JP2020157688A - Duct and method for manufacturing the same - Google Patents

Duct and method for manufacturing the same Download PDF

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JP2020157688A
JP2020157688A JP2019061902A JP2019061902A JP2020157688A JP 2020157688 A JP2020157688 A JP 2020157688A JP 2019061902 A JP2019061902 A JP 2019061902A JP 2019061902 A JP2019061902 A JP 2019061902A JP 2020157688 A JP2020157688 A JP 2020157688A
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duct
opening
porous body
duct wall
adjacent
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JP7256054B2 (en
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進一 本澤
Shinichi Motosawa
進一 本澤
山口　貴史
Takashi Yamaguchi
貴史 山口
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Inoac Corp
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Inoue MTP KK
Inoac Corp
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Abstract

To prevent a porous material from entering a duct.SOLUTION: In a porous material 20, at least a part of adjacent portions 28 adjacent to joint portions 24a and 24b that join to a duct wall portion 10a is formed to be thinner in thickness than a general portion 26 corresponding to the central portion of an opening area 18a of an opening portion 18. The duct wall portion 10a is molded in a mold 30 under the adjacent portions 28 are sandwiched in the plate thickness direction and compressed, to join the joint portions 24a and 24b of the porous material 20 and the duct wall portion 10a.SELECTED DRAWING: Figure 5

Description

この発明は、例えば車両などに用いられるダクトおよびこのダクトの製造方法に関するものである。 The present invention relates to a duct used in, for example, a vehicle and a method for manufacturing the duct.

特許文献１に開示の吸気ダクトのように、吸気ダクトを構成する分割体の壁面に形成された開口部を覆うように、多孔質シートを分割体に接合することで、騒音を防止することが提案されている。特許文献１の吸気ダクトは、多孔質シートをセットした成形型において分割体を成形するインサート成形により、多孔質シートを分割体に接合している。具体的には、成形型の凹型に多孔質シートをセットし、凹型と凸型とを型閉じすることで、凸型から突出する固定部によって多孔質シートの外縁部の内周側の部分を圧迫して凹型に押さえ付ける。次に、多孔質シートを配置した成形型のキャビティに溶融樹脂を注入する。このとき、多孔質シートには、溶融樹脂が多孔質シートの外縁部から徐々に含浸するが、外縁部の内周側が固定部と凹型とにより挟持されているので、内周側へ溶融樹脂が含浸することが防止される。そして、多孔質シートの外縁部に溶融樹脂を含浸させた状態で冷却すると、多孔質シートに侵入した樹脂による接合部が形成される。こうして、多孔質シートは、固化した樹脂からなる分割体と接合される。 Like the intake duct disclosed in Patent Document 1, noise can be prevented by joining the porous sheet to the divided body so as to cover the opening formed in the wall surface of the divided body constituting the intake duct. Proposed. In the intake duct of Patent Document 1, the porous sheet is joined to the divided body by insert molding in which the divided body is molded in a molding die in which the porous sheet is set. Specifically, by setting the porous sheet in the concave mold of the molding mold and closing the concave mold and the convex mold, the portion on the inner peripheral side of the outer edge portion of the porous sheet is formed by the fixing portion protruding from the convex mold. Press it into a concave shape. Next, the molten resin is injected into the cavity of the molding mold in which the porous sheet is arranged. At this time, the porous sheet is gradually impregnated with the molten resin from the outer edge portion of the porous sheet, but since the inner peripheral side of the outer edge portion is sandwiched between the fixed portion and the concave shape, the molten resin is transferred to the inner peripheral side. Impregnation is prevented. Then, when the outer edge portion of the porous sheet is cooled while being impregnated with the molten resin, a joint portion made of the resin that has penetrated into the porous sheet is formed. In this way, the porous sheet is joined to the split body made of the solidified resin.

特開２００２−１０６４３１号公報JP-A-2002-106431

多孔質シートとして、弾性を有する素材を用いると、成形型において凸型の固定部と凹型との間で挟持されていた多孔質シートの内周側が、その弾性により成形型から脱型した際に元の形状に復元する。このとき、多孔質シートが、開口部から吸気ダクトの内側に大きく入り込むように復元することがある。多孔質シートがダクトの内側へ入り込んでしまうと、空気流通路の断面積が減少することになり、圧力損失が大きくなるなどの問題が生じる。 When an elastic material is used as the porous sheet, when the inner peripheral side of the porous sheet sandwiched between the convex fixing portion and the concave mold in the molding die is removed from the molding die due to the elasticity. Restore to the original shape. At this time, the porous sheet may be restored so as to enter the inside of the intake duct from the opening. If the porous sheet gets into the inside of the duct, the cross-sectional area of the air flow passage is reduced, which causes problems such as a large pressure loss.

本発明は、従来の技術に係る前記問題に鑑み、これらを好適に解決するべく提案されたものであって、開口部を覆う多孔質体が、開口部からダクト内に大きく膨らむことが抑えられたダクトおよびその製造方法を提供することを目的とする。 The present invention has been proposed in view of the above-mentioned problems related to the prior art, and has been proposed to preferably solve these problems, and it is possible to prevent the porous body covering the opening from bulging significantly into the duct from the opening. It is an object of the present invention to provide a duct and a method for manufacturing the same.

前記課題を克服し、所期の目的を達成するため、本発明に係るダクトは、
ダクトにおいて空気流通路を画成する合成樹脂成形品であるダクト壁部と、
弾性を有し、前記ダクト壁部を貫通するように形成された開口部を塞ぐように該ダクト壁部の外面に接合された多孔質体と、を備え、
前記多孔質体は、前記開口部の開口縁に接合される接合部分に対して該開口部の開口領域側に隣接する隣接部分の少なくとも一部が、前記ダクト壁部に接合する前の状態において、該開口部の開口領域中央部に対応する一般部分よりも薄く形成されていることを要旨とする。 In order to overcome the above-mentioned problems and achieve the intended purpose, the duct according to the present invention is used.
The duct wall, which is a synthetic resin molded product that defines the air flow path in the duct,
A porous body having elasticity and joined to the outer surface of the duct wall portion so as to close the opening formed so as to penetrate the duct wall portion.
The porous body is in a state before at least a part of an adjacent portion adjacent to the opening region side of the opening is joined to the duct wall portion with respect to the joining portion joined to the opening edge of the opening. The gist is that the opening is formed thinner than the general portion corresponding to the central portion of the opening region.

