JP4186090B2

JP4186090B2 - Air guide duct

Info

Publication number: JP4186090B2
Application number: JP21126999A
Authority: JP
Inventors: 浩鈴木; 正昭杉浦
Original assignee: Inoac Corp
Current assignee: Inoac Corp
Priority date: 1999-07-26
Filing date: 1999-07-26
Publication date: 2008-11-26
Anticipated expiration: 2019-07-26
Also published as: JP2001039146A

Description

【０００１】
【発明の属する技術分野】
この発明は、空気案内ダクトに関し、更に詳細には、車両の乗員室に設置されるインストルメントパネルやフロアコンソールおよび天井パネル等の各種車両内装部材の内側等に配設され、エアコンユニットからの調温空気を該車両内装部材の所要位置に設けた空気吹出部へ案内する空気案内ダクトに関するものである。
【０００２】
【従来の技術】
乗用車等の車両における乗員室内部には、計器盤や空調制御操作盤およびオーディオ等の各種車載機器等を設置したインストルメントパネル、運転席および助手席間の床面に設置されるフロアーコンソール、乗員室天井に取付けられる天井パネル等の各種車両内装部材が装着されている。また乗員室の前方には、前記空調制御操作盤によって運転制御される乗員室空調用のエアコンユニットが、前記インストルメントパネルに被覆された状態で設置されており、このエアコンユニットで所定温度に調節された調温空気は、例えば該インストルメントパネルの乗員席側を指向した外面部の適宜位置に設けた空気吹出部、前記フロアーコンソールの適宜位置に設けた空気吹出部、天井パネルの適宜位置に設けた空気吹出部等から乗員室内へ吹出すようになっている。すなわち、インストルメントパネル,フロアーコンソール,天井パネル等の各車両内装部材の内側には、前記エアコンユニットと夫々の空気吹出部とを連通接続する空気案内ダクトが設けられており、該エアコンユニットから送出された調温空気は、これら空気案内ダクト内を流通して各空気吹出部へ案内される。
【０００３】
【発明が解決しようとする課題】
ところで前記空気案内ダクトは、前述した各種車両内装部材の内側に配設し得るように、矩形状,円形状または異形状の断面形状を有する中空体としてブロー成形等により成形される。しかるに従来の空気案内ダクトは、一般的にポリエチレン(ＰＥ)等の樹脂を素材としているため、例えば内部に画成された空気流通路に冷気が流通する場合には、該空気流通路と外部との温度差により撥水して結露し易い欠点を内在している。従って、この結露が水滴となって車体やブラケット等の鋼材部品に滴下すると錆発生の原因となると共に、また該水滴がハーネスや電装部品等に滴下するとショートや車載機器の誤作動および故障等を招来する重大な問題を内在していた。また、前記ハーネスや電装部品が空気案内ダクトに接触すると、不快な異音が発生する問題もある。このため、空気案内ダクトの表面にウレタンシート等を貼着することで結露防止および異音発生防止の対策を図っているが、ウレタンシートの材料費および貼着作業を要するため製造コストが嵩む欠点があった。更に、エアコンユニットの内部と各空気吹出部とが前記空気案内ダクトを介して空間的に連通しているため、該エアコンユニット内で駆動するブロアの運転騒音が、該空気案内ダクト内を伝播して乗員室内へ漏れる問題も指摘される。
【０００４】
【発明の目的】
本発明は、前述した課題を好適に解決するべく提案されたもので、断熱効果および防音効果等に優れる２枚の発泡樹脂シート材を所要形状に成形した第１基材および第２基材から構成することによって、結露の防止、他部材との接触による異音の発生防止、エアコンユニットの騒音吸収等を図ると共に、適宜の形状保持部材を装着することで強度向上をも図った空気案内ダクトを提供することを目的とする。
【０００５】
【課題を解決するための手段】
前記課題を解決して、所期の目的を達成するため、本発明に係る車両用空気案内ダクトは、車両の乗員室に設置される各種車両内装部材の内側に配設され、該車両に設けられるエアコンユニットと空気吹出部とを連通的に接続して調温空気を該空気吹出部へ案内する空気案内ダクトにおいて、
所要厚の発泡樹脂シート材から前記ダクトを長手方向に分割した際の半体として成形され、長手方向へ対応的に相互に接合することで内部に空気流通路を画成し、両端縁部に空気流入口および空気流出口を備える第１基材および第２基材と、
前記第１基材および第２基材の本体部における短手方向の中間部で長手方向に沿設された形状保持部材とを備え、
前記形状保持部材は、前記第１基材または第２基材の外面から内部方向へ拡大する形状を有することを特徴とする。
【０００６】
【発明の実施の形態】
次に、本発明に係る空気案内ダクトにつき、好適な実施例を挙げて、添付図面を参照しながら以下説明する。本発明が対象とする空気案内ダクトは、例えば図９に示すように、全体がＩ型,Ｕ型,Ｌ型等やこれ以外の様々な形状とされると共に径方向の横断面も矩形状,丸形状,異形状等の様々な形状に成形され得る。そして、車両の乗員室内に組付けられるインストルメントパネル,フロアーコンソール,天井パネル等(何れも図示せず)の各種車両内装部材の内側(裏側)に配設され、乗員室前方に搭載されるエアコンユニット５０と前記車両内装部材の所要位置に配設される空気吹出部５２とを連通的に接続し、該エアコンユニット５０から空気排出部位５１を介して送出される調温空気を対応の空気吹出部５２へ流通案内するようになっている。
