JP2019051749A - Silencer for vehicle, and method for manufacturing the same - Google Patents

Abstract

To provide a silencer for a vehicle in which the texture is improved.SOLUTION: A molded silencer 1 for a vehicle includes inserts 10 made of a foamed resin, and a main body part 40 that is formed by a foamed resin with a different material from the insert 10 and that shows elasticity. The insert 10 has a first surface 11 on the side of a surface 2 of the silencer 1 and a second surface 12 on the side of an inside 3 of the silencer 1, and is exposed at part of the surface 2 of the silencer 1. Also, the insert 10 has through holes 15 connecting the first surface 11 and the second surface 12. An opening rate Ro of the through holes 15 is 5 to 50% in the first surface 11. The insert 10 is integrated with the main body part 40, part of which is inserted into the through holes 15.SELECTED DRAWING: Figure 2

Description

  The present invention relates to a molded silencer for a vehicle and a method for manufacturing the same.

  As a silencer installed in an automobile, for example, a floor silencer interposed between a floor panel and a floor carpet is known. The floor silencer exhibits soundproof performance and also functions to prevent the unevenness of the floor panel from appearing on the surface of the carpet and to give the passenger a good feel when stepping on the foot. As a silencer for realizing these functions, a fibrous silencer is used.

It is also conceivable to use a flexible polyurethane foam exhibiting elasticity for the silencer. At that time, in order to improve the rigidity of the silencer, it is conceivable to use an insert together.
Patent Document 1 discloses a polyurethane resin foam integrally having an insert member made of an iron plate or a synthetic resin molded product therein. That is, the insert member is covered with the polyurethane resin foam and does not appear on the surface of the polyurethane resin foam.

Japanese Utility Model Publication No. 57-77062

Since the flexible polyurethane foam is soft, there is a possibility of giving the occupant a feel that is too soft when stepped on with a foot even if there is an insert inside.
The above-described problem may also exist in vehicle silencers other than floor silencers, such as door trim silencers.

  The present invention discloses a vehicle silencer with improved feel.

The present invention is a molded silencer for a vehicle,
A first surface on the surface side of the silencer and a second surface on the inner side of the silencer, and an insert made of foamed resin that appears on a part of the surface of the silencer;
A body portion formed of a foamed resin of a different material from the insert and exhibiting elasticity;
The insert has a through hole connected from the first surface to the second surface;
The opening ratio of the through hole in the first surface is 5 to 50%;
The said insert has the aspect integrated with the said main-body part in which a part has entered the said through-hole.

The present invention is also a method for manufacturing a molded silencer for a vehicle,
The first surface that is the surface side of the silencer, the second surface that is the inner side of the silencer, and the first surface is connected to the second surface, and the aperture ratio in the first surface is 5 to 50%. A step of setting a foamed resin insert having a through hole in a cavity of a mold;
A foamable resin material made of a material different from that of the insert is inserted into the cavity so as to enter the through-hole from the second surface side, and a body portion showing elasticity in a state where the insert appears on a part of the surface of the silencer. And foam molding.

  ADVANTAGE OF THE INVENTION According to this invention, the silencer for vehicles which improved the touch can be provided.

The disassembled perspective view which illustrates typically the appearance by the side of the cabin of a silencer and skin material. The figure which shows typically the example of a vertical cross section when a silencer is cut | disconnected in the position corresponded to A1 of FIG. 1 with a vehicle body panel and a skin material. The exploded view which shows typically the example of a vertical cross section when a silencer is cut | disconnected in the position corresponded to A1 of FIG. The figure which shows the example of the 1st surface of insert typically. The figure which shows the example of the uneven | corrugated shape of the 1st surface of insert typically. The figure which shows the example of the uneven | corrugated shape of the 1st surface of insert typically. The figure which shows typically the example of the manufacturing method of a silencer. The figure which illustrates typically a mode that the foaming resin material is inject | poured into the cavity of a shaping | molding die. The figure which illustrates typically a mode that the remaining gas escapes to the uneven | corrugated shape of the 1st surface of a parting line and insert. The figure which shows typically the example of the skin side of the silencer by which insert molding was carried out.