前記課題を克服し、所期の目的を達成するため、本発明に係るダクトの製造方法は、
合成樹脂からなるダクト壁部を成形型で成形する際に、弾性を有する多孔質体を、該ダクト壁部に貫通形成される開口部を塞ぐように該ダクト壁部の一面に接合するダクトの製造方法であって、
前記多孔質体において前記ダクト壁部に接合させる接合部分に隣接する隣接部分の少なくとも一部を、その板厚が、前記開口部の開口領域中央部に対応する一般部分よりも薄くなるように形成し、
前記隣接部分を前記成形型で板厚方向に挟んで圧縮した状態で、前記多孔質体を該成形型に収め、
前記接合部分が臨む前記成形型のキャビティに、溶融状態にある前記合成樹脂を供給し、圧縮された前記隣接部分によって該合成樹脂を封止しつつ該キャビティにおいて前記開口部を有する前記ダクト壁部を成形することで、前記多孔質体の接合部分と該ダクト壁部とを接合することを要旨とする。 In order to overcome the above-mentioned problems and achieve the desired object, the method for manufacturing a duct according to the present invention is:
When a duct wall made of synthetic resin is molded by a molding die, an elastic porous body is joined to one surface of the duct wall so as to close an opening formed through the duct wall. It ’s a manufacturing method,
At least a part of the adjacent portion of the porous body adjacent to the joint portion to be joined to the duct wall portion is formed so that the plate thickness thereof is thinner than the general portion corresponding to the central portion of the opening region of the opening. And
In a state where the adjacent portion is sandwiched between the molding dies in the plate thickness direction and compressed, the porous body is placed in the molding dies.
The duct wall portion having the opening in the cavity while supplying the synthetic resin in a molten state to the cavity of the molding mold facing the joint portion and sealing the synthetic resin by the compressed adjacent portion. The gist is that the joint portion of the porous body and the duct wall portion are joined by molding.

本発明に係るダクトによれば、開口部を覆う多孔質体が、開口部からダクト内に大きく膨らむことが抑えられている。
本発明に係るダクトの製造方法によれば、開口部を覆う多孔質体が、開口部からダクト内に大きく膨らむことが抑えられたダクトを得ることができる。 According to the duct according to the present invention, it is suppressed that the porous body covering the opening is greatly swelled into the duct from the opening.
According to the method for manufacturing a duct according to the present invention, it is possible to obtain a duct in which the porous body covering the opening is suppressed from greatly expanding into the duct from the opening.

本発明の実施例に係るダクトを示す概略斜視図である。It is a schematic perspective view which shows the duct which concerns on embodiment of this invention. 実施例に係るダクトの要部を示す概略斜視図である。なお、多孔質体を取り外してある。It is a schematic perspective view which shows the main part of the duct which concerns on Example. The porous body has been removed. 図１のＡ−Ａ線断面図である。FIG. 1 is a cross-sectional view taken along the line AA of FIG. 図１のＢ−Ｂ線断面図である。It is sectional drawing BB of FIG. 実施例のダクトの製造工程を示す説明図である。It is explanatory drawing which shows the manufacturing process of the duct of an Example. 実施例のダクトの製造工程を示す説明図である。It is explanatory drawing which shows the manufacturing process of the duct of an Example. 変更例の多孔質体によるダクトの製造工程を示す説明図である。It is explanatory drawing which shows the manufacturing process of the duct by the porous body of the modified example.

次に、本発明に係るダクトおよびこのダクトの製造方法につき、好適な実施例を挙げて、添付図面を参照して以下に説明する。 Next, the duct according to the present invention and the method for manufacturing the duct will be described below with reference to the accompanying drawings with reference to suitable examples.

図１に示すように、実施例に係るダクト１０は、空気が流通する空気流通路１２が内側に設けられた筒状体である。実施例のダクト１０は、複数(実施例は２個)の分体１４,１６を組み合わせて筒状に構成されており、互いの端縁を突き合わせた分体１４,１６同士が、図示しない爪嵌合構造や接着などによって組み付けられている。各分体１４,１６は、ポリプロピレン(ＰＰ)または高密度ポリエチレン(ＨＤＰＥ)などのソリッド樹脂(ソリッドの合成樹脂)を材質とし、インジェクション成形等によって得られる合成樹脂成形品である。ダクト１０は、空気流通路１２に向く側を内といい、その反対側を外という。 As shown in FIG. 1, the duct 10 according to the embodiment is a tubular body provided with an air flow passage 12 through which air flows. The duct 10 of the embodiment is formed in a tubular shape by combining a plurality of (two in the example) divisions 14,16, and the divisions 14, 16 having their edges abutted against each other are claws (not shown). It is assembled by fitting structure and adhesion. Each of the separate bodies 14 and 16 is a synthetic resin molded product obtained by injection molding or the like, using a solid resin (solid synthetic resin) such as polypropylene (PP) or high-density polyethylene (HDPE) as a material. The side of the duct 10 facing the air flow passage 12 is referred to as the inside, and the opposite side thereof is referred to as the outside.