【０００７】
図１は、本発明の好適な一実施例に係る空気案内ダクトを示す概略斜視図であり、また図２は、図１に示す空気案内ダクト１０の各構成部材を分解状態で示す概略斜視図である。この空気案内ダクト１０は、所要厚の発泡樹脂シート材１２から所要形状に成形された第１基材１１と、同じく所要厚の発泡樹脂シート材１４から所要形状に成形された第２基材１３と、これら第１基材１１および第２基材１３の外面部に装着されて当該基材１１,１３の強度向上および形状保持を図る第１形状保持部材２０,２０および第２形状保持部材２５,２５とから構成されている。そして、前記第１基材１１および第２基材１３を長手方向へ接合することで、長手方向の両端部が略直角に屈曲した角筒体状を呈し、一方端部に前記エアコンユニット５０の空気排出部位５１に連結される矩形状の空気流入口１５が開口形成されると共に、他方端部に前記空気吹出部５２に連設される矩形状の空気流出口１６が開口形成される。すなわち本実施例では、空気流入口１５と空気吹出口１６が同一方向を指向した略Ｕ型の空気案内ダクトを例示している。
【０００８】
(第１基材および第２基材)
前記第１基材１１および第２基材１３は、例えばポリエチレン(ＰＥ)やポリプロピレン(ＰＰ)等を材質とする発泡樹脂シート材１２,１４から、前記空気案内ダクト１０を長手方向に分割した際の半体として対称形状に成形され(後述)、図２に示すように、横断面コ字形の屈曲樋状を呈した本体部１１ａ,１３ａと、この本体部１１ａ,１３ａの短手方向の端縁部から水平外方へ延出した当接片部１１ｂ,１３ｂとが設けられている。前記発泡樹脂シート材１２,１４は、柔軟性に富んで単体では自体の形状保持に充分な剛性を有さないが、従来のブロー成形材と比較すると熱伝導率が低いので優れた断熱効果や防音,吸音効果を有する一方、同一厚さの該ブロー成形材と比較すると４０％程度軽量である。このような第１基材１１と第２基材１３は、夫々の当接片部１１ｂ,１３ｂの当接面同士を互いに密着的に当接させて長手方向へ接合することにより、内部に空気流通路１７を画成すると共に両端部に空気流入口１５および空気流出口１６を備えた中空体状の空気案内ダクト１０を形成するようになる。
【０００９】
(第１形状保持部材)
前記第１形状保持部材２０は、図１〜図３に示すように、本体２１が例えば鋼等を材質とする断面円形のワイヤ状線部材であって、第１基材１１または第２基材１３の本体部１１ａ,１３ａ外面に沿設して、当該第１基材１１および第２基材１３の長手方向の曲げ変形および撓み変形を抑制して形状を保持するよう機能する。この第１形状保持部材２０は、前記第１基材１１,第２基材１３の本体部１１ａ,１３ａの外面における短手方向の略中間部で長手方向に沿って延在する形状に成形され、本体２１の両端部は前記空気流入口１５および空気流出口１６の開口端縁近傍に到達する長さに設定されている。そして各第１形状保持部材２０,２０は、対応の第１基材１１または第２基材１３の成形工程時に同時に装着され(後述)、図７(ａ)および図７(ｂ)に示すように、第１基材１１,第２基材１３の外面にその全長に亘って略埋設された状態で配設される。このとき前記本体２１は、前述したように断面円形状を呈しているので、図７(ｃ)に拡大して示すように、第１基材１１,第２基材１３の外面から内部方向へ適宜拡大した形状となり、発泡樹脂シート材１２,１４の一部が該本体２１に覆い被さった結果として該本体２１が食込んだ状態となるため、第１形状保持部材２０は該基材１１,１３に係着されて容易な脱抜が不可能になっている。なお、第１基材１１または第２基材１３に対する第１形状保持部材２０の装着に際し、適宜の接着剤を使用すれば更なる装着強度の向上が期待できる。
【００１０】
また前記各第１形状保持部材２０,２０には、ビス孔２３を開設した矩形板状のブラケット(取付具)２２(本実施例では２個)が、本体２１から横方向へ延出した状態に配設されている。これらブラケット２２,２２は、当該の第１形状保持部材２０が第１基材１１または第２基材１３に装着された際に該基材１１,１３の外面から側外方へ延出するようになり(図１)、当該空気案内ダクト１０を車体や前記車両内装部材の内側等に組付固定するために供される。なお前記ブラケット２２の配設個数は、空気案内ダクト１０の全長や形状等によって適宜決定されるものであり、またその形状および設置角度等も該空気案内ダクト１０の設置部位の形状等によって適宜変更される。更に、当該の空気案内ダクト１０を車体または車両内装部材の内部裏側に直接的に固定する必要がない場合は、第１形状保持部材２０はブラケット２２を有さない本体２１だけからなる形態のものを使用してもよい。
【００１１】
(第２形状保持部材)
第２形状保持部材２５は、図１,図２および図５に示すように、第１基材１１および第２基材１３における長手方向の各端縁部に沿って装着され、これら第１基材１１および第２基材１３が接合された際に画成される前記空気流入口１５および空気流出口１６を囲繞するようになり、当該空気流入口１５および空気流出口１６の容易な変形を抑制して形状を保持するために供される。各第２形状保持部材２５は、例えばポリエチレン等を材質として各基材１１,１３の端縁部に沿いつつ密着的に延在するサイズでコ字形にインジェクション成形され、該基材１１,１３の外面部に密着しながら空気流入口１５または空気流出口１６の開口端縁に沿って延在する本体部２６と、この本体部２６に適宜段差状態で連設されて各基材１１,１３に係着状態で延在する取着部２７とからなる。そして前記取着部２７では、図６および図８に示すように、所要間隔毎に形成された複数個のテーパ状の係着孔２８が直列状に開設されると共に、前記第１形状保持部材２０の端部が嵌入可能な係止孔２９が短手方向側端面の略中央に形成されている。
