JP3794899B2

JP3794899B2 - Method for manufacturing waterproof cover for automobile door

Info

Publication number: JP3794899B2
Application number: JP2000140916A
Authority: JP
Inventors: 亨山下; 康成則武; 浩之松本
Original assignee: Marugo Rubber Industries Ltd; Mitsubishi Fuso Truck and Bus Corp
Current assignee: Marugo Rubber Industries Ltd; Mitsubishi Fuso Truck and Bus Corp
Priority date: 2000-04-05
Filing date: 2000-04-05
Publication date: 2006-07-12
Anticipated expiration: 2020-04-05
Also published as: JP2001287546A

Description

【０００１】
【発明の属する技術分野】
本発明は、自動車用ドアのインナパネルと同インナパネルの車室側の側面に装着されるドアトリムとの間に介装され、インナパネルを越えて雨水等が車室内に侵入することを防止する自動車用ドアの防水カバーに関するものである。
【０００２】
【従来の技術】
自動車用ドアの構造の一例を、便宜的に本発明の実施形態を示した図１の分解斜視図を援用して説明する。総括的に符号１０で示したドアは、薄鋼板をプレス成形したアウタパネル１２とインナパネル１４とからなるドア本体１６と、上記インナパネル１４の窓開口より下方部分の車室内側の側面に防水カバー１８を介して装着される化粧用のドアトリム２０とから構成され、上記アウタパネル１２とインナパネル１４との間の空間内に窓ガラスを昇降させるウィンドウレギュレータやスピーカ２２等の装備部品が収容される。スピーカ２２は車室側に設けられた取付フランジ２４を、上記インナパネル１４に設けられた開口２６の外周縁部に配設された複数の取付孔２８に挿通されるビスその他の固着具により固着することによって同インナパネル１４に固定される。
【０００３】
上記防水カバー１８は、インナパネル１４とドアトリム２０との間に介装される平らなカバー本体１８ａと、同カバー本体１８ａに設けられたスピーカ挿入用の透孔３０の周縁部に取付けられたカップ状又は皿状をなすカバー部材３２とから構成されている。同カバー部材３２は、上記インナパネル１４の開口２６に装着されたスピーカ２２のアウタパネル１２側に突出した外側部分３４を覆ってスピーカ２２を雨水等から保護するものであり、その開口端に形成された環状フランジ部が上記透孔３０の周縁部に重ね合わせ熱溶着されて、上記スピーカ２２の取付フランジ２４とインナパネル１４の開口２６の周縁部との間に介装され、上記固着具を締付けることにより水密接手が形成されるように構成されている。
【０００４】
上記防水カバー１８の従来の製造方法は、次のとおりである。先ず軟質の樹脂材料例えばＰＶＣのフィルムのロールから、図１に示されているような外部形状を有しかつ上記スピーカ挿入用の透孔３０を備えたカバー本体１８ａを成形する（実際には、上記透孔３０の外に、他の装備部品のための多数の透孔又は開口が同時に形成されるが、本発明とは直接関係がないので、図１では省略されている）と共に、別途真空成形により硬質のＰＶＣからなる厚肉のカップ状又は皿状をなすカバー部材３２が作られる。
【０００５】
また、スピーカ２２の振動が上記カバー部材３２に伝達されて同カバー部材３２がびびり振動を生起し雑音が発生することを防止するために、スピーカ２２の外側部分３４の端面に当接して振動の伝達を遮断するウレタン等の樹脂発泡材からなる円板状の内張り材３６が用意される。
図６に示されているように、上記カバー部材３２を高周波溶接装置の第１の電極Ｅ_１に設けた凹所ｅ_１内に挿入したのち、カバー部材３２内に内張り材３６を挿入する。次に、下端部が上記内張り部材３６の外径より小さい外径の円環状をなす第２の電極Ｅ_２を図中矢印で示すように圧下して、高周波電流を流すことにより、内張り材３６がカバー部材３２の底面に円環状の溶着部ｗ_１によって固着される。
【０００６】
次に、図７に示されているように、高周波溶接装置の第３の電極Ｅ_３に設けた円丘状突起ｅ_３に、上記カバー部材３２を逆さにして嵌装したのち、上記カバー本体１８ａの透孔３０を上記カバー部材３２に外嵌する。その後、上記透孔３０の周縁部とカバー部材３２のフランジ部との重なり合った環状のオーバラップ部分に、下端が円環状に形成された第４の電極Ｅ_４を図中矢印で示すように圧下して、高周波電流を流すことにより、上記オーバラップ部分に円環状の溶着部ｗ_２が形成される。