  Embodiments of the present invention will be described below. Of course, the following embodiments are merely examples of the present invention, and all the features shown in the embodiments are not necessarily essential to the means for solving the invention.

(1) Summary of technology included in the present invention:
First, the outline | summary of the technique included in this invention is demonstrated with reference to the example shown by FIGS. In addition, the figure of this application is a figure which shows an example typically, The expansion ratio of each direction shown by these figures may differ, and each figure may not match. Of course, each element of the present technology is not limited to the specific example indicated by the reference numeral.

[Aspect 1]
A silencer 1 according to an aspect of the present technology is a molded silencer 1 for a vehicle, and is formed of a foamed resin insert 10 and a foamed resin made of a material different from that of the insert 10 and exhibits elasticity. 40. The insert 10 has a first surface 11 on the surface 2 side of the silencer 1 and a second surface 12 on the inside 3 side of the silencer 1, and appears on a part of the surface 2 of the silencer 1. . Further, the insert 10 has a through hole 15 connected from the first surface 11 to the second surface 12. The opening ratio Ro of the through hole 15 in the first surface 11 is 5 to 50%. The insert 10 is integrated with the main body 40 that is partially in the through hole 15.
In the present application, “Min to Max” means a minimum value Min or more and a maximum value Max or less.

In the first aspect, the foamed resin insert 10 appears on a part of the surface 2 of the silencer 1, and a part of the main body portion 40 showing elasticity in the through hole 15 having an opening ratio Ro = 5 to 50% of the insert 10 is formed. The silencer 1 does not feel too hard or too soft. Therefore, this aspect can provide a vehicle silencer with improved feel.
In addition, since foamed resins of different materials appear on the surface of the silencer, it is possible to improve the sound absorbing performance of the silencer.

Here, the locations where the vehicle silencer of the present technology can be installed include the vehicle compartment floor, vehicle compartment side wall, vehicle compartment ceiling, deck floor, dashboard, engine hood, fender, etc. It may be an interior part or an exterior part.
All of the first surface of the insert may appear on the surface of the silencer, or only a part of the first surface of the insert may appear. Either case is included in the first aspect.
A silencer in which another member is attached to the insert and the main body portion afterward is also included in the first aspect.
In addition, the remarks of the said aspect 1 are the same also in the following aspects.

[Aspect 2]
As illustrated in FIGS. 4, 5 and the like, the first surface 11 of the insert 10 is formed with a concavo-convex shape 20 having a groove portion 21 connected from the through hole 15 to the main body portion 40 around the insert 10. May be. When the foamable resin material 50 is formed by arranging the insert 10 having the uneven shape 20, the gas Gs (see FIG. 9) in the cavity CA1 escapes to the groove portion 21, so that a conspicuous void (void) is a main body portion. 40 hardly occurs. Therefore, this aspect can provide a vehicle silencer with a further improved feel.
Moreover, since the uneven shape of the insert appears on the surface of the silencer, the contact area between the silencer and the skin material is reduced. Thereby, generation | occurrence | production of the noise when a skin material is pushed can be suppressed.
In addition, although it is not included in the said aspect 2, the case where the 1st surface of an insert does not have the uneven | corrugated shape 20 is also included in this technique.

[Aspect 3]
As illustrated in FIG. 3 and the like, the edge portion 11a of the first surface 11 of the insert 10 is formed with a step portion 30 that is lowered toward the inside 3 side of the silencer 1 and is covered with the main body portion 40. Also good. In this aspect, since the edge portion 11a of the first surface 11 of the insert 10 is hooked on the main body portion 40, it is possible to provide a vehicle silencer that makes it difficult to remove the insert from the main body portion.
In addition, although it is not included in the said aspect 3, the case where there is no step part 30 in the edge of the 1st surface of insert is also included in this technique.

