JP3579987B2 - Method of manufacturing insulator for case - Google Patents

Description

[0001]
[Industrial applications]
INDUSTRIAL APPLICABILITY The present invention relates to a method of manufacturing an insulator attached to an inner wall of a case body for heat insulation or sound absorption, and is suitable for use in a method of manufacturing an insulator of a vehicle air conditioner case.
[0002]
[Prior art]
Conventionally, as a method of forming an insulator attached to the inner wall of a vehicle air conditioner case, a forming method described in Japanese Patent Application Laid-Open No. 3-256726 has been proposed.
Specifically, a plate-shaped soft polyethylene insulator is squeezed deeply to the same depth as the air-conditioning case so as to follow the inner wall shape of the air-conditioning case, and vacuum-formed. Unnecessary portions of the outer edge of the insulator are cut and removed (trimmed) so as to meet the requirements.
[0003]
[Problems to be solved by the invention]
By the way, in a general-purpose cutting machine, since the cutting is performed by pressing vertically like a press machine, the side wall of the insulator formed by squeezing deeply is cut and removed by a cutting machine so as not to lose its shape (in a horizontal direction). Cutting and removal) was difficult.
Therefore, conventionally, the insulator was thickened so as not to lose its shape, and was cut and removed manually using scissors or the like. Therefore, there has been a problem that the productivity of the insulator is low, there is a lot of useless portions to be cut and removed, and there is a lot of waste of material cost.
[0004]
In view of the above, an object of the present invention is to reduce the cost of forming an insulator by mechanizing a cutting and removing step after molding an insulator.
[0005]
[Means for Solving the Problems]
The present invention uses the following technical means to achieve the above object.
The invention according to claim 1 is a method for manufacturing a resin insulator attached to an inner wall of a case body for heat insulation or sound absorption,
A cutting step of cutting the insulator (3) from a plate-like material into a predetermined shape;
A forming step of drawing the insulator (3) cut into the predetermined shape into a shape along the inner wall shape of the case (2) main body;
A trimming step of cutting and removing an outer edge of the insulator (3) drawn and formed in the forming step.
In the forming step, the case (2) is formed by squeezing it shallower than the body depth,
The trimming step is characterized in that the outer edge (3b) of the flat portion (3a) of the insulator (3) that is not narrowed is cut and removed.
[0006]
According to a second aspect of the invention, there is provided the method for manufacturing the case insulator according to the first aspect, wherein the forming step is performed by narrowing the case (2) to a depth of approximately 1/3 of a body depth. It is characterized by doing.
According to a third aspect of the present invention, there is provided an insulator attaching method for attaching an insulator manufactured by the manufacturing method according to the first or second aspect to an inner wall of the case (2),
A bending step of bending a flat portion (3a) of the insulator (3) that is not squeezed to form a shape along the inner wall shape of the case (2) main body;
A step of attaching the insulator (3) bent in the folding step to the inner wall of the case 2 with an adhesive.
[0007]
In the invention described in claim 4, the case (2) main body,
An insulator disposed on the inner wall of the case (2) main body and produced by the production method according to claim 1 or 2,
The insulator (3) is formed by bending a flat portion (3a) of the insulator (3) that is not squeezed and forming the insulator (3) into a shape along the shape of the case (2) main body inner wall. It is characterized by being adhered and fixed.
[0008]
In addition, the code | symbol in parenthesis of the said each means shows the correspondence with the concrete means of the Example described later.
[0009]
Operation and Effect of the Invention
According to the invention as set forth in claims 1 to 4, after the insulator is formed by being squeezed shallower than the depth of the case main body, the outer edge portion of the flat portion that is not squeezed is cut and removed, so that the insulator collapses due to the cutting force. It can be removed without cutting. Therefore, since the cutting and removing step can be mechanized, productivity can be greatly improved as compared with the case where cutting and removing are manually performed using scissors or the like.
[0010]
Further, since the insulator can be cut and removed by the cutting force without collapsing, the thickness of the insulator can be reduced, and the cost of the insulator manufacturing can be reduced in combination with the above-described improvement in productivity.
[0011]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the drawings.
(1st Embodiment)
FIG. 1 shows a state in which an insulator 1 manufactured by the method for manufacturing an insulator according to the present embodiment is attached to an air conditioning case 2 of a vehicle air conditioner.
[0012]
As shown in FIG. 1, the insulator 1 is formed into a shape along the inner wall of the air-conditioning case 2 and is adhered to the inner wall of the air-conditioning case 2 with a volatile adhesive or the like.
Hereinafter, a method of manufacturing the insulator 1 and steps until the insulator 1 is attached to the air conditioning case 2 will be described in the order of the steps.
1. Cutting Step A plate-shaped insulator material is cut into a predetermined shape in consideration of the depth of the air-conditioning case 2 to form an insulator sheet 3. The thickness of the insulator sheet 3 is about 2 to 3 mm, and the material is made of soft polyethylene.