【００１２】
このように形成された第２形状保持部材２５は、対応の第１基材１１または第２基材１３の成形工程時(後述)に同時に装着されるもので、図８(ａ)および図８(ｂ)に示すように、第１基材１１,第２基材１３の端縁部外面に密着した状態で配設される。このとき前記取着部２７の各係着孔２８は、前述したように円錐テーパ状を呈しているので、図８(ｃ)に拡大して示すように、発泡樹脂シート材１２,１４が各係着孔２８内へ膨出する結果として該係着孔２８の底縁部２８ａが基材１１,１３へ食込んだ状態となり、これにより第２形状保持部材２５は当該の第１基材１１または第２基材１３に係着されるようになる。なお、第１基材１１または第２基材１３に対する第２形状保持部材２５の装着に際し、適宜の接着剤を使用すれば更なる装着強度の向上が期待できる。
【００１３】
(第１基材および第２基材の成形について)
前述のような形状の第１基材１１および第２基材１３は、例えば公知の形成技術として既に実用化されている「圧空成形」または「真空成形」等により所定形状に形成される。このうち圧空成形法は、２枚のシート材を圧縮空気の圧力を利用して対応する夫々の成形型の内面(成形面)に押付けることにより、中空体を成形する方法であり、図１０〜図１４は、この圧空成形法を利用して本実施例の空気案内ダクト１０を成形する工程を経時的に示す説明図である。すなわち、先ず図１０に示すように、第１基材１１を成形するための発泡樹脂シート材１２と第２基材１３を成形するための発泡樹脂シート材１４とを、スペーサ４３を挟んで所要間隔に配置すると共に、各発泡樹脂シート材１２,１４の端縁部をクランプ４５,４５で把持する。
【００１４】
そして第１工程では、図１１に示すように、前記スペーサ４３およびクランプ４５,４５により所要間隔にセットした各発泡樹脂シート材１２,１４をヒータ４６,４６で予備加熱して軟化させると共に、スペーサ４３に形成された空気噴出孔４４を介して両発泡樹脂シート材１２,１４間に画成される空間４７へ圧縮空気を送り込むことにより、両シート材１２,１４を互いに離間する方向へ適宜拡開変形させる。
【００１５】
次いで第２工程では、図１２(ａ)および図１２(ｂ)に示すように、予め成形型４０の上型４１およぴ下型４２の各成形面４１ａ,４２ａに前記第１形状保持部材２０および第２形状保持部材２５をセットした前提において、該上型４１および下型４２とを近接移動させて型締めする。そして、更に前記空間４７へ圧縮空気を送り込むことにより、図１４(ａ)および図１４(ｂ)に示すように、上側の発泡樹脂シート材１２が上型４１の成形面４１ａに密着すると共に、下側の発泡樹脂シート材１４が下型４２の成形面４２ａに密着するようになる。また、上型４１の当接面４１ｂと下型４２の当接面４２ｂにより、両発泡樹脂シート材１２,１４の外周縁近傍が挟圧されて前記当接片部１１ｂ,１３ｂが形成され、両シート材１２,１４はこの当接片部１１ｂ,１３ｂの当接面が自己融着して互いに接合されるに至る。なお、前記成形型４０における上型４１および下型４２には、図示しない空気吸引機に接続された空気吸引ノズル４８,４８が配設されており、各ノズル４８から成形型４０内の空気を吸引することにより、各成形面４１ａ,４２ａに対する発泡樹脂シート材１２,１４の密着性向上が図られる。
【００１６】
ここで、各発泡樹脂シート材１２,１４が上型４１および下型４２の各成形面４１ａ,４２ａに密着するに際し、前記第１形状保持部材２０および第２形状保持部材２５にも接触して密着するようになる。この際に、前記第１形状保持部材２０では、図７に示すように、発泡樹脂シート材１２,１４が本体２１を包み込むように変形するので該本体２１が該シート材１２,１４に食込んだ状態となり、第１形状保持部材２０は対応のシート材１２,１４に係着して容易な脱抜が不可能に装着される。一方、第２形状保持部材２５では、図８に示すように、発泡樹脂シート材１２,１４が取着部２７の各係着孔２８を介して外方へ膨出するので該係着孔２８の底縁部２８ａが該シート材１２,１４に食込んだ状態となり、第２形状保持部材２５は対応のシート材１２,１４に係着して容易な離脱が不可能に装着される。
【００１７】
前記成形型４０による発泡樹脂シート材１２,１４の成形が完了して該シート材１２,１４が冷却,硬化したら、第３工程として、上型４１および下型４２を開放して互いに接合された第１基材１１および第２基材１３を成形型４０から脱型する。そして図１４に示すように、接合部分の適宜位置で不要部分を切除することにより、図１に示ような第１形状保持部材２０および第２形状保持部材２５を装着した空気案内ダクト１０が成形される。
【００１８】
前述した圧空成形では、第１基材１１と第２基材１３の成形および接合が同時になされると共に、これら各基材１１,１３に対する第１形状保持部材２０および第２形状保持部材２５の装着も同時になし得るので、成形作業の大幅な合理化を図り得る。なお圧空成形においては、前記第１基材１１と第２基材１３との材質を同系統のものにすることが望ましい。
【００１９】