[Aspect 4]
By the way, the manufacturing method of the silencer 1 which concerns on 1 aspect of this technique is a manufacturing method of the silencer 1 shape | molded for vehicles, Comprising: Set process ST1 and molding process ST2. In the setting step ST <b> 1, the first surface 11 that is the surface 2 side of the silencer 1, the second surface 12 that is the inside 3 side of the silencer 1, and the first surface 11 are connected to the second surface 12. Then, the foamed resin insert 10 having the through hole 15 having an opening ratio Ro of 5 to 50% in the first surface 11 is set in the cavity CA1 of the mold 210. In the molding step ST2, a foamable resin material 50 made of a material different from that of the insert 10 is placed in the cavity CA1 so as to enter the through hole 15 from the second surface 12 side, and is formed on a part of the surface 2 of the silencer 1. In the state where the insert 10 appears, the main body 40 showing elasticity is foam-molded.

  In the aspect 4, the foamed resin insert 10 appears on a part of the surface 2 of the silencer 1 to be obtained, and the insert 10 has an opening ratio Ro = 5 to 50%. Since the part enters, the feel of the silencer 1 is not too hard or too soft. Therefore, this aspect can provide a method for manufacturing a vehicle silencer with improved feel.

(2) Specific examples of vehicle silencers:
FIGS. 1-10 has shown the example which applied the silencer for vehicles of this technique to the silencer for motor vehicle floors. In these figures, FRONT, REAR, LEFT, RIGHT, UP, and DOWN indicate front, rear, left, right, top, and bottom, respectively. The left and right positional relationship is based on the direction of sitting in the driver's seat of the car and looking forward. In addition, the code | symbol D1 shown in FIG. 2 etc. shows the thickness direction of the silencer 1 for vehicles. Although the thickness direction D1 shown in FIG. 2 is an up-down direction, the thickness direction of a silencer can have various directions according to an installation location.

FIG. 1 schematically illustrates the appearance of the vehicle silencer 1 and the floor carpet 70 (an example of a skin material) on the side of the passenger compartment C1. In FIG. 1, the silencer 1 and the carpet 70 are disassembled and shown. FIG. 2 schematically illustrates a vertical section when the silencer 1 is cut along with the vehicle body panel 80 and the carpet 70 at a position corresponding to A1 in FIG.
On the floor panel (the vehicle body panel 80 illustrated in FIG. 2) in the passenger compartment of an automobile, a floor carpet 70 as illustrated in FIG. 1 is usually laid to cover and shield the floor panel. Thereby, the interior designability as a passenger room and the step comfort that means a good feel when the passenger steps on the foot are imparted. The carpet 70 shown in FIGS. 1 and 2 is press-molded to form a concave / convex shape 72 on the side of the passenger compartment C1, and is disposed facing the passenger compartment C1. The carpet 70 can be a tufted carpet, a needle punch carpet, or the like.

  The floor panel has a concavo-convex shape including a raised portion at the center in the vehicle width direction, a rising portion at the edge in the vehicle width direction, and the like. In order to absorb this uneven shape and ensure the flatness of the floor surface, a floor silencer functioning as a bulking material is installed between the floor panel and the floor carpet.

  The floor silencer 1 formed by insert molding is disposed on the back surface 74 of the footrest 73 of the floor carpet 70 shown in FIGS. The skin side 1 a of the silencer 1 is a surface along the back surface 74 of the carpet 70, and the panel side 1 b of the silencer 1 is a surface along the surface of the vehicle body panel 80 on the vehicle interior side. The silencer 1 shown in FIGS. 1 and 2 has a flat shape as a whole, with the skin side 1a and the panel side 1b parallel to each other. Although four silencers 1 are shown in FIG. 1, at least some of them may be integrated with each other. Further, the skin side 1 a of the silencer 1 may be bonded to the back surface 74 of the carpet 70 or may not be bonded to the back surface 74 of the carpet 70. The panel side 1 b of the silencer 1 is in contact with the vehicle body panel 80. The silencer of the present technology is not only installed on the floor part, but also in accordance with the shape of the parts such as the vehicle compartment side wall, vehicle compartment ceiling, deck floor, dashboard, engine hood, fender, etc. It is also possible to install in. Of course, the skin material is not limited to a carpet, and may be a non-woven fabric, a woven fabric, a knitted fabric, or the like.

FIG. 3 schematically illustrates a vertical section when the silencer 1 is cut at a position corresponding to A1 in FIG. In FIG. 3, the insert 10 and the main body 40 are shown in an exploded manner.
The silencer 1 shown in FIGS. 1 to 3 includes a foam resin insert 10 and a main body 40 formed of a foam resin made of a material different from that of the insert 10.