図２〜図４に示すように、ダクト１０は、空気流通路１２を画成するダクト壁部１０ａを貫通するように形成された開口部１８と、この開口部１８を塞ぐようにダクト壁部１０ａの外面に接合された多孔質体２０とを備えている。ダクト１０は、開口部１８を塞ぐ多孔質体２０が、その特性により、吸音や断熱や軽量化などの機能を有する機能部となり、実施例の多孔質体２０は、バッテリを冷却する空気を案内する冷却ダクトにおいて、空気を吸い込むブロアなどによる騒音が、空気取入口側から漏れないように防止する吸音部として設定されている。実施例のダクト１０は、開口部１８および多孔質体２０が第１分体１４に設けられており、合成樹脂からなる第１分体１４の成形時に、開口部１８が形成されると共に、多孔質体２０がダクト壁部１０ａに接合される。 As shown in FIGS. 2 to 4, the duct 10 has an opening 18 formed so as to penetrate the duct wall portion 10a defining the air flow passage 12, and a duct wall portion so as to close the opening 18. It is provided with a porous body 20 bonded to the outer surface of 10a. In the duct 10, the porous body 20 that closes the opening 18 becomes a functional part having functions such as sound absorption, heat insulation, and weight reduction due to its characteristics, and the porous body 20 of the embodiment guides the air that cools the battery. In the cooling duct, it is set as a sound absorbing part that prevents noise from a blower that sucks in air from leaking from the air intake side. In the duct 10 of the embodiment, the opening 18 and the porous body 20 are provided in the first division 14, and the opening 18 is formed and the porous body 20 is formed when the first division 14 made of synthetic resin is formed. The body 20 is joined to the duct wall portion 10a.

多孔質体２０は、圧縮して変形させた状態を解除すると元の形状に戻る弾性を有している。また、前述した吸音用途であるならば、通気性を有しているとよい。多孔質体２０は、例えば、ポリウレタンフォームや、ポリプロピレンフォーム等のオレフィン系フォームなどの発泡体、あるいはセルとなる核剤を抽出する抽出法によって製造されるものなどを用いることができる。この中でも、連続気泡構造のポリウレタンフォームを用いることが好ましい。なお、実施例では、多孔質体２０として、５０％圧縮後の復元率が９２％以上の連続気泡構造のポリウレタンフォームを用いている。 The porous body 20 has elasticity to return to its original shape when the compressed and deformed state is released. Further, if it is used for sound absorption described above, it is preferable that it has breathability. As the porous body 20, for example, a polyurethane foam, a foam such as an olefin-based foam such as polypropylene foam, or a material produced by an extraction method for extracting a nucleating agent to be a cell can be used. Among these, it is preferable to use a polyurethane foam having an open cell structure. In the examples, as the porous body 20, a polyurethane foam having an open cell structure having a restoration rate of 92% or more after 50% compression is used.

図２に示すように、ダクト壁部１０ａは、開口部１８に架け渡すように形成された桟部２２を備え、桟部２２によって開口部１８が複数(実施例は２つ)の開口領域１８ａに区分されている。多孔質体２０は、ダクト壁部１０ａにおける開口部１８の開口縁および桟部２２に接合されており、開口縁に接合する外周接合部分２４ａおよび桟部２２に接合する桟部接合部分２４ｂが、開口領域１８ａの中央部に対応する一般部分２６よりも薄くなっている。なお、外周接合部分２４ａおよび桟部接合部分２４ｂを区別しない場合、単に接合部分という。多孔質体２０は、一般部分２６が、接合部分２４ａ,２４ｂよりもダクト壁部１０ａと反対側へ張り出すように形成されている(図３および図４参照)。また、多孔質体２０は、開口部１８を塞ぐダクト壁部１０ａ側の内面が、空気取入口から空気送出口に向かう空気流通方向において、周辺のダクト壁部１０ａに倣うように延在し、開口部１８を塞ぐ面によって周辺と連続する空気案内面を構成している。多孔質体２０の接合部分２４ａ,２４ｂは、ダクト壁部１０ａの成形時に接合される。このため、ダクト壁部１０ａとなる溶融状態の合成樹脂Ｒ(図６(ａ))との接触により接合部分２４ａ,２４ｂが融解して、ダクト壁部１０ａとこのダクト壁部１０ａに接合した接合部分２４ａ,２４ｂとは融合した状態にある。なお、図中では、多孔質体２０の接合部分２４ａ,２４ｂとダクト壁部１０ａとの境界を便宜的に示しているが、互いの境界が曖昧になっていると考えられる。 As shown in FIG. 2, the duct wall portion 10a includes a crosspiece 22 formed so as to bridge the opening 18, and the crosspiece 22 has a plurality of openings 18 (two in the embodiment) opening regions 18a. It is divided into. The porous body 20 is joined to the opening edge and the crosspiece 22 of the opening 18 in the duct wall portion 10a, and the outer peripheral joining portion 24a joined to the opening edge and the crosspiece joining portion 24b joined to the crosspiece 22 are formed. It is thinner than the general portion 26 corresponding to the central portion of the opening region 18a. When the outer peripheral joint portion 24a and the crosspiece joint portion 24b are not distinguished, they are simply referred to as joint portions. The porous body 20 is formed so that the general portion 26 projects from the joint portions 24a and 24b toward the side opposite to the duct wall portion 10a (see FIGS. 3 and 4). Further, in the porous body 20, the inner surface on the duct wall portion 10a side that closes the opening 18 extends so as to follow the surrounding duct wall portion 10a in the air flow direction from the air intake port to the air outlet. The surface that closes the opening 18 constitutes an air guide surface that is continuous with the surrounding area. The joining portions 24a and 24b of the porous body 20 are joined at the time of molding the duct wall portion 10a. Therefore, the joint portions 24a and 24b are melted by contact with the molten synthetic resin R (FIG. 6A) that becomes the duct wall portion 10a, and the duct wall portion 10a and the duct wall portion 10a are joined to each other. It is in a fused state with the portions 24a and 24b. In the figure, the boundaries between the joint portions 24a and 24b of the porous body 20 and the duct wall portion 10a are shown for convenience, but it is considered that the boundaries between them are ambiguous.