一方、真空成形を利用して本実施例の空気案内ダクト１０を成形する場合には、第１基材１１用の真空成形型を利用して発泡樹脂シート材１２から前記第１基材１１を成形すると共に、第２基材１３用の真空成形型を利用して発泡樹脂シート材１４から前記第２基材１３を成形する。そして次工程において、第１基材１１の当接片部１１ｂ,１１ｂと第２基材１３の当接片部１３ｂ,１３ｂ同士を接着剤等で接着して、該第１基材１１および第２基材１３を長手方向へ接合する。そして、前記第１基材１１および第２基材１３の成形に際し、前記第１形状保持部材２０および第２形状保持部材２５を前記各真空成形型の成形面にセットするようにすれば、第１基材１１の成形と同時に各形状保持部材２０,２５を該第１基材１１の外面所定位置へ装着可能であり、また第２基材１３の成形と同時に各形状保持部材２０,２５を該第２基材１３の外面所定位置へ装着可能である。なお前記第１基材１１と第３基材１３とは、前述した接着剤による接着接合の他に、例えば振動溶着(融着)、熱板等を利用した熱溶着(融着)、超音波溶着(融着)等の方法によっても好適に接合し得る。
【００２０】
【実施例の作用】
次に、前述のように構成された本実施例の空気案内ダクトの作用につき説明する。
【００２１】
空気案内ダクト１０における第１基材１１は、ポリエチレンまたはポリプロピレン等を材質とする発泡樹脂シート材１２から所要形状に一体成形され、また第２基材１３は、ポリエチレンまたはポリプロピレン等の同材質の発泡樹脂シート材１４から所要形状に一体成形される。なお、圧空成形により成形する場合は、第１基材１１と第２基材１３の成形と接合が同時になされると共に、前記第１形状保持部材２０と第２形状保持部材２５の装着も同時になされる。一方、真空成形により成形する場合は、第１基材１１の成形および該基材１１に対する前記第１形状保持部材２０と第２形状保持部材２５の装着と、第２基材１３の成形および該基材１３に対する前記第１形状保持部材２０と第２形状保持部材２５の装着とが夫々個別に実施された後、成形された両基材１１,１３を後工程で互いに接合する。
【００２２】
前記圧空成形または真空成形により成形された本実施例の空気案内ダクト１０では、第１基材１１および第２基材１３の各本体部１１ａ,１３ａの外面に、長手方向へ延在する第１形状保持部材２０,２０が沿設されているので、弾力性を有する該基材１１,１３の長手方向への曲げ変形や撓み変形およびこれによる座屈変形等を好適に抑制することができる。更に本実施例の空気案内ダクト１０では、第１基材１１および第２基材１３の長手方向の各端縁部に第２形状保持部材２５,２５が装着されているので、両端部に形成された空気流入口１５および空気流出口１６の形状も好適に保持され、該空気流入口１５とエアコンユニット５０の空気排出部位５１との連結保持や、該空気流出口１６と前記空気吹出部５２との連結保持が好適になされる。しかも、第１形状保持部材２０の両端部が各第２形状保持部材２５,２５の係止孔２９に嵌入しているので、これら第１形状保持部材２０および第２形状保持部材２５,２５は単一部材の如く構成され、対応の第１基材１１,第２基材１３に対する形状保持の好適な向上が図られる。
【００２３】
前述のように形成された空気案内ダクト１０は、前記第１形状保持部材２０に形成された各ブラケット２２,２２を、前記車両内装部材の内部裏側の所定位置に整合させ、例えばビス等の固定部材を利用して取付固定される。なお、この空気案内ダクト１０が前記インストルメントパネルの内部裏側に設置される場合には、図９に示すように、空気流入口１５をエアコンユニット５０の空気排出部位５１の空気排出口に直結すると共に、空気流出口１６を該インストルメントパネルの所要位置に設けた空気吹出部５２に連結する。
【００２４】
そして、前記インストルメントパネルに配設した空調制御操作盤での所要操作により前記エアコンユニット５０の運転を開始すると、該エアコンユニット５０内で所定温度に調節された調温空気は、前記空気排出部位５１から空気流入口１５を介して空気流通路１７内へ流出する。その後、空気案内ダクト１０の空気流通路１７を移動した調温空気は、空気流出口１６から空気吹出部５２へ通出された後、該空気吹出部５２の吹出口から乗員室内へ吹出すようになる。
【００２５】
このように構成された本実施例の空気案内ダクト１０では、該ダクト１０の全体を構成する第１基材１１および第２基材１３が、断熱効果および吸音効果に優れる発泡樹脂シート材１２,１４から形成されている。従って、空気案内ダクト１０における空気流通路１７の内部と、車両内装部材の内部裏側(空気案内ダクト１０の外側)との温度差が大きくても、該空気案内ダクト１０の外表面に結露が発生することがないと共に、この結露による水滴の発生および滴下も好適に防止される。また、車両内装部材の内部に配設されたハーネスや車載機器に水滴が滴下することもないので、ショートしたり車載機器の誤作動や故障等を招来することもない。更に、水滴の滴下による車体等の鋼材部品の錆発生も好適に防止し得る。
【００２６】
また第１基材１１および第２基材１３は吸音効果にも優れているので、例えばこれら基材１１,１３の何れかに他部材(ハーネス等)が接触していたとしても、異音の発生が好適に防止される。更には、前記エアコンユニット５０内で駆動するブロアの運転騒音は、第１基材１１および第２基材１３である程度吸収されてしまうので、該ブロアの運転騒音が空気吹出部５２を介して乗員室内へ漏れることも好適に防止される。一方、発泡樹脂シート材１２,１４自体が軽量であるため、これにより形成された実施例の空気案内ダクト１０は、従来のブロー成形により成形された空気案内ダクトに対して大幅な軽量化(４０％程度)が図られる。