【０００７】
上記従来の防水カバー１８の構造では、カップ状又は皿状をなすカバー部材３２を硬質の樹脂材料で別途に成形しなければならないこと、及びカバー部材３２に対して内張り材３６を溶着する工程と、カバー部材３２のフランジ部をカバー本体１８ａの透孔３０の周縁部分と重ね合わせて溶接する工程とからなる２つの溶着工程が必要であること等の理由から、製造コストが高くなる不具合があった。
【０００８】
【発明が解決しようとする課題】
本発明は、自動車用ドアのインナパネルとドアトリムとの間に介装されて雨水等が車室内へ侵入することを防止する安価な防水カバーの製造方法を提供することを、主たる目的とするものである。
【０００９】
【課題を解決するための手段】
上記目的を達成するため、本発明にかかる請求項１記載の自動車用ドアの防水カバー製造方法は、自動車用ドアのインナパネルとドアトリムとの間に介装され、上記インナパネルに設けられた装備品取付け用の開口に略対応する周縁形状を有する透孔を備えた軟質樹脂材料製の第１防水フイルムと、上記インナパネル開口からドアアウタパネル側に突出する上記装備品の外側部分を覆うことができる広さを有し、かつ、上記透孔を閉塞するように重ね合わされて上記透孔の周縁外側部分で上記第１防水フイルムとオーバラップする外周縁を有する軟質樹脂材料製の第２防水フイルムとを、上記装備品の外側部分を収容することができる凹所を備えた雌型と上記雌型の凹所内に進入することができる突部を備えた雄型との間に介装して上記雌雄の型を圧接させることにより、上記第２防水フイルムに複数のひだ、または、しわを形成させながら折り畳んで上記第２防水フイルムを上記装備品の外側部分を覆う形状に成形したのち、上記雌雄の型における上記オーバラップ部分にそれぞれ備えられた環状の加熱手段により上記第１防水フイルムの透孔周縁部と上記第２防水フイルムの外周縁とを熱溶着している。
【００１０】
さらに、本発明にかかる請求項２記載の自動車用ドアの防水カバー製造方法は、請求項１において、上記雌型の凹所と上記雄型の突部とにそれぞれ備えられた加熱手段により、上記雌雄の型の圧接時に上記雌型の凹所内に軟質樹脂発泡材製の内張り材を熱溶着している。
【００１１】
【発明の実施の形態】
以下本発明の好ましい実施形態を図１ないし図５を参照して説明する。（なお、従来の防水カバー及びその製造方法に関連し図１を援用して既に説明した事項については再述を省略し、また従来の防水カバーと実質的に同一又は対応する部材及び部分には、同一の符号を用いる。）
先ず、図２の要部拡大断面図において、符号３８は、ドア１０のインナパネル１４にビス等適宜の固着具４０によって防水カバー１８を介し装着されるスピーカ２２の取付フランジ２４のインナパネル１４側の側面に予め装着されているゴム等からなるパッキング又はガスケット、４２はドアトリム２０のスピーカ２２に対向する部分に多数穿設され、スピーカ２２の発生音波を車室内に放散する小径の透孔である。
【００１２】
図３は防水カバー１８のスピーカ２２を覆う部分に拡大断面図であって、同防水カバー１８は、熱溶着に適する軟質樹脂材料、例えばＰＶＣのフィルム（一例として厚さ０．０７ｍｍのフィルム）を図１の斜視図に示すように打抜いて形成され、スピーカ２２の外側部分３４を挿通させる大きさの円形の透孔３０を備えた第１防水フィルム１８ａと、上記スピーカ２２の外側部分を覆うことができるように後述する方法でカップ状又は皿状に成形された第２防水フィルム３２と、同第２防水フィルム３２のカップ状又は皿状成形体の底面に熱溶着されたウレタン等の樹脂発泡体からなる円板状の内張り材３６とから形成されている。上記第２防水フィルム３２は、その外周縁の環状フランジ部３２ａを、第１防水フィルム１８ａの透孔３０の外周縁部に重ね合わせて熱溶着することが可能な適宜の軟質樹脂材料のフィルムによって形成され、第１防水フィルム１８ａと同一の樹脂材で作られることが好ましく、さらに同一厚さのフィルムで作られることが有利である。
【００１３】