図５(ａ)に示すように、多孔質体２０は、開口部１８の開口縁に接合される外周接合部分２４ａに対して該開口部１８の開口領域１８ａ側に隣接する隣接部分２８の少なくとも一部が、ダクト壁部１０ａに接合する前の状態において、一般部分２６よりも薄く形成される。実施例の多孔質体２０は、外周接合部分２４ａから隣接部分２８にかけて、ダクト壁部１０ａに接合する前の状態において、一般部分２６よりも薄く形成されている。また、実施例の多孔質体２０は、４辺の開口縁に対応する外周接合部分２４ａに隣接する隣接部分２８の全てが、ダクト壁部１０ａに接合する前の状態において、一般部分２６よりも薄く形成されている。 As shown in FIG. 5A, the porous body 20 has at least an adjacent portion 28 adjacent to the opening region 18a side of the opening 18 with respect to the outer peripheral joining portion 24a joined to the opening edge of the opening 18. A part is formed thinner than the general part 26 in the state before being joined to the duct wall part 10a. The porous body 20 of the embodiment is formed thinner than the general portion 26 from the outer peripheral joining portion 24a to the adjacent portion 28 in a state before joining to the duct wall portion 10a. Further, in the porous body 20 of the embodiment, in a state where all of the adjacent portions 28 adjacent to the outer peripheral joining portion 24a corresponding to the opening edges of the four sides are joined to the duct wall portion 10a, the porous body 20 is more than the general portion 26. It is thinly formed.

図５(ａ)に示すように、多孔質体２０は、桟部２２に接合される桟部接合部分２４ｂに対して該開口部１８の開口領域１８ａ側に隣接する隣接部分２８の少なくとも一部が、ダクト壁部１０ａに接合する前の状態において、一般部分２６よりも薄く形成される。実施例の多孔質体２０は、桟部接合部分２４ｂから隣接部分２８にかけて、ダクト壁部１０ａに接合する前の状態において、一般部分２６よりも薄く形成されている。また、実施例の多孔質体２０は、１条の桟部２２に対応する桟部接合部分２４ｂに隣接する隣接部分２８の全てが、ダクト壁部１０ａに接合する前の状態において、一般部分２６よりも薄く形成されている。 As shown in FIG. 5A, the porous body 20 is at least a part of an adjacent portion 28 adjacent to the opening region 18a side of the opening 18 with respect to the crosspiece joint portion 24b joined to the crosspiece 22. Is formed thinner than the general portion 26 in a state before being joined to the duct wall portion 10a. The porous body 20 of the embodiment is formed thinner than the general portion 26 from the crosspiece joint portion 24b to the adjacent portion 28 in a state before being joined to the duct wall portion 10a. Further, in the porous body 20 of the embodiment, the general portion 26 is in a state before all of the adjacent portions 28 adjacent to the crosspiece joint portion 24b corresponding to the crosspiece portion 22 of one line are joined to the duct wall portion 10a. It is formed thinner than.

実施例に係るダクト１０は、所定形状に形成した多孔質体２０をセットした成形型３０においてダクト壁部１０ａを成形するインサート成形によって、第１分体１４が得られる(図５および図６参照)。そして、別途型成形することで得られた第２分体１６と、第１分体１４とを組み付けることで、ダクト１０を得ることができる。 As for the duct 10 according to the embodiment, the first division 14 is obtained by insert molding in which the duct wall portion 10a is molded in the molding die 30 in which the porous body 20 formed in a predetermined shape is set (see FIGS. 5 and 6). ). Then, the duct 10 can be obtained by assembling the second body 16 obtained by separately molding and the first body 14.

図５および図６に示すように、成形型３０は、下型３４と、この下型３４と相対的に開閉可能に構成された上型３２とから構成され、型閉じした際に、下型３４と上型３２との間にダクト壁部１０ａ(第１分体１４)の形状に合わせたキャビティ３６が形成される。上型３２には、開口部１８の開口領域１８ａの形成位置に合わせて凹部３８が設けられている。また、上型３２には、開口部１８の開口領域１８ａのうち、開口部１８の開口縁に隣接する位置に対応して、下型３４にセットされた多孔質体２０を下型３４との間で押さえ付けて圧縮可能な圧縮部４０が設けられている。実施例では、圧縮部４０が、開口部１８の開口縁に対応する位置および桟部２２に対応する位置に亘って設けられ、多孔質体２０における接合部分２４ａ,２４ｂとなる位置も、圧縮部４０によって下型３４へ向けて押さえ付け可能に構成されている。下型３４には、開口部１８の開口領域１８ａに対応して、凸部４２が設けられている。 As shown in FIGS. 5 and 6, the molding die 30 is composed of a lower die 34 and an upper die 32 that is configured to be relatively openable and closable with the lower die 34, and when the die is closed, the lower die is formed. A cavity 36 that matches the shape of the duct wall portion 10a (first body 14) is formed between the 34 and the upper mold 32. The upper die 32 is provided with a recess 38 in accordance with the formation position of the opening region 18a of the opening 18. Further, in the upper mold 32, the porous body 20 set in the lower mold 34 corresponds to the position adjacent to the opening edge of the opening 18 in the opening region 18a of the opening 18 with the lower mold 34. A compression unit 40 that can be pressed and compressed is provided. In the embodiment, the compression portion 40 is provided over the position corresponding to the opening edge of the opening 18 and the position corresponding to the crosspiece 22, and the positions of the joint portions 24a and 24b in the porous body 20 are also the compression portions. It is configured so that it can be pressed toward the lower mold 34 by the 40. The lower mold 34 is provided with a convex portion 42 corresponding to the opening region 18a of the opening 18.

図５および図６に示すように、成形型３０は、型閉じした際に、圧縮部４０と凸部４２との間に、多孔質体２０においてダクト壁部１０ａに接合させる接合部分２４ａ,２４ｂに隣接する隣接部分２８を挟んで、隣接部分２８を圧縮した状態で挟持可能に構成されている。成形型３０は、凹部３８と凸部４２との間が、多孔質体２０において開口部１８の開口領域１８ａの中央部に対応する一般部分２６の板厚よりも小さく設定されている。成形型３０は、型閉じした際に、凹部３８と凸部４２との間に、多孔質体２０の一般部分２６を圧縮した状態で挟持可能に構成されている。ここで、成形型３０は、圧縮部４０と凸部４２とによる多孔質体２０の隣接部分２８の圧縮度合いが、凹部３８と凸部４２とによる多孔質体２０の一般部分２６の圧縮度合いよりも大きく設定されている。 As shown in FIGS. 5 and 6, in the molding die 30, when the mold is closed, the joining portions 24a and 24b are joined between the compression portion 40 and the convex portion 42 to the duct wall portion 10a in the porous body 20. The adjacent portion 28 is sandwiched between the adjacent portions 28, and the adjacent portion 28 can be sandwiched in a compressed state. In the molding die 30, the distance between the concave portion 38 and the convex portion 42 is set to be smaller than the plate thickness of the general portion 26 corresponding to the central portion of the opening region 18a of the opening 18 in the porous body 20. The molding die 30 is configured so that when the mold is closed, the general portion 26 of the porous body 20 can be sandwiched between the concave portion 38 and the convex portion 42 in a compressed state. Here, in the molding die 30, the degree of compression of the adjacent portion 28 of the porous body 20 by the compression portion 40 and the convex portion 42 is higher than the degree of compression of the general portion 26 of the porous body 20 by the concave portion 38 and the convex portion 42. Is also set large.

