet. Back material: surface density 50 g / m 2 plate thickness 0.15 mm
Glass wool: surface density 1000g / m 2 thickness 10mm
Skin material: surface density 350 g / m 2 plate thickness 0.5 mm
-Method By changing the air permeability of the back material, the following experiments 1 to 8 are set, and in each experiment, the normal incident sound absorption coefficient with respect to the center frequency (Hz) of 1/3 octave band is examined.

・実験1 裏面材の通気度:3.0cm/cm/sec
・実験2 裏面材の通気度:5.7cm/cm/sec
・実験3 裏面材の通気度:10cm/cm/sec
・実験4 裏面材の通気度:20cm/cm/sec
・実験5 裏面材の通気度:30cm/cm/sec
・実験6 裏面材の通気度:50cm/cm/sec
・実験7 裏面材の通気度:70cm/cm/sec
・実験8 裏面材の通気度:100cm/cm/sec
Experiment 1 Air permeability of the back surface material: 3.0 cm 3 / cm 2 / sec
Experiment 2 Air permeability of the back surface material: 5.7 cm 3 / cm 2 / sec
Experiment 3 Air permeability of the back material: 10 cm 3 / cm 2 / sec
Experiment 4 Air permeability of the back surface material: 20 cm 3 / cm 2 / sec
Experiment 5 Air permeability of the back surface material: 30 cm 3 / cm 2 / sec
Experiment 6 Air permeability of the back material: 50 cm 3 / cm 2 / sec
Experiment 7 Air permeability of the back material: 70 cm 3 / cm 2 / sec
Experiment 8 Air permeability of the back surface material: 100 cm 3 / cm 2 / sec

実験1〜8の結果を図4に示す。図中、横軸は、1/3オクターブバンド中心周波数(Hz)、縦軸は垂直入射吸音率である。
図4に示すように、実験1〜4の結果より、通気度が小さいと、低周波数域では吸音率が高くなる一方、高周波数域では吸音率が低くなる傾向を示した。また、実験5〜8の結果より、通気度が大きいと、低周波数域では吸音率が低くなる一方、高周波数域では吸音率が高くなる傾向を示した。
The results of Experiments 1-8 are shown in FIG. In the figure, the horizontal axis represents the 1/3 octave band center frequency (Hz), and the vertical axis represents the normal incident sound absorption coefficient.
As shown in FIG. 4, from the results of Experiments 1 to 4, when the air permeability was small, the sound absorption rate increased in the low frequency range, whereas the sound absorption rate tended to decrease in the high frequency range. In addition, from the results of Experiments 5 to 8, when the air permeability is large, the sound absorption rate is low in the low frequency range, while the sound absorption rate tends to be high in the high frequency range.

この結果より、裏面材の通気度を大きく設定し過ぎると、エンジンルーム内において、低周波数域での吸音性能が得にくくなり、小さく設定し過ぎると、高周波数域での吸音性能が得にくくなることが分かる。
以上の実験結果を総合的に考えると、低周波数域から高周波数域に至る広範囲Rに対して適正な吸音性能を得るためには、裏面材の通気度は5〜50cm/cm/secの範囲から選択することが、有効であると言える。
From this result, if the air permeability of the back material is set too large, it is difficult to obtain sound absorbing performance in the low frequency range in the engine room, and if it is set too small, it is difficult to obtain sound absorbing performance in the high frequency range. I understand that.
Considering the above experimental results comprehensively, in order to obtain an appropriate sound absorbing performance over a wide range R from the low frequency range to the high frequency range, the air permeability of the back surface material is 5 to 50 cm 3 / cm 2 / sec. It can be said that selecting from the range is effective.

次に、エンジンカバー30の製造方法を図5に基づいて説明する。
エンジンカバー30の製造方法は、三層素材を加熱する加熱工程と、加熱された三層素材を金型にセットする素材セット工程と、三層素材をプレス成形する成形工程とからなる。
Next, a method for manufacturing the engine cover 30 will be described with reference to FIG.
The manufacturing method of the engine cover 30 includes a heating process for heating the three-layer material, a material setting process for setting the heated three-layer material in a mold, and a molding process for press-molding the three-layer material.

図5(a)に示すように、加熱工程では、予め製造した表皮材の素材41、基材の素材42、裏面材の素材43を重ね、三層素材45を形成し、この三層素材45をヒータ46で加熱して軟化させる。基材の素材42に発泡剤を配合したときは、熱反応により、基材の素材42を十分に膨張させる。   As shown in FIG. 5 (a), in the heating process, a previously manufactured skin material 41, base material 42, and back material 43 are stacked to form a three-layer material 45. This three-layer material 45 Is heated by the heater 46 and softened. When a foaming agent is added to the base material 42, the base material 42 is sufficiently expanded by a thermal reaction.