  The main body 40 shown in FIG. 3 has an open cell structure that is a cell structure in which fine bubbles B2 are continuous, and thus exhibits elasticity including volume elasticity. Elasticity means a property in which an object that is distorted (deformed) by an external force generates a force that attempts to restore the distortion. Volume elasticity means the property that an object subjected to a strain whose volume changes due to an external force generates a force that attempts to restore the strain. The main body 40 exhibits greater elasticity than the insert 10, and particularly exhibits greater volume elasticity than the insert 10.

The insert 10 shown in FIG. 3 has a closed cell structure in which fine cells B1 are independent cell structures. The insert 10 is harder than the main body 40 and improves the rigidity of the silencer 1. The insert 10 shown in FIG. 3 has a flat plate shape as a whole, with the first surface 11 on the surface 2 side of the silencer 1 and the second surface 12 on the inner 3 side of the silencer 1 being parallel to each other.
The insert 10 is not entirely covered by the main body 40, but a part of the insert 10 appears on the surface 2 of the silencer 1. A part of the first surface 11 of the insert 10 appears on the front surface 2 of the silencer 1 so as to contact the back surface 74 of the carpet 70. The first surface 11 means a surface on the carpet 70 side, and includes a stepped portion 30 that is lowered to the inside 3 side of the silencer 1. The step portion 30 is on the edge portion 11 a of the first surface 11 of the insert 10 and is covered with the main body portion 40. The position of the first surface 11 appearing on the surface 2 is adjusted to the positions of the surrounding and inner body portions 40. The second surface 12 of the insert 10 is entirely covered with the main body 40. The insert 10 does not appear on the panel side 1b of the silencer 1 shown in FIGS. Of course, it is also possible to design the second surface 12 of the insert 10 to appear on a part of the panel side 1b of the silencer 1. The insert 10 shown in FIGS. 2 and 3 has a plurality of through holes 15 connected from the first surface 11 to the second surface 12. Each through hole 15 penetrates the insert 10 in the thickness direction D1. The opening ratio Ro (see FIG. 4) of the plurality of through holes 15 in the first surface 11 is 5 to 50% (more preferably 25 to 40%).

FIG. 4 schematically illustrates the first surface 11 of the insert 10. Here, a virtual plane PL1 (see FIG. 3) orthogonal to the thickness direction D1 of the silencer 1 at the center CE1 set on the first surface 11 is assumed. The center CE <b> 1 is an intermediate position in the longest portion of two directions (for example, the vehicle longitudinal direction and the vehicle width direction) orthogonal to each other on the first surface 11. The opening ratio Ro of the through hole 15 in the first surface 11 is all relative to the entire area S1 of the first surface 11 (including the area S2 of the through hole 15) when the first surface 11 is projected onto the virtual plane PL1. It is set as a percentage of area S2 which put together the through-hole 15 of.
Ro = (S2 / S1) × 100%
Each through-hole 15 contains a part of the main body 40 (the entry portion 42). The insert 10 is integrated with the main body 40 that is partially in the through hole 15. Since the main body portion 40 is bonded to at least the second surface 12 and the inner side surface 15a of the through hole 15 in the insert 10, the adhesive strength between the insert 10 and the main body portion 40 is improved as compared with the case where the through hole 15 is not provided. ing.

  The insert 10 can be formed of a synthetic resin such as a thermoplastic resin. Examples of the thermoplastic resin include polyolefin resins such as polypropylene (PP) resin and polyethylene (PE) resin, polystyrene (PS) resin, acrylonitrile styrene (AS) resin, resins obtained by modifying these resins, combinations thereof, and the like. Can be used. From the viewpoint of improving the durability of the silencer 1, for example, PP resin is a preferred thermoplastic resin. The synthetic resin may contain additives such as fillers and colorants as long as the effects are not impaired. For the insert 10, a foamed particle molded body, an injection foam molded body, or the like can be used. For example, a large number of foamable resin particles are formed by impregnating a foamed bead-like or cylindrical thermoplastic resin with a foaming agent and pre-foamed at a predetermined magnification, and the foams are formed in a mold having the shape of the insert 10. When the foamable resin particles are filled and the mold is heated to foam and fuse the numerous foamable resin particles, a foamed particle molded body can be formed. Further, when a resin material is injected into a mold having the shape of the insert 10 and foamed with a foaming agent and molded, an injection foam molded article can be obtained. As the foaming agent, a volatile foaming agent that generates hydrocarbons such as butane and pentane, an inorganic foaming agent that generates carbon dioxide gas such as ammonium carbonate, and the like can be used. From the point of improving the durability of the silencer 1, for example, a molded body of bead-shaped expandable resin particles is preferable as the insert 10.