【００２７】
【変更例】
図１５は、本発明の変更例に係る空気案内ダクトの概略斜視図であって、この変更例の空気案内ダクト３５は、前記実施例の空気案内ダクト１０を基本とした下で、第１基材１１および第２基材１３の各本体部１１ａ,１３ａにおける長手方向の略中央位置に、前記第１形状保持部材２０と交差して該基材１１,１３の外面形状に沿いつつ延在する第３形状保持部材３６を更に追加装着したものである。従ってこの空気案内ダクト３５では、長手方向の略中央部が第３形状保持部材３６で形状保持されるので、長手軸心を中心とした周方向への捻れ変形をも好適に抑制して形状を保持することが可能となる。なお第３形状保持部材３６は、前記第１形状保持部材２０および第２形状保持部材２５と同様に、第１基材１１および第２基材１３の成形時に同時に装着することが可能であり、またここでは該第２形状保持部材２５と同一形態のものを例示している。すなわち、ポリエチレン等を材質としてインジェクション成形され、長手方向へ所要間隔毎に複数個の係着孔３７を形成することで、この係着孔３７と発泡樹脂シート材１２,１４との係着下に当該基材１１,１３に対する装着が好適に図られる。
【００２８】
また図１６は、前記第１形状保持部材２０の変更例を例示したもので、図１６(ａ),(ｂ)に示すように、本体２１の適宜位置に、装着する基材１１,１３の奥側へ変位した屈曲部２４を形成したものである。これにより、第１基材１１または第２基材１３に装着された変更例の第１形状保持部材２０では、図１６(ｃ)に示すように、前記屈曲部２４が当該基材１１,１３の奥側へ大きく食込むと共に該屈曲部２４の外側へ発泡樹脂シート材１２,１４が張出すようになり、この屈曲部２４での係着力が大幅に高められて基材１１,１３からの脱抜防止が好適に図られる。
【００２９】
なお前記実施例および変更例では、第１形状保持部材２０として鋼等を材質とする断面円形のワイヤ状線部材を例示したが、この第１形状保持部材２０の形態はこれに限定されるものではなく、例えばポリエチレン等を材質とする細長棒状や細長板状の一体成形品としてもよい。ここで細長棒状とした場合には、その横断面形状は前記円形に限定されるものではなく、基材１１,１３の外面から内部方向へ適宜拡大する断面形状であれば逆三角形や台形等としてもよい。また細長板状とした場合には、前記第２形状保持部材２５と同様な係着孔を長手方向へ所要間隔毎に形成して、この係着孔と発泡樹脂シート材との係着下に装着する形態としてもよい。なお、第１形状保持部材２０を樹脂製とした場合には、前記第２形状保持部材２５,２５と該第１形状保持部材２０は素材が同一材質の樹脂製部品として一体成形することが可能となり、これにより単一部材として構成されるから部品管理および取扱いが容易となる。
【００３０】
また前記第２形状保持部材２５は、ポリエチレン製の一体成形品に限定されるものではなく、前記第１形状保持部材２０と同様に鋼等を材質とする断面円形のワイヤ状線部材としてもよい。この場合に、第１形状保持部材２０と第２形状保持部材２５は素材が同一材質の鋼製となるので、該第１形状保持部材２０の両端部に第２形状保持部材２５,２５を溶接接合すれば、両者２０,２５は単一部材の如く構成されるから部品管理および取扱いが容易となる。更に前記第３形状保持部材３６は、前記第１形状保持部材２０を樹脂製とした場合には、第３形状保持部材３６と第１形状保持部材２０は素材が同一材質の樹脂製部品として一体成形することが可能となる一方、また前記第３形状保持部材３６を鋼等を材質とする断面円形のワイヤ状線部材としてもよく、この場合は該第３形状保持部材３６と第１形状保持部材２０は素材が同一材質の鋼製となるので、両者３６,２０を溶接接合すれば単一部材の如く構成し得る。一方、第１形状保持部材２０に設けたブラケット２２を、第２形状保持部材２５または第３形状保持部材３６に設けてもよい。
【００３１】
前記実施例および変更例の各空気案内ダクト１０,３５は、インストルメントパネル,フロアーコンソール,ピラーガーニッシュおよび天井パネル等の各種車両内装部材の内部裏側に配設される各空気案内ダクトに好適に応用し得る。
【００３２】
【発明の効果】
以上説明した如く、本発明に係る空気案内ダクトは、該ダクト全体を構成する第１基材および第２基材を、断熱効果および吸音効果に優れる発泡樹脂シート材から形成した。従って、空気案内ダクトにおける空気流通路の内部と、車両内装部材の内部裏側(空気案内ダクトの外側)との温度差が大きくても、該空気案内ダクトの外表面に結露が発生することがないと共に、この結露による水滴の発生および滴下も好適に防止されるので、車両内装部材の内部に配設されたハーネスや車載機器に水滴が滴下することを起因としたショートや車載機器の誤作動および故障等の発生や、水滴の滴下による車体等の鋼材部品の錆発生等を好適に防止し得る利点がある。また、第１基材および第２基材は吸音効果にも優れているので、例えばこれら基材の何れかに他部材(ハーネス等)が接触していたとしても異音の発生が好適に防止される一方、エアコンユニット内で駆動するブロアの運転騒音は、第１基材および第２基材で吸収されてしまうので、該ブロアの運転騒音が空気吹出部を介して乗員室内へ漏れることも好適に防止される利点もある。しかも、従来のブロー成形製の空気案内ダクトと比較すると、大幅な軽量化を図り得る。
【００３３】