図４及び図５は、上記第２防水フィルム３２をカップ状又は皿状に成形すると共に、その底面にスピーカ２２の振動伝達を抑制する内張り材３６を熱溶着し、さらに成形されて第２防水フィルム３２の環状フランジ部３２ａと第１防水フィルム１８ａの透孔３０の外周縁部とを重ね合わせて熱溶着する装置の概略構造を示す断面図である。上記成形及び熱溶着装置は、第２防水フィルム３２を上記スピーカ２２の外側部分３４を覆うのに適合する形状のカップ状又は皿状に形成するための凹所４４と、同凹所４４の底面に円環状にかつ略同心的に配置された加熱手段４６と、凹所４４の開口端に連続する平面部において同開口端の周縁部分に円環状にかつ略同心的に配置された加熱手段４８とを備えた雌型５０、及び上記凹所４４内に進入することができ、かつ進入したときに同凹所４４の内周面との間に上記第２防水フィルム３２と厚さ以上の隙間が形成されるような形状の突部５２と、同突部５２の下端面に設けられ上記加熱手段４６と実質的に同心でかつ同一半径の円環状をなす加熱手段５４と同突部５２の上端に連続する平面部において上記加熱手段４８と実質的に同心でかつ同一半径の円環状をなす加熱手段５６とを備えた雄型５８を備え、雌型５０は溶着装置のベッドに固定され、雄型５８は同溶着装置の昇降ヘッドに装着される。
【００１４】
上記加熱手段４６，４８，５４及び５６は、ニクロム線等の通電発熱体を雌型５０、雄型５８の上記所定位置に埋設して形成しても良く、また高周波溶着を行う場合は、高周波電流を流す導電体によって形成される。
【００１５】
図１の斜視図に示されているように、所定の外部形状を有し、かつスピーカ挿入用の透孔３０を備えた第１防水フィルム１８ａ、及び円板状をなす内張り材３６が従来の防水カバー１８と同様に予め製作される。一方、雌型５０の凹所４４の開口端の半径より十分大きな半径を有し、雄型５８の突部５２によって上記凹所４４内に押込まれたとき外周縁部３２ａが第１防水フィルム１８ａの透孔３０の周縁外側部分に重なり合いオーバラップ部を形成するような円板状をなす第２防水フィルム３２が、好ましくは第１防水フィルム１８ａと同一材質の樹脂フィルム、さらに、望ましくは同一厚さの樹脂フィルムから打抜いて準備される。
【００１６】
図４に示されているように、先ず、雌型５０上に円板状の第２防水フィルム３２が凹所４４に対し略同心的に載置され、その上に樹脂発泡材製の軽い内張り材３６が凹所４４に対し略同心的に載置される。次に、第１防水フィルム１８ａが、凹所４４に対し透孔３０が略同心になるように載置される。それらの作業中、雄型５８は図示位置より十分上方の作業を妨げない高位置に上昇している。
次に、図５に示されているように雄型５８を下降させると、突部５２が雌型５０の凹所４４内に進入するにつれて、内張り材３６と一体に第２防水フィルム３２の中央部分が凹所４４内に押込まれて、同第２防水フィルム３２がカップ状又は皿状に成形される。
【００１７】
上記第２防水フィルム３２の成形は、金属薄板のプレス加工のように、塑性変形によって成形されるのではなく、凹所４４の側壁に沿う部分に、図３にその一部を符号６０で示したように、複数のひだ又はしわを形成しながら折畳み成形される。図５に示す位置から雄型５８がさらに下降して、突部５２の上端に連続する平面部が第１防水フィルム１８ａの透孔３０の周縁部と第２防水フィルム３２の外周縁のフランジ部３２ａとを圧接させたのち、雌雄両型５０及び５８の加熱手段４６，４８，５４及び５６に通電することによって、内張り材３６と第２防水フィルム３２のカップ状又は皿状成形部の底面に熱溶着されると共に、第１防水フィルム１８ａの透孔３０の周縁部と第２防水フィルム３２の外周縁のフランジ部３２ａとのオーバラップ部が円環状に熱溶着される。
なお、上記において第２防水フィルム３２の上に第１防水フィルム１８ａを載置した例を示したが、第１防水１８ａを雌型５０上に載置し次に第２防水フィルム３２を上記第１防水フィルム１８ａ上に重ねて載置し、第１防水フィルム１８ａの透孔３０の周縁部と第２防水フィルム３２の外周縁のフランジ部３２ａとのオーバラップ部を円環状に熱溶着してもよい。
【００１８】
上記防水カバー１８は、前記従来の防水カバーと較べ、スピーカ２２の外側部分を覆うカップ状又は皿状の硬質樹脂材からなるカバー部材３２を真空成形等により別途製造する必要がなく、またカバー部材３２とカバー本体１８ａとの溶着、及び同カバー部材３２と内張り材３６との溶着を別工程で夫々異なる溶着電極を用いて行う必要がなく、一組の雌型５０及び雄型５８を用いて、第２防水フィルム３２の成型、第１及び第２防水フィルム１８ａ及び３２の熱溶着、第２防水フィルム３２と内張り材３６との熱溶着を同一工程で行うことができるので、構造簡単で製造コストを大幅に低減し得る利点がある。
なお、第２防水フィルム３２と内張り材３６の熱溶着工程を、上記の第１及び第２防水フィルム１８ａ及び３２の熱溶着工程と同時に行わない場合であつても本発明の主旨を逸脱するもので無いことは勿論である。
【００１９】