The cell structure of the bubble B1 of the insert 10 is preferably a closed cell structure from the viewpoint of making the insert 10 lightweight and highly rigid. The foaming ratio of the insert 10 can be, for example, about 10 to 50 times (more preferably about 20 to 40 times). The density of the foamed molded product can be, for example, about 0.02 to 0.1 g / cm ³ (more preferably about 0.03 to 0.05 g / cm ³ ).

  The main body 40 can be formed of a synthetic resin made of a material different from that of the insert 10. The synthetic resin is preferably a polyurethane resin that forms a flexible polyurethane foam, but a PE resin, a PS resin, an AS resin, a resin obtained by modifying these resins, a combination thereof, or the like can also be used. The synthetic resin may contain additives such as fillers and colorants as long as the effects are not impaired. The flexible polyurethane foam is a foamed material mainly composed of polyol and polyisocyanate. Carbon dioxide gas generated by the reaction of water and isocyanate can be used as the gas for foaming the material. In addition, a foaming agent such as a volatile foaming agent, a foam stabilizer, a catalyst, and the like may be mixed with the material forming the flexible polyurethane foam. Flexible polyurethane foams include polyester foams and polyether foams having different polyol structures.

The cell structure of the bubble B2 of the main body 40 is preferably an open cell structure from the viewpoint of imparting a large volume elasticity to the main body 40. The expansion ratio of the main body 40 can be, for example, about 10 to 50 times (more preferably about 15 to 25 times). The density of the foam molded article can be set to, for example, about 0.02 to 0.1 g / cm ³ (more preferably about 0.04 to 0.08 g / cm ³ ).

  The reason why the opening ratio Ro shown in FIG. 4 is 5% or more is to make the feel (stepping comfort) when the carpet 70 is stepped on with a foot flexible. More preferable flexible foot comfort is obtained when the opening ratio Ro is 25% or more. The reason why the opening ratio Ro is set to 50% or less is to obtain a stable rigidity feeling so as not to sink too much when the carpet 70 is stepped on with a foot. A more preferable feeling of rigidity is obtained when the aperture ratio is 40% or less.

  FIG. 5 schematically illustrates a main part of the uneven shape 20 on the first surface 11 of the insert 10. The concavo-convex shape 20 shown in FIG. 5 has a large number of cylindrical convex portions 22 protruding in the thickness direction D1 of the silencer 1. Each convex part 22 is separated from the adjacent convex part 22. Accordingly, the convex portions 22 are connected in a groove shape. A portion connected to the groove shape in the concavo-convex shape 20 is referred to as a groove portion 21. As shown in the skin side 1 a of the silencer 1 in FIG. 10, the groove portion 21 of the first surface 11 of the insert 10 is connected to the main body portion 40 around the insert 10 from the through hole 15. In the case of the silencer 1 shown in FIG. 10, the groove portion 21 has a groove portion 21 a connected from the through hole 15 to the main body portion 40 around the insert 10 at the shortest distance, and a through hole adjacent to the through hole 15 at the shortest distance. A groove portion 21 b connected to the hole 15 is included. Since this groove part 21b is connected to the groove part 21a, it is connected to the main body part 40 around the insert 10. By having such a groove portion 21 on the first surface 11 of the insert 10, the gas in the cavity is driven into the groove portion 21 when the foamable resin material for forming the main body portion 40 is filled in the cavity of the mold. Can do.

  The diameter R1 of each convex part 22 shown in FIG. 5 can be 1-5 mm (more preferably 2-4 mm), for example. The height H1 of each convex part 22, ie, the depth of the groove part 21, can be 1-5 mm, for example. The interval W1 between the adjacent convex portions 22, that is, the width of the groove portion 21 can be set to 1 to 5 mm, for example.