また本発明の空気案内ダクトは、第１基材および第２基材の外面に、短手方向の中間部で長手方向へ延在する形状保持部材が装着されているので、弾力性を有する該基材の長手方向への曲げ変形や撓み変形およびこれによる座屈変形等を好適に抑制することができる有益な効果を奏する。また、第１基材および第２基材の長手方向の各端縁部に第２の形状保持部材を装着すれば、両端部に形成された空気流入口および空気流出口の形状保持も好適になされるようになり、該空気流入口とエアコンユニットとの連結保持や、該空気流出口と前記空気吹出部との連結保持も好適になし得る利点もある。更に、第１基材および第２基材の長手方向中間部に第３の形状保持部材を装着すれば、夫々の基材の捻れ変形を抑制することも可能となる。なお、前記第１基材および第２基材に対する形状保持部材,第２の形状保持部材および第３の形状保持部材の装着は、夫々の基材を成形する圧空成形または真空成形時に同時に行なうことができるので、製造の合理化や効率化を損なうことがない。しかも、形状保持部材、第２の形状保持部材および第３の形状保持部材は、第１基材および第２基材に対して食込んだ状態で係着されるので、これら基材から容易に脱抜しない。更に、各形状保持部材の素材を同一材質とした場合には、夫々を溶接または一体成形して構成することが可能となり、部品管理および取扱いが容易となる利点もある。
【図面の簡単な説明】
【図１】本発明の好適な一実施例に係る空気案内ダクトの概略斜視図である。
【図２】図１に示す空気案内ダクトの分解斜視図である。
【図３】第１形状保持部材の概略斜視図である。
【図４】 (ａ)は図３のIII−III線断面図、(ｂ)は図３のIV−IV線断面図である。
【図５】第２形状保持部材の概略斜視図である。
【図６】 (ａ)は図５のＶ−Ｖ線断面図、(ｂ)は図５のVI−VI線断面図である。
【図７】基材に対する第１形状保持部材の装着状態を示し、(ａ)は図１のVII−VII線断面図、(ｂ)は図１のVIII−VIII線断面図、(ｃ)は(ｂ)の要部拡大図である。
【図８】基材に対する第２形状保持部材の装着状態を示し、(ａ)は図１のIX−IX線断面図、(ｂ)は図１のＸ−Ｘ線断面図、(ｃ)は(ｂ)の要部拡大図である。
【図９】エアコンユニットの空気排出部位と車両内装部材に設置される空気吹出部とを連結する空気案内ダクトの実施形態を示す分解斜視図である。
【図１０】空気案内ダクトを構成する第１基材および第２基材を圧空成形により成形する工程の説明図であって、二枚の発泡樹脂シート材をスペーサを挟んで位置決めしてクランプで把持する状態を示している。
【図１１】空気案内ダクトを構成する第１基材および第２基材を圧空成形により成形する第１工程の説明図であって、スペーサを挟んで固定した二枚の発泡樹脂シート材間の空間に圧縮空気を送り込むと共に、両発泡樹脂シート材をヒータで予備加熱している状態を示している。
【図１２】空気案内ダクトを構成する第１基材および第２基材を圧空成形により成形する第２工程の説明図であって、(ａ)は成形面に第１形状保持部材および第２形状保持部材セットした成形型の上型および下型を、加熱された両発泡樹脂シート材の上下方向から近接する状態を背面側から示す要部断面図、(ｂ)は(ａ)の状態を側面および正面側から示す要部断面図である。
【図１３】空気案内ダクトを構成する第１基材および第２基材を圧空成形により成形する第３工程の説明図であって、(ａ)は上型および下型が型締めされると共に該上型および下型の各成形面に発泡樹脂シート材が密着した状態を背面側から示す要部断面図、(ｂ)は(ａ)の状態を側面および正面側から示す要部断面図である。
【図１４】二枚の発泡樹脂シート材から成形された第１基材および第２基材を示し、(ａ)は不要部分を切除する状態を背面側から示す要部断面図、(ｂ)は不要部分を切除する状態を側面および正面側から示す要部断面図である。
【図１５】変更例に係る空気案内ダクトの概略斜視図であって、第１形状保持部材と第２形状保持部材の他に新たに第３形状保持部材を装着することで捻れ変形をも抑制し得る形態を例示したものである。
【図１６】 (ａ)は変更例に係る第１形状保持部材を基材に装着した状態を示す断面図であって、(ｂ)は(ａ)の要部拡大図であり、(ｃ)は(ｂ)のＹ−Ｙ線断面図である。
【符号の説明】
１１第１基材
１１ａ本体部
１２発泡樹脂シート材
１３第２基材
１３ａ本体部
１４発泡樹脂シート材
１５空気流入口
１６空気流出口
１７空気流通路
２０第１形状保持部材(形状保持部材)
２２ブラケット(取付具)
２５第２形状保持部材
３６第３形状保持部材
５２空気吹出部
５０エアコンユニット[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an air guide duct. More specifically, the present invention is disposed inside various vehicle interior members such as an instrument panel, a floor console, and a ceiling panel installed in a passenger compartment of a vehicle, and is adjusted from an air conditioner unit. The present invention relates to an air guide duct for guiding warm air to an air blowing portion provided at a required position of the vehicle interior member.