また、第１防水フィルム１８ａと第２防水フィルム３２とは、熱溶着部の信頼性の観点から同一の樹脂材であることが好ましく、さらに材料歩止り等の観点から同一厚さのフィルムであることが望ましいが、熱溶着可能な異種の樹脂材料を用いることができ、またフィルムの厚さは必ずしも同一である必要はない。さらに、第２防水フィルム３２のカップ状又は皿状成形体の内側面に溶着される内張り材３６は、例示した円板状以外の形状、例えば成形後にスピーカ２２の外側部分３４の後端面とそれに隣接する外周面とに当接する皿状部材となるような形状のものでも良く、またスピーカ２２の振動に基づきびびり振動が生起されることがない場合、又はスピーカ２２以外の装備部品の場合は、内張り材３６を省略することができる。なお、上記実施形態に係る防水カバー１８は、夫々の厚さが０．１ｍｍ前後の薄い軟質樹脂フィルムからなる第１及び第２防水フィルム１８ａ及び３２と、軟質の樹脂発泡材製の内張り材３６とから構成され、全体として変形自在な構造であるので、図３は上記雌雄の型５０及び５８内で成形及び熱溶着が終了した瞬間の形状を示し、型から取出した後は一定の形状を保持せず、その後ドア１０に取付けたとき図２に示されるように略図３に示す形状に近い形状を呈することとなる。
【００２０】
【発明の効果】
本発明にかかる請求項１所載の自動車用ドアの防水カバー製造方法は、自動車用ドアのインナパネルとドアトリムとの間に介装され、上記インナパネルに設けられた装備品取付け用の開口に略対応する周縁形状を有する透孔を備えた軟質樹脂材料製の第１防水フイルムと、上記インナパネル開口からドアアウタパネル側に突出する上記装備品の外側部分を覆うことができる広さを有し、かつ、上記透孔を閉塞するように重ね合わされて上記透孔の周縁外側部分で上記第１防水フイルムとオーバラップする外周縁を有する軟質樹脂材料製の第２防水フイルムとを、上記装備品の外側部分を収容することができる凹所を備えた雌型と上記雌型の凹所内に進入することができる突部を備えた雄型との間に介装して上記雌雄の型を圧接させることにより、上記第２防水フイルムに複数のひだ、または、しわを形成させながら折り畳んで上記第２防水フイルムを上記装備品の外側部分を覆う形状に成形したのち、上記雌雄の型における上記オーバラップ部分にそれぞれ備えられた環状の加熱手段により上記第１防水フイルムの透孔周縁部と上記第２防水フイルムの外周縁とを熱溶着するものであって、防水カバーを製造するための設備及び作業工程を簡素化して、製造コストを大幅に低減させうる利点がある。
【００２１】
また、本発明にかかる請求項２記載の自動車用ドアの防水カバー製造方法は、請求項１において、上記雌型の凹所と上記雄型の突部とにそれぞれ備えられた加熱手段により、上記雌雄の型の圧接時に上記雌型の凹所内に軟質樹脂発泡材製の内張り材を熱溶着するものであって、防水カバーを製造するための設備及び作業工程を一層簡素化して、製造コストをさらに低減させうる利点がある。
【図面の簡単な説明】
【図１】本発明に係る防水カバーを含む自動車用ドアの分解斜視図である。
【図２】図１に示した自動車用ドアの装備部品（図示の場合はスピーカ）取付部分の断面図である。
【図３】図２の装備部品取付部分における防水カバーを抽出して示した部分的拡大断面図である。
【図４】図３に示した防水カバーにおける第２防水フィルムの成形及び熱溶着工程の最初の状態を示した断面図である。
【図５】図４示した成形及び熱溶着工程の完了直前の状態を示した断面図である。
【図６】従来の防水カバー製造方法においてカバー部材に内張り材を溶着する工程を示す断面図である。
【図７】図６に示した工程の後、カバー部材をカバー本体に溶着する工程を示す断面図である。
【符号の説明】
１０…ドア、１２…アウタパネル、１４…インナパネル、１６…ドア本体、１８…防水カバー、２０…ドアトリム、１８ａ…カバー本体又は第１防水フィルム、２２…スピーカ（装備部品）、２４…スピーカの取付フランジ、２６…開口、３０…透孔、３２…カバー部材又は第２防水フィルム、３４…スピーカの外側部分、３６…内張り材、４４…凹所、５０…雌型、５２…突部、５８…雄型。[0001]
BACKGROUND OF THE INVENTION
The present invention is interposed between an inner panel of an automobile door and a door trim attached to a side surface of the inner panel on the passenger compartment side, and prevents rainwater or the like from entering the passenger compartment beyond the inner panel. The present invention relates to a waterproof cover for an automobile door.