図5(b)に示すように、素材セット工程では、軟化した三層素材45を上型47と下型48の間にセットする。なお、上型47の成形面51には、素材の表面(意匠面)52に転写させる模様が刻まれる。また、上型47に真空ポンプ53が弁54を介して接続される。   As shown in FIG. 5B, in the material setting step, the softened three-layer material 45 is set between the upper die 47 and the lower die 48. A pattern to be transferred to the surface (design surface) 52 of the material is engraved on the molding surface 51 of the upper mold 47. Further, a vacuum pump 53 is connected to the upper mold 47 via a valve 54.

図5(c)に示すように、成形工程では、表面52を真空ポンプ53で真空引きしながら、上型47と下型48で三層素材45をプレスし、本体部32、側壁部33、厚肉部34、薄肉部35を成形し、所定の寸法のエンジンカバー30を得る。この真空成形により、表面52が上型47の成形面51に良好に密接するため、シボ加工による模様が表面52に鮮明に形成される。   As shown in FIG. 5 (c), in the molding process, the three-layer material 45 is pressed by the upper mold 47 and the lower mold 48 while the surface 52 is evacuated by the vacuum pump 53, and the main body 32, the side wall 33, The thick part 34 and the thin part 35 are molded to obtain the engine cover 30 having a predetermined size. By this vacuum forming, the surface 52 is in good contact with the forming surface 51 of the upper die 47, so that a textured pattern is clearly formed on the surface 52.

なお、この製造方法では、三層素材45を加熱して成形した。しかし、表皮材の素材41と基材の素材42を重ねた二層素材と、裏面材の素材43とを別々に加熱し、これら二つの素材を成形工程前に積層圧着し、得られた三層素材をプレス成形してもよい。   In this manufacturing method, the three-layer material 45 was heated and molded. However, the two-layer material in which the skin material 41 and the base material 42 are stacked and the back material 43 are heated separately, and these two materials are laminated and pressure-bonded before the molding process, and the three obtained The layer material may be press-molded.

また、成形工程において、上型47のみで真空引きを行ったが、上型47及び下型48のそれぞれで真空引きを行うことができる。この場合、素材41と素材42と素材43が良好に圧着する上、成形時間と冷却時間を短縮することもできる   Further, in the molding process, evacuation is performed only with the upper die 47, but evacuation can be performed with each of the upper die 47 and the lower die 48. In this case, the material 41, the material 42, and the material 43 can be pressure-bonded well, and the molding time and the cooling time can be shortened.

以上説明したエンジンカバー30の作用を説明する。
図6に示すように、裏面材38の通気度を好適な範囲(5〜50cm/cm/sec)から設定したので、低周波数域から高周波数域に至る広範囲において、エンジン21からの音は、裏面材38へ入射し(矢印(1))、裏面材38及び基材36にて良好に吸音される(矢印(2))。更に、基材36を発泡剤で加熱発泡された繊維強化樹脂とすれば、基材36が板厚の大なる多孔質体となるため、吸音性能が一層高まる。加えて、表皮材37を非通気性としたので、裏面材38や基材36の吸音作用に加え、表皮材37の膜振動による吸音作用も得られる。
The operation of the engine cover 30 described above will be described.
As shown in FIG. 6, since the air permeability of the back material 38 is set from a suitable range (5 to 50 cm 3 / cm 2 / sec), the sound from the engine 21 is wide in a wide range from a low frequency range to a high frequency range. Enters the back material 38 (arrow (1)) and is well absorbed by the back material 38 and the substrate 36 (arrow (2)). Furthermore, if the base material 36 is a fiber reinforced resin heated and foamed with a foaming agent, the base material 36 becomes a porous body having a large plate thickness, so that the sound absorbing performance is further enhanced. In addition, since the skin material 37 is made air-impermeable, in addition to the sound absorbing action of the back material 38 and the base material 36, the sound absorbing action by the membrane vibration of the skin material 37 is also obtained.