[0002]
[Prior art]
Inside the passenger compartment of vehicles such as passenger cars, instrument panels with instrument panels, air conditioning control operation panels, and various in-vehicle devices such as audio, floor consoles installed on the floor between the driver's seat and passenger seat, passengers Various vehicle interior members such as a ceiling panel attached to the room ceiling are mounted. In addition, an air conditioning unit for passenger compartment air conditioning, which is controlled by the air conditioning control operation panel, is installed in front of the passenger compartment so as to be covered with the instrument panel, and adjusted to a predetermined temperature by the air conditioning unit. The temperature-controlled air is, for example, an air blowing portion provided at an appropriate position on the outer surface portion facing the passenger seat side of the instrument panel, an air blowing portion provided at an appropriate position on the floor console, and an appropriate position on the ceiling panel. The air is blown into the passenger compartment from the provided air blowing section. That is, an air guide duct is provided inside each vehicle interior member such as an instrument panel, a floor console, a ceiling panel, etc. to connect the air conditioner unit and the respective air outlets. The temperature-controlled air thus circulated in these air guide ducts is guided to each air blowing section.
[0003]
[Problems to be solved by the invention]
By the way, the air guide duct is formed by blow molding or the like as a hollow body having a rectangular shape, a circular shape, or a different cross-sectional shape so as to be disposed inside the various vehicle interior members described above. However, since conventional air guide ducts are generally made of resin such as polyethylene (PE), for example, when cold air flows through an air flow passage defined inside, the air flow passage and the outside Due to the temperature difference between the two, there is a drawback that water repellency and condensation easily occur. Therefore, if this condensation forms water droplets and drops onto steel parts such as the car body and brackets, it causes rust, and if the water droplets drop onto harnesses or electrical parts, it can cause short circuits or malfunctions and failures of in-vehicle equipment. Inherent a serious problem to invite. Further, when the harness or the electrical component comes into contact with the air guide duct, there is a problem that unpleasant noise is generated. For this reason, measures are taken to prevent condensation and abnormal noise by sticking a urethane sheet or the like to the surface of the air guide duct. was there. Further, since the interior of the air conditioner unit and each air blowing portion are in spatial communication via the air guide duct, the operating noise of the blower driven in the air conditioner unit propagates through the air guide duct. The problem of leaking into the passenger compartment is also pointed out.
[0004]
OBJECT OF THE INVENTION
The present invention has been proposed to suitably solve the above-described problems, and includes a first base material and a second base material obtained by molding two foamed resin sheet materials excellent in a heat insulating effect and a soundproof effect into a required shape. The air guide duct is designed to prevent condensation, prevent the generation of abnormal noise due to contact with other members, absorb the noise of the air conditioner unit, and improve the strength by attaching an appropriate shape retaining member. The purpose is to provide.
[0005]
[Means for Solving the Problems]
  In order to solve the above-described problems and achieve an intended object, a vehicle air guide duct according to the present invention is disposed inside various vehicle interior members installed in a passenger compartment of a vehicle, and is provided in the vehicle. An air guide duct that connects the air-conditioning unit and the air blowing unit connected to each other and guides the temperature-controlled air to the air blowing unit,
  It is molded as a half when the duct is divided in the longitudinal direction from the foam resin sheet material of the required thickness, and the air flow passage is defined inside by correspondingly joining to each other in the longitudinal direction, and at both end edges A first substrate and a second substrate comprising an air inlet and an air outlet;
  Of the first substrate and the second substrate.In the middle part of the main body in the short directionAlong the longitudinal directionWasWith shape retention memberWith
  The shape holding member has a shape that expands inward from the outer surface of the first base material or the second base material.It is characterized by that.
[0006]
DETAILED DESCRIPTION OF THE INVENTION
Next, a preferred embodiment of the air guide duct according to the present invention will be described below with reference to the accompanying drawings. For example, as shown in FIG. 9, the air guide duct targeted by the present invention has an overall shape of I type, U type, L type, etc. and various other shapes, and also has a rectangular cross section in the radial direction. It can be formed into various shapes such as round shape and irregular shape. The air conditioner is installed in front of the passenger compartment and is arranged inside (back side) of various vehicle interior members such as instrument panels, floor consoles, ceiling panels, etc. (all not shown) assembled in the passenger compartment of the vehicle. The unit 50 and the air blowing portion 52 disposed at a required position of the vehicle interior member are connected in communication, and the temperature-controlled air sent from the air conditioner unit 50 through the air discharge portion 51 is correspondingly blown out. Distribution guidance is provided to the section 52.
[0007]
FIG. 1 is a schematic perspective view showing an air guide duct according to a preferred embodiment of the present invention, and FIG. 2 is a schematic perspective view showing components of the air guide duct 10 shown in FIG. 1 in an exploded state. It is. The air guide duct 10 includes a first base material 11 formed from a foam resin sheet material 12 having a required thickness into a required shape, and a second base material 13 formed from a foam resin sheet material 14 having a required thickness to a required shape. The first shape holding members 20 and 20 and the second shape holding member 25 which are attached to the outer surface portions of the first base material 11 and the second base material 13 to improve the strength and shape holding of the base materials 11 and 13. , 25. And by joining the said 1st base material 11 and the 2nd base material 13 to a longitudinal direction, the both ends of a longitudinal direction exhibit the square cylinder shape bent at substantially right angle, and the one end part of the said air-conditioner unit 50 is exhibited. A rectangular air inlet 15 connected to the air discharge part 51 is formed as an opening, and a rectangular air outlet 16 connected to the air blowing part 52 is formed as an opening at the other end. That is, in this embodiment, a substantially U-shaped air guide duct in which the air inlet 15 and the air outlet 16 are directed in the same direction is illustrated.