[0013]
2. Forming process (vacuum forming method)
The insulator sheet 3 cut and formed in the above-described cutting step is formed by a vacuum forming method described below. FIG. 2 is a schematic view of the vacuum forming apparatus. Reference numeral 4 denotes a jig for holding the insulator sheet 3, and the jig 4 is used to hold the end of the insulator sheet 3 cut in the previous cutting step. .
[0014]
Then, as shown in FIG. 2, the insulator sheet 3 is fixed to the upper part of the paper surface of the vacuum forming mold 5. The mold 5 for vacuum forming includes a core 5a formed in a convex shape and a pedestal 5b integrally connected to the core 5a. A large number of small holes 6 for vacuum suction are formed on the upper side of the paper surface of the core 5a, and these small holes 6 communicate with a vacuum generator such as a vacuum pump (not shown).
[0015]
Next, after the insulator sheet 3 is heated and softened by a heating device (not shown), as shown in FIG. 3, the mold 5 or the insulator sheet 3 is moved while pressing the insulator sheet 3 against the core 5a. The air in the space 35 between the mold 5 and the insulator 3 is rapidly removed by a vacuum pump or the like. Then, since the pressure in the space 35 is reduced, the insulator sheet 3 is pressed against the core 5a by the atmospheric pressure and is formed so as to conform to the shape of the core 5a (see FIG. 4). Then, after cooling, the insulator sheet 3 is taken out and the molding step is completed.
[0016]
In addition, the squeezing depth (h dimension in FIG. 4) of the insulator sheet 3 formed in this forming step is squeezed to be shallower than the depth of the air conditioning case 2 (H dimension in FIG. 1). It is about 1/3 of the depth of the case 2 (H dimension in FIG. 1).
3. Trimming Step An unnecessary portion (3b in FIG. 5) located at the outer edge of the flat portion 3a of the insulator sheet 3 formed in the forming process, which is not squeezed, is cut and removed (trimmed). This cutting and removing is performed by a cutting machine 7, and the structure of the cutting machine 7 is, as shown in FIG. 5, a cutting tool (Thomson blade) 7b on a pedestal 7a and a wooden holding the Thomson blade 7b. And the holding member 7c are disposed.
[0017]
In the holding member 7c, a concave portion is formed at a portion where the convex portion of the insulator sheet 3 comes into contact with the convex shape of the insulator sheet 3.
At the time of cutting, a plate 7d made of a resin (in this embodiment, vinyl chloride) for protecting the insulator sheet 3 is placed on the flat portion 3a (see FIG. 4) of the insulator sheet 3. Then, by pressing the press 7e toward the plate 7d, the unnecessary portion 3b of the insulator sheet 3 is cut and removed together with the plate 7d. Incidentally, the processing of cutting using the cutting machine 7 as described above is called Thomson processing.
[0018]
4. Insulator sticking step The flat part 3a of the insulator sheet 3 (see FIGS. 6 and 7) which has been subjected to the Thomson processing in the above-mentioned cutting and removing step is bent to form the inner wall side surface part 2a of the air conditioning case 2 as shown in FIG. . Then, the insulator 1 is fitted into the air-conditioning case 2 while being bent by hand, and is attached to the inner wall of the air-conditioning case 2 using a volatile adhesive.
[0019]
Next, features of the present embodiment will be described.
After forming by squeezing (H> h) shallower than the depth of the case body, the flat portion 3a that is not squeezed is cut and removed, so the unnecessary 3b portion of the insulator 3 is cut without the insulator 3 being deformed by the cutting force. It can be cut and removed by the machine 7. Therefore, since the trimming process can be mechanized, the productivity can be greatly improved as compared with the case where the trimming process is manually cut and removed.
[0020]
In addition, since the insulator 3 can be cut and removed by the cutting force without deforming, the thickness of the insulator can be reduced, and the manufacturing cost of the insulator 1 can be reduced in combination with the above-described improvement in productivity. it can. Incidentally, the thickness of the insulator 1 when the trimming process was performed manually was about 5 mm.
[0021]
Incidentally, the cutting machine 7 used in the trimming step is not limited to the structure shown in FIG. 5, and a Thomson blade 7b may be provided on the press 7e side as shown in FIG. In this case, a protection plate 7f made of urethane is disposed between the Thomson blades 7b to protect the insulator sheet 3.
[Brief description of the drawings]
FIG. 1 is a perspective view showing a state in which an insulator manufactured by a method for manufacturing an insulator according to the present embodiment is attached to an air conditioning case.
FIG. 2 is a schematic view showing a mold for a vacuum forming method.
FIG. 3 is a schematic view showing a vacuum suction state in a vacuum forming method.
FIG. 4 is a schematic view showing an insulator sheet after a vacuum forming method is completed.
FIG. 5 is a schematic view showing a cutting machine.
FIG. 6 is a perspective view showing a first state of the insulator during a sticking step.
FIG. 7 is a perspective view showing a second state of the insulator during a sticking step.
FIG. 8 is a perspective view showing a third state of the insulator during an attaching step.
FIG. 9 is a schematic diagram showing another embodiment of the cutting machine used in the trimming step.
[Explanation of symbols]
1 ... insulator, 2 ... air conditioning case, 3 ... insulator sheet,
3a: plane portion, 3b: unnecessary portion, 4: jig, 5: mold, 5a: core,
7 cutting machine, 7a pedestal, 7b cutting tool (Thomson blade), 7c holding member,
7d: plate, 7e: press.