前述した成形型３０を用いたダクト１０(第１分体１４)の製造方法は以下の通りである。開口部１８の開口領域１８ａの中央部に対応する一般部分２６の板厚と同じ板厚で形成された板状の多孔質体２０を用意する。図５(ａ)に示すように、多孔質体２０におけるダクト壁部１０ａに接合させる接合部分２４ａ,２４ｂに隣接する隣接部分２８の少なくとも一部を、その板厚が、一般部分２６の板厚よりも薄くなるように形成する。実施例では、多孔質体２０における成形型３０で挟持される隣接部分２８の全体を、一般部分２６よりも薄くなるように切断加工している。多孔質体２０は、ダクト壁部１０ａにおける開口部１８の開口縁に接合される外周接合部分２４ａおよび外周接合部分２４ａに隣接する隣接部分２８に対応するように、外周縁部が薄く形成される。また、多孔質体２０は、ダクト壁部１０ａにおける桟部２２に接合される桟部接合部分２４ｂおよび桟部接合部分２４ｂに隣接する隣接部分２８に対応するように薄く形成される。多孔質体２０は、接合部分２４ａ,２４ｂから隣接部分２８にかけて、一般部分２６の板厚よりも薄くなるように形成される。多孔質体２０は、接合部分２４ａ,２４ｂから隣接部分２８側に向かうにつれて板厚が厚くなるように形成されており、接合部分２４ａ,２４ｂから隣接部分２８にかけてダクト壁部１０ａと反対側が傾斜面となっている。ここで、多孔質体２０には、該多孔質体２０におけるダクト壁部１０ａと反対側を、一般部分２６よりも凹むように形成して、一般部分２６より薄い隣接部分２８を設けている。 The method for manufacturing the duct 10 (first body 14) using the molding die 30 described above is as follows. A plate-shaped porous body 20 formed with the same plate thickness as the plate thickness of the general portion 26 corresponding to the central portion of the opening region 18a of the opening portion 18 is prepared. As shown in FIG. 5A, at least a part of the adjacent portions 28 adjacent to the joint portions 24a and 24b to be joined to the duct wall portion 10a in the porous body 20 has a thickness of the general portion 26. It is formed so as to be thinner than. In the embodiment, the entire adjacent portion 28 sandwiched between the molding dies 30 in the porous body 20 is cut so as to be thinner than the general portion 26. The outer peripheral edge of the porous body 20 is formed thinly so as to correspond to the outer peripheral joining portion 24a joined to the opening edge of the opening 18 in the duct wall portion 10a and the adjacent portion 28 adjacent to the outer peripheral joining portion 24a. .. Further, the porous body 20 is formed thinly so as to correspond to the crosspiece joint portion 24b joined to the crosspiece 22 in the duct wall portion 10a and the adjacent portion 28 adjacent to the crosspiece joint portion 24b. The porous body 20 is formed from the joint portions 24a and 24b to the adjacent portion 28 so as to be thinner than the plate thickness of the general portion 26. The porous body 20 is formed so that the plate thickness becomes thicker from the joint portions 24a and 24b toward the adjacent portion 28 side, and the side opposite to the duct wall portion 10a is an inclined surface from the joint portions 24a and 24b to the adjacent portion 28. It has become. Here, in the porous body 20, the side opposite to the duct wall portion 10a in the porous body 20 is formed so as to be recessed from the general portion 26, and an adjacent portion 28 thinner than the general portion 26 is provided.

一般部分２６を凹部３８に対応させると共に隣接部分２８を圧縮部４０に対応させて、多孔質体２０を下型３４に配置する。成形型３０を型閉じすることで、隣接部分２８を上型３２の圧縮部４０と下型３４の凸部４２との間に板厚方向に挟んで、隣接部分２８を圧縮する(図５(ｂ)参照)。このように、隣接部分２８を成形型３０で板厚方向に挟んで圧縮すると共に接合部分２４ａ,２４ｂをキャビティ３６に臨ませた状態で、多孔質体２０を成形型３０に収める。この際、圧縮された隣接部分２８が、一般部分２６や接合部分２４ａ,２４ｂと比べて高密度になっている。 The general portion 26 corresponds to the recess 38 and the adjacent portion 28 corresponds to the compression portion 40, and the porous body 20 is arranged in the lower mold 34. By closing the molding die 30, the adjacent portion 28 is sandwiched between the compression portion 40 of the upper mold 32 and the convex portion 42 of the lower mold 34 in the plate thickness direction, and the adjacent portion 28 is compressed (FIG. 5 (FIG. 5). b) See). In this way, the porous body 20 is housed in the molding die 30 with the adjacent portions 28 sandwiched between the molding dies 30 in the plate thickness direction and compressed, and the joint portions 24a and 24b facing the cavity 36. At this time, the compressed adjacent portion 28 has a higher density than the general portion 26 and the joint portions 24a and 24b.