In addition, as illustrated in FIG. 6, the convex portion 22 of the concave-convex shape 20 of the insert 10 is not limited to a cylindrical shape. The concavo-convex shape 20 shown in FIG. 6 has a number of quadrangular columnar convex portions 22 protruding in the thickness direction D1 of the silencer 1. Each convex part 22 is separated from the adjacent convex part 22. The groove portion 21 connected in a groove shape between the convex portions 22 is connected to the main body portion 40 around the insert 10 from the through hole 15.
The length L1 of one side of each convex portion 22 shown in FIG. 6 can be set to 1 to 5 mm (more preferably 2 to 4 mm), for example. The height H1 of each convex part 22, ie, the depth of the groove part 21, can be 1-5 mm, for example. The interval W1 between the adjacent convex portions 22, that is, the width of the groove portion 21 can be set to 1 to 5 mm, for example.

  Of course, the shape of each convex portion 22 may be a triangular prism shape or the like. Moreover, the uneven | corrugated shape 20 may be the shape which combined the convex part of several mutually different shapes, such as the shape which combined the cylindrical convex part 22 shown in FIG. 5, and the square columnar convex part 22 shown in FIG.

  The shape of the opening of the through hole 15 shown in FIG. 4 is a rectangular shape with rounded corners. Of course, the shape of the opening of the through hole 15 is not limited to a rectangular shape with rounded corners, and may be an ellipse including a circle, a triangle, a pentagon or more polygon, and the like. In addition, the plurality of through holes 15 may include a plurality of through holes having different opening shapes, such as a through hole having a rectangular opening and a through hole having an elliptical opening.

The size of the silencer 1 including the insert 10 having the through hole 15 is not particularly limited, and may be designed according to the vehicle shape, for example.
The thickness Ts (see FIG. 2) of the thickest part of the silencer 1 can be, for example, about 10 to 100 mm, more preferably about 15 to 70 mm, and further preferably about 20 to 50 mm.
The thickness Ti (see FIG. 3) of the thickest portion of the insert 10 can be set to, for example, about 10 to 50 mm, more preferably about 15 to 40 mm under the condition of the thickness Ts or less of the silencer 1. The depth Di of the through hole 15 is a length (Ti−H1) obtained by subtracting the height H1 of the convex portion 22 from the thickness Ti of the insert 10.
The length L11 (see FIG. 4) in the longitudinal direction of the through hole 15 can be, for example, about 30 to 300 mm, more preferably about 40 to 200 mm. Here, the length L11 is the length of the long side of the rectangular shape when the opening shape of the through hole 15 is rectangular, and the length L11 of the elliptical shape when the opening shape of the through hole 15 is elliptical. The major axis.
The length L12 (see FIG. 4) in the short direction of the through hole 15 can be, for example, about 5 to 50 mm, and more preferably about 30 to 45 mm under the condition of L12 <L11. Here, the length L12 is the length of the short side of the rectangular shape when the opening shape of the through hole 15 is rectangular, and the length L12 of the elliptical shape when the opening shape of the through hole 15 is elliptical. The short diameter.

(3) Specific example, method and effect of manufacturing method of vehicle silencer:
FIG. 7 schematically illustrates a method for manufacturing the silencer 1 together with the molding apparatus 200.
In the molding apparatus 200 shown in FIG. 7, an upper mold 212 and a lower mold 214 constituting the molding mold 210 are provided so as to be close to and away from each other. The upper mold 212 is a mold having a mold surface 213 on the opposing surface that matches the shape of the skin 1a of the silencer 1. The lower die 214 is a die having a die surface 215 that matches the shape of the panel side 1b of the silencer 1 on the opposing surface. The parting line PL of the mold 210 is formed with a path P1 for discharging the gas Gs (see FIGS. 8 and 9) that is not the bubble B2 when the molds 212 and 214 are closed (when the molds are clamped). In FIG. 7, the upper mold 212 is movable and the lower mold 214 is fixed. However, the upper mold 212 may be fixed and the lower mold 214 may be movable, or both molds 212 and 214 may be movable. Good.