Claims (4)

A method for manufacturing a resin insulator attached to the inner wall of the case body for heat insulation or sound absorption,
A cutting step of cutting into a predetermined shape from the insulator plate material,
A forming step of drawing the insulator cut into the predetermined shape into a shape along the inner wall shape of the case body;
Trimming step of cutting and removing the outer edge of the insulator drawn and formed in the forming step,
The molding step, squeezing and molding shallower than the case body depth,
The method for manufacturing an insulator for a case, wherein the trimming step cuts and removes an outer edge portion of a flat portion of the insulator that is not squeezed. The method of manufacturing an insulator for a case according to claim 1, wherein in the forming step, the forming is performed by narrowing down to a depth of approximately 1/3 of a depth of the case main body. An insulator sticking method for sticking an insulator manufactured by the manufacturing method according to claim 1 or 2 to an inner wall of a case,
A bending step of bending a flat portion of the insulator that is not squeezed, and bending the insulator into a shape along the inner wall shape of the case body.
Attaching the insulator bent in the folding step to the inner wall of the case with an adhesive. The case body,
An insulator arranged on the inner wall of the case main body and manufactured by the manufacturing method according to claim 1 or 2,
The insulator is characterized in that the insulator is bent and fixed to the inner wall of the case main body in a state where the flat portion of the insulator that is not squeezed is formed in a shape along the inner wall shape of the case main body. Case.

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