接合部分２４ａ,２４ｂが臨む成形型３０のキャビティ３６に、溶融状態にある合成樹脂Ｒを、圧力をかけながら供給する。そして、圧縮された隣接部分２８によって合成樹脂Ｒを封止しつつ、キャビティ３６において開口部１８を有するダクト壁部１０ａを成形する(図６(ａ)参照)。ここで、多孔質体２０においてキャビティ３６に臨むように配置された接合部分２４ａ,２４ｂが、溶融して高温である合成樹脂Ｒに接触することで溶融する。このとき、溶融した合成樹脂Ｒが接合部分２４ａ,２４ｂから多孔質体２０に含浸しようとするが、接合部分２４ａ,２４ｂに隣接する隣接部分２８が圧縮されて高密度になっているので、合成樹脂Ｒが隣接部分２８を越えて含浸することを防止することができる。溶融した合成樹脂Ｒを冷却・固化することで、ダクト壁部１０ａが成形され、多孔質体２０の接合部分２４ａとダクト壁部１０ａとが接合し、多孔質体２０が開口部１８の開口領域１８ａを塞いだ状態でダクト壁部１０ａに一体的に固定される。 The synthetic resin R in a molten state is supplied to the cavity 36 of the molding die 30 facing the joint portions 24a and 24b while applying pressure. Then, while sealing the synthetic resin R by the compressed adjacent portion 28, the duct wall portion 10a having the opening 18 is formed in the cavity 36 (see FIG. 6A). Here, the joint portions 24a and 24b arranged so as to face the cavity 36 in the porous body 20 are melted and melted by coming into contact with the high temperature synthetic resin R. At this time, the molten synthetic resin R tries to impregnate the porous body 20 from the joint portions 24a and 24b, but the adjacent portion 28 adjacent to the joint portions 24a and 24b is compressed to have a high density. It is possible to prevent the resin R from impregnating beyond the adjacent portion 28. By cooling and solidifying the molten synthetic resin R, the duct wall portion 10a is formed, the joint portion 24a of the porous body 20 and the duct wall portion 10a are joined, and the porous body 20 is the opening region of the opening 18. The 18a is integrally fixed to the duct wall portion 10a in a closed state.

成形型３０を型開きして、多孔質体２０が一体化された第１分体１４を取り出す(図６(ｂ)参照)。多孔質体２０は、成形型３０で圧縮されていた隣接部分２８および一般部分２６が自身の弾性により復元する。一方、多孔質体２０は、接合部分２４ａ,２４ｂがダクト壁部１０ａと一体化して、元(接合前)の板厚よりも薄くなる。 The molding die 30 is opened, and the first body 14 in which the porous body 20 is integrated is taken out (see FIG. 6B). In the porous body 20, the adjacent portion 28 and the general portion 26 compressed by the molding die 30 are restored by their own elasticity. On the other hand, in the porous body 20, the joint portions 24a and 24b are integrated with the duct wall portion 10a, and the thickness is thinner than the original (before joining) plate thickness.

ダクト１０は、インサート成形により多孔質体２０とダクト壁部１０ａとを一体化する際に、多孔質体２０におけるダクト壁部１０ａとの接合部分２４ａ,２４ｂに隣接する隣接部分２８を圧縮して合成樹脂Ｒの含浸を封止している。従って、多孔質体２０の隣接部分２８を予め薄く形成しておくと、隣接部分２８が圧縮状態から復元するときの変化量を小さくすることができる。このように、圧縮した隣接部分２８が復元するときの変化量を小さくすることで、隣接部分２８が復元時にダクト壁部１０ａ側へ膨らんでしまうことを抑えることができる。従って、得られるダクト１０は、開口部１８を塞ぐようにダクト壁部１０ａの外面に接合された多孔質体２０が、開口部１８から空気流通路１２に入り込んでしまうことを回避できる。そして、ダクト１０は、開口部１８が多孔質体２０で塞がれた部位においても空気流通路１２の断面積を適切に確保でき、空気を円滑に流通させることができる。 When the porous body 20 and the duct wall portion 10a are integrated by insert molding, the duct 10 compresses the adjacent portions 28 adjacent to the joint portions 24a and 24b of the porous body 20 with the duct wall portion 10a. The impregnation of synthetic resin R is sealed. Therefore, if the adjacent portion 28 of the porous body 20 is formed thin in advance, the amount of change when the adjacent portion 28 is restored from the compressed state can be reduced. In this way, by reducing the amount of change when the compressed adjacent portion 28 is restored, it is possible to prevent the adjacent portion 28 from bulging toward the duct wall portion 10a during restoration. Therefore, in the obtained duct 10, it is possible to prevent the porous body 20 joined to the outer surface of the duct wall portion 10a so as to close the opening 18 from entering the air flow passage 12 through the opening 18. Then, the duct 10 can appropriately secure the cross-sectional area of the air flow passage 12 even in the portion where the opening 18 is closed by the porous body 20, and the air can flow smoothly.

多孔質体２０は、開口部１８の開口縁に接合させる外周接合部分２４ａに隣接する隣接部分２８だけでなく、開口部１８に架け渡して形成される桟部２２に接合させる桟部接合部分２４ｂに隣接する隣接部分２８についても、ダクト壁部１０ａに接合する前の状態において一般部分２６よりも薄く形成されている。このようにすることで、多孔質体２０の復元がダクト壁部１０ａ(空気流通路１２)側へ向かわないように制御することができる。従って、ダクト１０は、開口部１８が多孔質体２０で塞がれた部位においても空気流通路１２の断面積を適切に確保でき、空気を円滑に流通させることができる。 The porous body 20 is formed not only of the adjacent portion 28 adjacent to the outer peripheral joint portion 24a to be joined to the opening edge of the opening 18, but also to the crosspiece joint portion 24b to be joined to the crosspiece 22 formed over the opening 18. The adjacent portion 28 adjacent to the above is also formed thinner than the general portion 26 in the state before being joined to the duct wall portion 10a. By doing so, it is possible to control the restoration of the porous body 20 so as not to go toward the duct wall portion 10a (air flow passage 12) side. Therefore, the duct 10 can appropriately secure the cross-sectional area of the air flow passage 12 even in the portion where the opening 18 is closed by the porous body 20, and the air can flow smoothly.