  An insert 10 made of foamed resin (for example, PP resin) having a through hole 15 connected from the first surface 11 to the second surface 12 can be formed according to the above-described molding method of the foamed particle molded body. In the first setting step ST1, the insert 10 is set at a predetermined position in the cavity CA1 of the mold 210 in the mold open state. The insert 10 is disposed at a position where the first surface 11 faces upward and the first surface 11 contacts the mold surface 213 of the upper mold 212 during mold clamping. Although not shown, a structure for holding the insert 10 may be formed on at least one of the mold surfaces 213 and 215, and the insert 10 may be held in this structure.

  In the next molding step ST2, the molds 212 and 214 are closed, and a foamable resin material 50 (for example, a material that becomes a flexible polyurethane foam) is injected into the cavity CA1 so as to enter the through hole 15 from the second surface 12 side of the insert 10. Then, the main body 40 is foam-molded. As illustrated in FIG. 8, the injected foamable resin material 50 is buried from the bottom of the cavity CA1 while generating a large number of fine bubbles B2. At this time, the gas Gs remaining in the cavity CA1 is pushed up by the rising foamable resin material 50 and discharged to the outside through the gas discharge path P1 of the parting line PL. When the gas Gs is discharged and the foamable resin material 50 having the open cell structure B2 is solidified or cured, the main body 40 having the entry portion 42 that has entered the through hole 15 of the insert 10 and exhibiting volume elasticity is formed. The The position of the first surface 11 that appears on the surface 2 in the insert 10 is matched to the surroundings and the position of the main body 40 in the through hole 15.

  In addition, as illustrated in FIG. 9, the remaining gas Gs may leave the gas discharge path P1. FIG. 9 shows the gas Gs1 remaining on the upper portion of the through hole 15 and the gas Gs2 remaining on the stepped portion 30. Since there is a concavo-convex shape 20 having a groove portion 21 that is continuous in a groove shape beside these gases Gs1 and Gs2, these gases Gs1 and Gs2 escape to the groove portion 21. Therefore, a conspicuous void is unlikely to occur in the main body 40. In addition, when the gas Gs does not enter the groove portion 21, the foamable resin material 50 may enter. For this reason, at least a part of the groove 21 may be covered with the main body 40. The tip of the convex portion 22 of the concavo-convex shape 20 generally appears on the surface 2 of the silencer 1.

When the molds 212 and 214 are opened, the insert-molded silencer 1 can be taken out. In the obtained silencer 1, at least a part of the first surface 11 of the insert 10 appears on a part of the surface 2. Since the insertion portion 42 of the main body portion 40 showing elasticity is contained in the through hole 15 having an opening ratio Ro = 5 to 50% of the insert 10, the silencer 1 does not feel too hard or too soft. In addition, a conspicuous void does not appear in the main body 40. Therefore, this example can improve the feel of the silencer.
Furthermore, since the soft polyurethane foam and the foamed PP resin which are different from each other appear on the surface 2 of the silencer 1, the sound absorption performance of the silencer is improved.

Furthermore, since the uneven shape 20 of the insert 10 made of foamed PP resin appears on the surface 2 of the silencer 1, the contact area between the silencer 1 and the carpet 70 is reduced. Thereby, generation | occurrence | production of the abnormal noise when the carpet 70 is stepped on with a foot is suppressed.
Furthermore, there is a stepped portion 30 that is lowered to the inside 3 side of the silencer 1 at the edge 11 a of the first surface 11 of the insert 10, and the stepped portion 30 is covered with the main body portion 40. Thereby, the edge part 11a of the 1st surface 11 of the insert 10 will be in the state caught on the main-body part 40. FIG. Therefore, it is difficult for the insert 10 to come off from the main body 40.

(4) Modification:
Various modifications can be considered for the present invention.
For example, the silencer to which the present invention can be applied is not only a floor silencer for a passenger compartment, but also a silencer for a luggage compartment, a door silencer, a ceiling silencer, a dash silencer, an engine silencer, a fender silencer, Etc.