[0002]
[Prior art]
An example of the structure of an automobile door will be described with the aid of the exploded perspective view of FIG. 1 showing an embodiment of the present invention for convenience. In general, a door denoted by reference numeral 10 includes a door body 16 composed of an outer panel 12 and an inner panel 14 formed by press-molding a thin steel plate, and a waterproof cover on the side of the inner panel 14 below the window opening on the vehicle interior side. A door trim 20 for makeup mounted through 18 is installed, and equipment components such as a window regulator and a speaker 22 for raising and lowering the window glass are accommodated in a space between the outer panel 12 and the inner panel 14. The speaker 22 is fixed to a mounting flange 24 provided on the passenger compartment side by screws or other fixing tools inserted into a plurality of mounting holes 28 provided at the outer peripheral edge of the opening 26 provided in the inner panel 14. By doing so, it is fixed to the inner panel 14.
[0003]
The waterproof cover 18 includes a flat cover main body 18a interposed between the inner panel 14 and the door trim 20, and a cup attached to a peripheral portion of a speaker insertion through hole 30 provided in the cover main body 18a. And a cover member 32 having a plate shape or a plate shape. The cover member 32 covers the outer portion 34 protruding to the outer panel 12 side of the speaker 22 attached to the opening 26 of the inner panel 14 to protect the speaker 22 from rainwater and the like, and is formed at the opening end thereof. The annular flange portion is overlapped and thermally welded to the peripheral portion of the through hole 30, and is interposed between the mounting flange 24 of the speaker 22 and the peripheral portion of the opening 26 of the inner panel 14, and tightens the fixing tool. In this way, a water-tight hand is formed.
[0004]
A conventional method for manufacturing the waterproof cover 18 is as follows. First, from a roll of a soft resin material such as PVC film, the cover body 18a having an external shape as shown in FIG. A large number of through holes or openings for other equipment parts are formed at the same time outside the through hole 30 but are not directly related to the present invention, and are omitted in FIG. 1). The cover member 32 having a thick cup shape or dish shape made of hard PVC is formed by molding.
[0005]
In addition, in order to prevent the vibration of the speaker 22 from being transmitted to the cover member 32 and causing the chatter vibration to generate chatter vibration, noise is generated by contacting the end surface of the outer portion 34 of the speaker 22. A disc-shaped lining material 36 made of a resin foam material such as urethane that blocks transmission is prepared.
As shown in FIG. 6, the cover member 32 is inserted into the recess e ₁ provided in the _first electrode E ₁ of the high frequency welding apparatus, and then the lining material 36 is inserted into the cover member 32. Then, a lower end and rolling as shown by the arrow a second electrode E ₂ forming an annular outside diameter smaller than that of the lining member 36, by flowing a high frequency current, the lining material 36 There are fixed by welding portions w ₁ of the annular on the bottom surface of the cover member 32.
[0006]
Next, as shown in FIG. 7, after the cover member 32 is fitted upside down on the conical protrusion e ₃ provided on the _third electrode E ₃ of the high frequency welding apparatus, the cover body The through hole 30 of 18a is fitted on the cover member 32. Thereafter, pressure as shown in overlapped overlapping portion of the annular flange portion of the peripheral edge and the cover member 32 of the through hole 30, the fourth electrode E ₄ that the lower end is formed in an annular shape by the arrow and, by flowing a high frequency current, the welding portion w ₂ of the annular above overlap portion is formed.
[0007]
In the structure of the conventional waterproof cover 18, the cup-shaped or dish-shaped cover member 32 must be separately formed of a hard resin material, and the lining material 36 is welded to the cover member 32. There is a problem that the manufacturing cost is increased due to the necessity of two welding processes including a process of superimposing and welding the flange portion of the cover member 32 to the peripheral portion of the through hole 30 of the cover body 18a. It was.
[0008]
[Problems to be solved by the invention]
The present invention is to provide a method for producing a cheaper waterproof cover you prevent interposed in rainwater or the like between the inner panel and the door trim of an automotive door from entering into the passenger compartment, a main object It is what.