多孔質体２０は、ダクト壁部１０ａに接合する前の状態において、ダクト壁部１０ａと反対側を一般部分２６よりも凹むように形成して、一般部分２６よりも薄い隣接部分２８を設けている。ダクト壁部１０ａに接合した多孔質体２０は、一般部分２６が接合部分２４ａ,２４ｂよりもダクト壁部１０ａと反対側へ張り出すように形成される。このようにすることで、多孔質体２０の復元がダクト壁部１０ａ(空気流通路１２)側へ向かわないように制御することができる。従って、ダクト１０は、開口部１８が多孔質体２０で塞がれた部位においても空気流通路１２の断面積を適切に確保でき、空気を円滑に流通させることができる。 In the state before joining the porous body 20 to the duct wall portion 10a, the side opposite to the duct wall portion 10a is formed so as to be recessed from the general portion 26, and an adjacent portion 28 thinner than the general portion 26 is provided. There is. The porous body 20 joined to the duct wall portion 10a is formed so that the general portion 26 projects from the joint portions 24a and 24b toward the side opposite to the duct wall portion 10a. By doing so, it is possible to control the restoration of the porous body 20 so as not to go toward the duct wall portion 10a (air flow passage 12) side. Therefore, the duct 10 can appropriately secure the cross-sectional area of the air flow passage 12 even in the portion where the opening 18 is closed by the porous body 20, and the air can flow smoothly.

多孔質体２０は、ダクト壁部１０ａに接合する前の状態において、接合部分２４ａ,２４ｂおよび隣接部分２８の両方を一般部分２６よりも薄くする構成であると、隣接部分２８の薄肉化加工を行い易い。特に、図５(ａ)に示すように、接合部分２４ａ,２４ｂから隣接部分２８に向かうにつれて板厚が増す構成であると、多孔質体２０の薄肉化加工を行い易い。 If the porous body 20 has a configuration in which both the joint portions 24a and 24b and the adjacent portion 28 are thinner than the general portion 26 in a state before being joined to the duct wall portion 10a, the adjacent portion 28 is thinned. Easy to do. In particular, as shown in FIG. 5A, if the plate thickness increases from the joint portions 24a and 24b toward the adjacent portions 28, the porous body 20 can be easily thinned.

（変更例）
前述した構成に限らず、例えば、以下のように変更してもよい。 (Change example)
The configuration is not limited to the above, and may be changed as follows, for example.

(１)実施例では、多孔質体の外周縁部を斜めにカットすることで、外周接合部分に対応する隣接部分を薄肉化し、多孔質体をＶ字状にカットすることで、桟部接合部分に対応する隣接部分を薄肉化したが、これに限らない。例えば、図７(ａ)に示すように、多孔質体２０をダクト壁部１０ａ側の面に沿って切り欠いたように形成することで、接合部分２４ａ,２４ｂおよび隣接部分２８を薄肉化する構成であってもよい。なお、図７の変更例では、接合部分２４ａ,２４ｂおよび隣接部分２８を、多孔質体２０におけるダクト壁部１０ａ側となる面に沿って切り欠いたように形成している。 (1) In the embodiment, the outer peripheral edge portion of the porous body is cut diagonally to thin the adjacent portion corresponding to the outer peripheral joint portion, and the porous body is cut into a V shape to join the crosspiece. The adjacent part corresponding to the part has been thinned, but it is not limited to this. For example, as shown in FIG. 7A, the joint portions 24a and 24b and the adjacent portions 28 are thinned by forming the porous body 20 so as to be cut out along the surface on the duct wall portion 10a side. It may be a configuration. In the modified example of FIG. 7, the joint portions 24a and 24b and the adjacent portion 28 are formed so as to be cut out along the surface of the porous body 20 on the duct wall portion 10a side.

(２)実施例では、多孔質体においてダクト壁部に接合される接合部分に隣接する隣接部分全体を薄肉化したが、これに限らず、多孔質体の一縁部だけを薄肉化する、あるいは桟部接合部分に隣接する隣接部分を薄肉化しないなど、隣接部分の一部だけを薄肉化してもよい。
(３)実施例では、複数の分体を組み合わせてダクトを構成したが、これに限らず、成形型においてダクト全体を一度に成形してもよい。
(４)本発明は、バッテリを冷却する空気を案内する冷却ダクトや、エンジン等に空気を案内する吸気ダクトなど、様々なダクトに適用可能である。
(５)実施例では、多孔質体の接合部分および隣接部分の薄肉化を切断により行ったが、プレス成形によって多孔質体の接合部分および隣接部分を薄肉化してもよい。
(６)実施例では、上下型開きの成形型を使用したが、左右に型開きする成形型を用いてもよい。 (2) In the embodiment, the entire adjacent portion of the porous body adjacent to the joint portion to be joined to the duct wall portion is thinned, but the present invention is not limited to this, and only one edge portion of the porous body is thinned. Alternatively, only a part of the adjacent portion may be thinned, such as not thinning the adjacent portion adjacent to the crosspiece joint portion.
(3) In the embodiment, the duct is constructed by combining a plurality of divided bodies, but the present invention is not limited to this, and the entire duct may be molded at once in the molding die.
(4) The present invention can be applied to various ducts such as a cooling duct for guiding air for cooling a battery and an intake duct for guiding air to an engine or the like.
(5) In the example, the joint portion and the adjacent portion of the porous body are thinned by cutting, but the joint portion and the adjacent portion of the porous body may be thinned by press molding.
(6) In the embodiment, a molding die that opens vertically is used, but a molding die that opens left and right may be used.