また、基材36を繊維強化樹脂としたので、エンジンカバー30の軽量化を実現することができる。例えば、基材36の面密度を1000g/m、表皮材の面密度を400g/m、裏面材38の面密度を100g/mに設定した場合、エンジンカバー30の総質量を300gに抑えることができる。これにより、従来のエンジンカバー(図7(b)、符号100)の総質量550gに比べて、大幅にエンジンカバーの軽量化を実現することができる。 Moreover, since the base material 36 is made of fiber reinforced resin, the weight of the engine cover 30 can be reduced. For example, when the surface density of the base material 36 is set to 1000 g / m 2 , the surface density of the skin material is set to 400 g / m 2 , and the surface density of the back material 38 is set to 100 g / m 2 , the total mass of the engine cover 30 is set to 300 g. Can be suppressed. Thereby, compared with the total mass 550g of the conventional engine cover (FIG.7 (b), code | symbol 100), the weight reduction of an engine cover can be implement | achieved significantly.

また、シボ加工における転写性の高いオレフィン系樹脂製、例えば、オレフィン系樹脂エラストマーで表皮材37を形成すれば、意匠面31に模様(図2(a)、符号31a・31b)が更に鮮明に形成される。結果、エンジンカバー30の意匠性を一層高めることができる。   Further, if the skin material 37 is made of an olefin resin having a high transferability in the embossing process, for example, an olefin resin elastomer, the pattern (FIG. 2 (a), reference numerals 31a and 31b) becomes clearer on the design surface 31. It is formed. As a result, the design of the engine cover 30 can be further enhanced.

なお、実施形態では、エンジンカバー30の構成を説明したが、エンジンカバー30の基本構成は、ルームサイドカバー(図1、符号60)、フロントサイドカバー(図1、符号70)についても同様である。   Although the configuration of the engine cover 30 has been described in the embodiment, the basic configuration of the engine cover 30 is the same for the room side cover (FIG. 1, reference numeral 60) and the front side cover (FIG. 1, reference numeral 70). .

以上、実施形態を用いて本発明を説明したが、本発明の技術的範囲は上記実施形態に記載の範囲には限定されないことは言うまでもない。上記実施形態に、多様な変更または改良を加えることが可能であることが当業者に明らかである。またその様な変更または改良を加えた形態も本発明の技術的範囲に含まれ得ることが、特許請求の範囲の記載から明らかである。   As mentioned above, although this invention was demonstrated using embodiment, it cannot be overemphasized that the technical scope of this invention is not limited to the range as described in the said embodiment. It will be apparent to those skilled in the art that various modifications or improvements can be added to the above-described embodiments. Further, it is apparent from the scope of the claims that the embodiments added with such changes or improvements can be included in the technical scope of the present invention.

10・・・車両、21・・・エンジン、22・・・エンジンルーム、30・・・エンジンカバー(車両用カバー材)、31・・・意匠面、36・・・基材、37・・・表皮材、38・・・裏面材、60・・・ルームサイドカバー(車両用カバー材)、61・・・意匠面、70・・・ルームフロントカバー(車両用カバー材)、71・・・意匠面。 DESCRIPTION OF SYMBOLS 10 ... Vehicle, 21 ... Engine, 22 ... Engine room, 30 ... Engine cover (cover material for vehicles), 31 ... Design surface, 36 ... Base material, 37 ... Skin material 38 ... Back material 60 ... Room side cover (vehicle cover material) 61 ... Design surface 70 ... Room front cover (vehicle cover material) 71 ... Design surface.

Claims (4)

エンジンルームの所定箇所を覆う車両用カバー材において、
繊維強化樹脂で形成される基材と、
この基材の上面に設けられて意匠面を形成する非通気性で且つオレフィン系樹脂製又はオレフィン系樹脂エラストマーの表皮材と、
前記基材の裏面に設けられ、通気度が5〜50cm/cm/secに設定される通気性フィルム又は不織布の裏面材と、からなることを特徴とする車両用カバー材。
In the vehicle cover material covering a predetermined part of the engine room,
A substrate formed of fiber reinforced resin;
A non-breathable olefin resin or olefin resin elastomer skin material provided on the upper surface of the base material to form a design surface;
A vehicle cover material comprising a breathable film or a non-woven fabric back material provided on the back surface of the base material and having an air permeability of 5 to 50 cm 3 / cm 2 / sec.
前記基材は、発泡剤で加熱発泡された繊維強化樹脂であることを特徴とする請求項1記載の車両用カバー材。   2. The vehicle cover material according to claim 1, wherein the base material is a fiber reinforced resin heated and foamed with a foaming agent. 前記意匠面にシボ加工を施したことを特徴とする請求項1又は請求項2記載の車両用カバー材。   3. The vehicle cover material according to claim 1, wherein the design surface is subjected to a textured process. エンジンを上から覆うエンジンカバーであることを特徴とする請求項1〜請求項3のいずれか1項記載の車両用カバー材。   The vehicle cover material according to any one of claims 1 to 3, wherein the vehicle cover material covers an engine from above.
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