[0009]
[Means for Solving the Problems]
In order to achieve the above object, a method for manufacturing a waterproof cover for an automobile door according to claim 1 according to the present invention is provided between an inner panel and a door trim of an automobile door and is provided on the inner panel. covering the first waterproof film made of a soft resin material having a hole having a peripheral shape substantially corresponding to the opening for goods attachment, the outer portion of the equipment which protrudes from the upper Symbol inner panel opening in the door outer panel side And a second waterproofing made of a soft resin material having an outer peripheral edge that overlaps with the first waterproofing film at an outer peripheral edge portion of the through hole that is overlapped so as to close the through hole. A film is interposed between a female mold having a recess capable of accommodating the outer portion of the equipment and a male mold having a protrusion capable of entering the female mold recess. Male and female By pressing the mold, the second waterproof film is folded while forming a plurality of pleats or wrinkles, and the second waterproof film is formed into a shape that covers the outer portion of the equipment, and then the male and female molds are formed. The peripheral edge portion of the first waterproof film and the outer peripheral edge of the second waterproof film are heat-welded by the annular heating means respectively provided in the overlap portion.
[0010]
Furthermore, the waterproof cover manufacturing method for an automobile door according to claim 2 according to the present invention is the method according to claim 1, wherein the heating means provided in each of the female recess and the male projection are used to A lining material made of a soft resin foam is thermally welded into the recess of the female mold when the male and female molds are pressed.
[0011]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, preferred embodiments of the present invention will be described with reference to FIGS. (It should be noted that, with respect to the conventional waterproof cover and the manufacturing method thereof, the description already made with reference to FIG. 1 is omitted, and members and portions substantially the same as or corresponding to the conventional waterproof cover are not included. , The same code is used.)
2, reference numeral 38 denotes an inner panel 14 side of the mounting flange 24 of the speaker 22 that is attached to the inner panel 14 of the door 10 via a waterproof cover 18 with an appropriate fixing tool 40 such as a screw. Packing or gasket made of rubber or the like, which is pre-mounted on the side of the door trim, is a small-diameter through hole that is perforated in a portion facing the speaker 22 of the door trim 20 and diffuses sound waves generated by the speaker 22 into the vehicle interior. .
[0012]
Figure 3 is an enlarged sectional view of a portion covering the speaker 22 of the waterproof cover 18, the waterproof cover 18, a soft resin material suitable for heat-welding, for example a PVC film (film thickness of 0.07mm as one example) As shown in the perspective view of FIG. 1, a first waterproof film 18 a having a circular through hole 30 sized to insert the outer portion 34 of the speaker 22 and the outer portion of the speaker 22 are formed. A second waterproof film 32 formed into a cup shape or a dish shape by a method described later so that it can be covered, and urethane or the like thermally welded to the bottom surface of the cup shape or dish shape molded body of the second waterproof film 32 It is formed from a disk-shaped lining material 36 made of a resin foam. Film of the second waterproof film 32, an annular flange portion 32a of the outer peripheral edge thereof, as appropriate of the soft resin material capable of thermal welding superimposed on the outer peripheral edge of the through hole 30 of the first waterproof film 18 a is formed by, is preferably made of a first waterproof film 18 a and the same resin material, it further made with a film of the same thickness is advantageous.
[0013]
4 and 5, the second waterproof film 32 is formed into a cup shape or a dish shape, and a lining material 36 for suppressing vibration transmission of the speaker 22 is thermally welded to the bottom surface of the second waterproof film 32, and further molded to form a second waterproof film. by superimposing the outer peripheral edge of the through hole 30 of the annular flange portion 32a and the first waterproof film 18a of the film 32 is a sectional view showing a schematic structure of equipment to be thermally welded. The molding and heat welding apparatus includes a recess 44 for forming the second waterproof film 32 into a cup shape or a dish shape adapted to cover the outer portion 34 of the speaker 22, and a bottom surface of the recess 44. The heating means 46 arranged in a ring shape and substantially concentrically, and the heating means 48 arranged in a ring shape and substantially concentrically at the peripheral portion of the opening end in the plane portion continuous to the opening end of the recess 44. The second waterproof film 32 and a gap larger than the thickness between the female mold 50 provided with the inner die and the inner peripheral surface of the recess 44 when entering. Of the projection 52 and the heating means 54 provided on the lower end surface of the projection 52 and substantially concentric with the heating means 46 and having an annular shape with the same radius. Substantially concentric with the heating means 48 in a flat portion continuous to the upper end. And comprising a male 58 and a heating means 56 which forms an annular same radius, the female mold 50 is fixed to the bed of the welding device, the male 58 is mounted on the lifting head of the welding device.
[0014]
The heating means 46, 48, 54 and 56 may be formed by burying an energization heating element such as a nichrome wire in the predetermined position of the female mold 50 and the male mold 58. It is formed by a conductor that conducts current.