Even if the insert 10 does not have the stepped portion 30 and the edge portion 11a of the first surface 11 appears on the surface 2 of the silencer 1, the inner side surface 15a of the through hole 15 is bonded to the main body portion 40. The adhesive strength between the insert 10 and the main body 40 is improved as compared with the case where 15 is not provided. Therefore, this case is also suitable as a vehicle silencer with improved feel.
Moreover, even if the insert 10 does not have the concavo-convex shape 20 and the portion of the first surface 11 that appears on the surface 2 of the silencer 1 is flat and a void appears in the main body 40, it is hidden by the skin material. This case is also suitable as a vehicle silencer with improved feel.

(5) Example:
EXAMPLES Hereinafter, although an Example is shown and this invention is demonstrated concretely, this invention is not limited by the following examples.

[Example]
As the insert 10, a plate-shaped foamed PP resin bead body (closed cell structure with a foaming ratio of 30 times) having through holes 15 with an opening ratio of 30% was used. This molded body is set at a predetermined position of the cavity CA1 of the mold 210, and a material that becomes a flexible polyurethane foam in the mold-clamped state is injected into the cavity CA1 so as to enter the through hole 15 from the second surface 12 side of the insert 10, The main body portion 40 having an open cell structure with an expansion ratio of 30 was subjected to foam molding. In the insert-molded sample, the main body 40 showed a larger volume elasticity than the insert 10. Moreover, when the sample was installed between the metal plate and the floor carpet and the foot comfort was confirmed, it was a good touch that was neither too hard nor too soft.

(6) Conclusion:
As described above, according to the present invention, techniques such as a vehicle silencer with improved feel can be provided by various aspects. Needless to say, the above-described basic functions and effects can be obtained even with the technology consisting only of the constituent elements according to the independent claims.
In addition, the configurations disclosed in the above-described examples are mutually replaced or the combination is changed, the known technology and the configurations disclosed in the above-described examples are mutually replaced or the combinations are changed. The configuration described above can also be implemented. The present invention includes these configurations and the like.

DESCRIPTION OF SYMBOLS 1 ... Silencer, 1a ... Skin side, 1b ... Panel side, 2 ... Surface, 3 ... Inside,
10 ... Insert, 11 ... First surface, 11a ... Edge, 12 ... Second surface,
15 ... through hole, 15a ... inside surface,
20 ... Uneven shape, 21 ... groove, 22 ... convex,
30 ... Step,
40 ... main body part, 42 ... entry part,
50 ... Expandable resin material,
70 ... carpet (example of skin material), 80 ... body panel,
200 ... Molding device 210 ... Molding die 212 ... Upper die 214 ... Lower die
B1, B2 ... Air bubbles, C1 ... Cab, CA1 ... Cavity, CE1 ... Center,
D1 ... thickness direction, Gs ... gas,
P1 ... path, PL ... parting line, Ro ... opening ratio,
ST1 ... setting process, ST2 ... molding process.

Claims (4)

A molded silencer for a vehicle,
A first surface on the surface side of the silencer and a second surface on the inner side of the silencer, and an insert made of foamed resin that appears on a part of the surface of the silencer;
A body portion formed of a foamed resin of a different material from the insert and exhibiting elasticity;
The insert has a through hole connected from the first surface to the second surface;
The opening ratio of the through hole in the first surface is 5 to 50%;
The inserter is a silencer that is integrated with the main body part of the through hole.   2. The silencer according to claim 1, wherein the first surface of the insert is formed with a concavo-convex shape having a groove portion connected to the main body portion around the insert from the through hole.   The silencer according to claim 1 or 2, wherein a stepped portion is formed on an edge portion of the first surface of the insert so as to be lowered toward an inner side of the silencer and covered with the main body portion. A method of manufacturing a molded silencer for a vehicle, comprising:
The first surface that is the surface side of the silencer, the second surface that is the inner side of the silencer, and the first surface is connected to the second surface, and the aperture ratio in the first surface is 5 to 50%. A step of setting a foamed resin insert having a through hole in a cavity of a mold;
A foamable resin material made of a material different from that of the insert is inserted into the cavity so as to enter the through-hole from the second surface side, and a body portion showing elasticity in a state where the insert appears on a part of the surface of the silencer. A method of producing a silencer, comprising a step of foam molding.

Images