１０ ダクト，１０ａ ダクト壁部，１２ 空気流通路，１８ 開口部，
１８ａ 開口領域，２０ 多孔質体，２２ 桟部，２４ａ 外周接合部分(接合部分)，
２４ｂ 桟部接合部分(接合部分)，２６ 一般部分，２８ 隣接部分，３０ 成形型，
３６ キャビティ，Ｒ 合成樹脂 10 ducts, 10a duct walls, 12 air flow passages, 18 openings,
18a opening area, 20 porous body, 22 crosspieces, 24a outer peripheral joint part (joint part),
24b crosspiece joint part (joint part), 26 general part, 28 adjacent part, 30 molding mold,
36 Cavity, R Synthetic resin

Claims (6)

ダクトにおいて空気流通路を画成する合成樹脂成形品であるダクト壁部と、
弾性を有し、前記ダクト壁部を貫通するように形成された開口部を塞ぐように該ダクト壁部の外面に接合された多孔質体と、を備え、
前記多孔質体は、前記開口部の開口縁に接合される接合部分に対して該開口部の開口領域側に隣接する隣接部分の少なくとも一部が、前記ダクト壁部に接合する前の状態において、該開口部の開口領域中央部に対応する一般部分よりも薄く形成されている
ことを特徴とするダクト。 The duct wall, which is a synthetic resin molded product that defines the air flow path in the duct,
A porous body having elasticity and joined to the outer surface of the duct wall portion so as to close the opening formed so as to penetrate the duct wall portion.
The porous body is in a state before at least a part of an adjacent portion adjacent to the opening region side of the opening is joined to the duct wall portion with respect to the joining portion joined to the opening edge of the opening. , A duct characterized in that it is formed thinner than a general portion corresponding to the central portion of the opening region of the opening. 前記ダクト壁部は、前記開口部に架け渡すように形成された桟部を備え、
前記多孔質体は、前記桟部に接合される接合部分に対して該開口部の開口領域側に隣接する隣接部分の少なくとも一部が、前記ダクト壁部に接合する前の状態において、前記一般部分よりも薄く形成されている請求項１記載のダクト。 The duct wall portion includes a crosspiece formed so as to bridge the opening.
The porous body is generally said to be in a state before at least a part of an adjacent portion adjacent to the opening region side of the opening is joined to the duct wall portion with respect to the joint portion to be joined to the crosspiece. The duct according to claim 1, which is formed thinner than the portion. 前記多孔質体は、前記一般部分が前記接合部分よりも前記ダクト壁部と反対側へ張り出すように形成されている請求項１または２記載のダクト。 The duct according to claim 1 or 2, wherein the porous body is formed so that the general portion projects from the joint portion to the side opposite to the duct wall portion. 合成樹脂からなるダクト壁部を成形型で成形する際に、弾性を有する多孔質体を、該ダクト壁部に貫通形成される開口部を塞ぐように該ダクト壁部の一面に接合するダクトの製造方法であって、
前記多孔質体において前記ダクト壁部に接合させる接合部分に隣接する隣接部分の少なくとも一部を、その板厚が、前記開口部の開口領域中央部に対応する一般部分よりも薄くなるように形成し、
前記隣接部分を前記成形型で板厚方向に挟んで圧縮した状態で、前記多孔質体を該成形型に収め、
前記接合部分が臨む前記成形型のキャビティに、溶融状態にある前記合成樹脂を供給し、圧縮された前記隣接部分によって該合成樹脂を封止しつつ該キャビティにおいて前記開口部を有する前記ダクト壁部を成形することで、前記多孔質体の接合部分と該ダクト壁部とを接合する
ことを特徴とするダクトの製造方法。 When a duct wall made of synthetic resin is molded by a molding die, an elastic porous body is joined to one surface of the duct wall so as to close an opening formed through the duct wall. It ’s a manufacturing method,
At least a part of the adjacent portion of the porous body adjacent to the joint portion to be joined to the duct wall portion is formed so that the plate thickness thereof is thinner than the general portion corresponding to the central portion of the opening region of the opening. And
In a state where the adjacent portion is sandwiched between the molding dies in the plate thickness direction and compressed, the porous body is placed in the molding dies.
The duct wall portion having the opening in the cavity while supplying the synthetic resin in a molten state to the cavity of the molding mold facing the joint portion and sealing the synthetic resin by the compressed adjacent portion. A method for manufacturing a duct, which comprises joining a joint portion of the porous body and the duct wall portion by molding. 前記多孔質体における前記ダクト壁部側となる面と反対側を、前記一般部分よりも凹むように形成して、該一般部分よりも薄い前記隣接部分を設ける請求項４記載のダクトの製造方法。 The method for manufacturing a duct according to claim 4, wherein the side of the porous body opposite to the surface of the duct wall portion is formed so as to be recessed from the general portion, and the adjacent portion thinner than the general portion is provided. .. 前記多孔質体を、前記接合部分から前記隣接部分にかけて、前記一般部分の板厚よりも薄くなるように形成する請求項４または５記載のダクトの製造方法。 The method for manufacturing a duct according to claim 4 or 5, wherein the porous body is formed from the joint portion to the adjacent portion so as to be thinner than the plate thickness of the general portion.
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Publication number Priority date Publication date Assignee Title
JP2002106431A (en) * 2000-09-29 2002-04-10 Toyoda Gosei Co Ltd Air intake duct and its manufacturing method
JP2003080556A (en) * 2001-09-13 2003-03-19 Inoac Corp Method for molding resin molding with foamed resin sheet
JP2004285895A (en) * 2003-03-20 2004-10-14 Toyoda Gosei Co Ltd Intake device
JP2011012581A (en) * 2009-06-30 2011-01-20 Inoac Corp Intake duct
WO2011155437A1 (en) * 2010-06-08 2011-12-15 株式会社イノアックコーポレーション Intake duct
JP2020101146A (en) * 2018-12-25 2020-07-02 トヨタ紡織株式会社 Air intake duct of internal combustion engine

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2002106431A (en) * 2000-09-29 2002-04-10 Toyoda Gosei Co Ltd Air intake duct and its manufacturing method
JP2003080556A (en) * 2001-09-13 2003-03-19 Inoac Corp Method for molding resin molding with foamed resin sheet
JP2004285895A (en) * 2003-03-20 2004-10-14 Toyoda Gosei Co Ltd Intake device
JP2011012581A (en) * 2009-06-30 2011-01-20 Inoac Corp Intake duct
WO2011155437A1 (en) * 2010-06-08 2011-12-15 株式会社イノアックコーポレーション Intake duct
JP2020101146A (en) * 2018-12-25 2020-07-02 トヨタ紡織株式会社 Air intake duct of internal combustion engine

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