[0015]
As shown in the perspective view of FIG. 1, a first waterproof film 18a having a predetermined external shape and provided with a through hole 30 for inserting a speaker, and a lining material 36 having a disk shape are conventional. Like the waterproof cover 18, it is manufactured in advance. On the other hand, the outer peripheral edge 32a has a radius sufficiently larger than the radius of the opening end of the recess 44 of the female mold 50, and the outer peripheral edge 32a is pushed into the recess 44 by the protrusion 52 of the male mold 58. The second waterproof film 32 having a disk shape that overlaps the outer peripheral portion of the through hole 30 and forms an overlap portion is preferably a resin film made of the same material as the first waterproof film 18a, and more preferably the same thickness. It is prepared by punching from the resin film.
[0016]
As shown in FIG. 4, first, a disc-shaped second waterproof film 32 is placed on the female mold 50 substantially concentrically with respect to the recess 44, and a light lining made of a resin foam material is placed thereon. The material 36 is placed substantially concentrically with respect to the recess 44. Next, the first waterproof film 18 a is placed so that the through hole 30 is substantially concentric with the recess 44. During these operations, the male mold 58 is raised to a high position that does not hinder the operation sufficiently above the illustrated position.
Next, as shown in FIG. 5, when the male mold 58 is lowered, as the protrusion 52 enters the recess 44 of the female mold 50, the center of the second waterproof film 32 is integrated with the lining material 36. The portion is pushed into the recess 44, and the second waterproof film 32 is formed into a cup shape or a dish shape.
[0017]
The second waterproof film 32 is not formed by plastic deformation as in the press working of a thin metal plate, but a part along the side wall of the recess 44 is indicated by reference numeral 60 in FIG. As described above, it is folded while forming a plurality of pleats or wrinkles. The male mold 58 further descends from the position shown in FIG. 5, and the flat portion continuing to the upper end of the projection 52 is the peripheral edge of the through hole 30 of the first waterproof film 18 a and the flange of the outer peripheral edge of the second waterproof film 32. 32a is brought into pressure contact with the heating means 46, 48, 54, and 56 of the male and female molds 50 and 58, whereby the lining material 36 and the second waterproof film 32 are formed on the bottom surface of the cup-shaped or dish-shaped molded portion. While being thermally welded, an overlap portion between the peripheral edge portion of the through hole 30 of the first waterproof film 18a and the flange portion 32a of the outer peripheral edge of the second waterproof film 32 is thermally welded in an annular shape.
In addition, although the example which mounted the 1st waterproofing film 18a on the 2nd waterproofing film 32 was shown above, the 1st waterproofing 18a was mounted on the female type | mold 50, and the 2nd waterproofing film 32 was then attached to the said 2nd waterproofing film 32 above. The first waterproof film 18a is placed on top of each other, and an overlap portion between the peripheral edge portion of the through hole 30 of the first waterproof film 18a and the flange portion 32a of the outer peripheral edge of the second waterproof film 32 is welded in an annular shape. Also good.
[0018]
Compared to the conventional waterproof cover, the waterproof cover 18 does not need to be separately manufactured by vacuum molding or the like for the cover member 32 made of a cup-shaped or dish-shaped hard resin material that covers the outer portion of the speaker 22. There is no need to perform welding between the cover member 32 and the cover main body 18a and between the cover member 32 and the lining material 36 in different processes using different welding electrodes, and a pair of female mold 50 and male mold 58 are used. Since the second waterproof film 32 can be molded, the first and second waterproof films 18a and 32 can be thermally welded, and the second waterproof film 32 and the lining material 36 can be thermally welded in the same process, the structure is simple and manufactured. There is an advantage that the cost can be greatly reduced.
Even if the thermal welding process between the second waterproof film 32 and the lining material 36 is not performed at the same time as the thermal welding process of the first and second waterproof films 18a and 32, it does not depart from the gist of the present invention. Of course not.
[0019]
Moreover, it is preferable that the 1st waterproof film 18a and the 2nd waterproof film 32 are the same resin materials from a viewpoint of the reliability of a heat weld part, and also are films of the same thickness from viewpoints, such as material yield. Although it is desirable, different resin materials that can be thermally welded can be used, and the thicknesses of the films are not necessarily the same. Furthermore, the lining material 36 to be welded to the inner surface of the cup-shaped or dish-shaped molded body of the second waterproof film 32 has a shape other than the illustrated disk shape, for example, the rear end surface of the outer portion 34 of the speaker 22 after molding, It may be shaped like a dish-shaped member that comes into contact with the adjacent outer peripheral surface, and when chatter vibration does not occur based on the vibration of the speaker 22, or in the case of equipment parts other than the speaker 22, The lining material 36 can be omitted. The waterproof cover 18 according to the above-described embodiment includes the first and second waterproof films 18a and 32 made of thin soft resin films each having a thickness of about 0.1 mm, and a lining material 36 made of a soft resin foam material. 3 is a structure that can be deformed as a whole. FIG. 3 shows the shape of the male and female molds 50 and 58 at the moment when molding and heat welding are completed, and after the mold is taken out, it has a certain shape. When not attached and then attached to the door 10, as shown in FIG. 2, a shape close to the shape shown in FIG. 3 will be exhibited.
[0020]
【The invention's effect】
According to a first aspect of the present invention, there is provided a method for manufacturing a waterproof cover for a door of an automobile, wherein the waterproof cover is provided between an inner panel of the automobile door and a door trim and is provided in an opening for mounting equipment provided on the inner panel. Yes first waterproof film soft resin material made of having a hole having a peripheral shape substantially corresponding to the size capable of covering the outer portion of the equipment which protrudes from the upper Symbol inner panel opening in the door outer panel side And a second waterproof film made of a soft resin material, which is overlapped so as to close the through hole and has an outer peripheral edge that overlaps the first waterproof film at an outer peripheral portion of the through hole. The male and female molds are interposed between a female mold having a recess capable of accommodating the outer portion of the product and a male mold having a protrusion capable of entering the female mold recess. By pressure welding The second waterproof film is folded while forming a plurality of pleats or wrinkles, and the second waterproof film is formed into a shape that covers the outer portion of the equipment, and then formed on the overlap portion of the male and female molds. Equipment for manufacturing a waterproof cover and work steps are provided for heat-welding the peripheral edge of the through hole of the first waterproof film and the outer peripheral edge of the second waterproof film by the respective annular heating means. There is an advantage that the manufacturing cost can be greatly reduced by simplification.
[0021]
According to a second aspect of the present invention, there is provided a method for manufacturing a waterproof cover for an automobile door according to the first aspect, wherein the heating means provided in each of the female recess and the male projection is used in the first aspect. A soft resin foam lining material is thermally welded into the female recess when the male and female molds are pressed together, further simplifying the equipment and work process for manufacturing the waterproof cover, thereby reducing the manufacturing cost. There is an advantage that can be further reduced.
[Brief description of the drawings]
FIG. 1 is an exploded perspective view of an automobile door including a waterproof cover according to the present invention.
FIG. 2 is a cross-sectional view of a mounting part (speaker in the case of illustration) of the automobile door shown in FIG. 1;
3 is a partially enlarged cross-sectional view showing a waterproof cover extracted from the equipment component mounting portion of FIG. 2; FIG.
4 is a cross-sectional view showing an initial state of a second waterproof film forming and heat welding step in the waterproof cover shown in FIG. 3;
FIG. 5 is a cross-sectional view showing a state immediately before completion of the molding and heat welding process shown in FIG. 4;
FIG. 6 is a cross-sectional view showing a process of welding a lining material to a cover member in a conventional waterproof cover manufacturing method.
7 is a cross-sectional view showing a step of welding a cover member to a cover body after the step shown in FIG. 6;
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 ... Door, 12 ... Outer panel, 14 ... Inner panel, 16 ... Door main body, 18 ... Waterproof cover, 20 ... Door trim, 18a ... Cover main body or 1st waterproof film, 22 ... Speaker (equipment part), 24 ... Installation of speaker Flange, 26 ... opening, 30 ... through hole, 32 ... cover member or second waterproof film, 34 ... outer portion of speaker, 36 ... lining material, 44 ... recess, 50 ... female mold, 52 ... projection, 58 ... Male type.

Claims

A first waterproofing made of a soft resin material having a through hole interposed between an inner panel and a door trim of an automobile door and having a peripheral shape substantially corresponding to an opening for mounting equipment provided on the inner panel. and the film, has an upper Symbol size capable of covering the outer portion of the equipment which projects from the inner panel opening in the door outer panel side, and the periphery of superimposed so as to close the hole the hole A female mold having a recess capable of accommodating the outer portion of the equipment, and a female die having a second waterproof film made of a soft resin material having an outer peripheral edge that overlaps the first waterproof film at the outer portion, and the female A plurality of pleats or wrinkles are formed in the second waterproof film by interposing between the male mold and the male mold having a protrusion capable of entering into the recess of the mold and press-contacting the male and female molds. Sena Folded the second after the waterproof film is molded into a shape to cover the outer portion of the equipment, through hole peripheral edge of the first waterproof film by heating means cyclic provided respectively in the overlapped portion in the mold of the male and female A method for manufacturing a waterproof cover for an automobile door, wherein the outer periphery of the second waterproof film is thermally welded.

The lining material made of a soft resin foam material in the female mold recess according to claim 1, wherein the female mold recess and the male mold protrusion are provided with heating means, respectively, when the male and female molds are pressed against each other. A method for manufacturing a waterproof cover for automobile doors that is thermally welded.