[0008]
(First base material and second base material)
The first base material 11 and the second base material 13 are obtained by dividing the air guide duct 10 in the longitudinal direction from foamed resin sheet materials 12 and 14 made of, for example, polyethylene (PE) or polypropylene (PP). As shown in FIG. 2, the main body parts 11a and 13a are formed in a symmetrical shape as a half of the body (shown later), and the ends of the main body parts 11a and 13a are arranged in the short direction. Abutting piece portions 11b and 13b extending horizontally outward from the edge portion are provided. The foamed resin sheet materials 12 and 14 are rich in flexibility and do not have sufficient rigidity to hold the shape of the foamed resin sheet alone. However, since the thermal conductivity is lower than that of a conventional blow molding material, While having soundproofing and sound absorbing effects, it is about 40% lighter than the blow molded material having the same thickness. The first base material 11 and the second base material 13 have the contact surfaces of the respective contact piece portions 11b and 13b in close contact with each other, and are joined in the longitudinal direction so that the air is contained therein. A hollow air guide duct 10 having an air inlet 15 and an air outlet 16 is formed at both ends while defining a flow passage 17.
[0009]
(First shape retaining member)
As shown in FIGS. 1 to 3, the first shape holding member 20 is a wire-like wire member having a circular cross section in which the main body 21 is made of, for example, steel, and the first base member 11 or the second base member. 13 along the outer surface of the main body portions 11a, 13a, and functions to hold the shape by suppressing the bending deformation and bending deformation in the longitudinal direction of the first base material 11 and the second base material 13. The first shape holding member 20 is formed into a shape extending along the longitudinal direction at a substantially intermediate portion in the short direction on the outer surfaces of the main body portions 11a and 13a of the first base material 11 and the second base material 13. The both ends of the main body 21 are set to a length that reaches the vicinity of the opening edges of the air inlet 15 and the air outlet 16. Each of the first shape holding members 20 and 20 is mounted at the same time as the corresponding first base material 11 or second base material 13 is formed (described later), as shown in FIGS. 7 (a) and 7 (b). In addition, the first base material 11 and the second base material 13 are disposed so as to be substantially embedded over the entire length thereof. At this time, since the main body 21 has a circular cross section as described above, as shown in an enlarged view in FIG. 7C, the main body 21 extends inward from the outer surface of the first base material 11 and the second base material 13. Since the main body 21 is bitten as a result of appropriately expanding the shape and covering the main body 21 with a part of the foamed resin sheet material 12, 14, the first shape holding member 20 includes the base material 11, 13 is not easily removed. In addition, when the first shape holding member 20 is attached to the first base material 11 or the second base material 13, further improvement in the attachment strength can be expected if an appropriate adhesive is used.
[0010]
Each of the first shape holding members 20, 20 has a rectangular plate-shaped bracket (attachment tool) 22 (two in this embodiment) having a screw hole 23 extending in the lateral direction from the main body 21. It is arranged. The brackets 22 and 22 extend outward from the outer surfaces of the base materials 11 and 13 when the first shape holding member 20 is mounted on the first base material 11 or the second base material 13. (FIG. 1), the air guide duct 10 is provided to be assembled and fixed to the inside of the vehicle body or the vehicle interior member. The number of brackets 22 is appropriately determined depending on the overall length, shape, etc. of the air guide duct 10, and the shape, installation angle, etc. are appropriately changed according to the shape of the installation site of the air guide duct 10. Is done. Further, when it is not necessary to directly fix the air guide duct 10 to the inner back side of the vehicle body or the vehicle interior member, the first shape holding member 20 is configured by only the main body 21 having no bracket 22. May be used.
[0011]
(Second shape holding member)
As shown in FIGS. 1, 2, and 5, the second shape holding member 25 is mounted along the longitudinal edge portions of the first base material 11 and the second base material 13, and these first base members The air inlet 15 and the air outlet 16 defined when the material 11 and the second base material 13 are joined are surrounded, and the air inlet 15 and the air outlet 16 are easily deformed. Served to suppress and retain shape. Each of the second shape holding members 25 is injection-molded into a U-shape with a size that extends in close contact with the edge of each of the base materials 11 and 13 using, for example, polyethylene or the like. A main body portion 26 extending along the opening edge of the air inlet 15 or the air outlet 16 while being in close contact with the outer surface portion, and connected to each of the base materials 11 and 13 in an appropriate stepped state on the main body portion 26. It consists of an attachment part 27 extending in the engaged state. In the attachment portion 27, as shown in FIGS. 6 and 8, a plurality of tapered engagement holes 28 formed at required intervals are opened in series, and the first shape retaining member is formed. A locking hole 29 into which the end of 20 can be fitted is formed in the approximate center of the end surface on the short side.
[0012]
The second shape holding member 25 formed in this way is attached simultaneously during the molding process (described later) of the corresponding first base material 11 or second base material 13, and is shown in FIGS. As shown to (b), it arrange | positions in the state closely_contact | adhered to the outer surface of the edge part of the 1st base material 11 and the 2nd base material 13. As shown in FIG. At this time, each engaging hole 28 of the attachment portion 27 has a conical taper shape as described above. Therefore, as shown in an enlarged view in FIG. As a result of bulging into the engagement hole 28, the bottom edge portion 28 a of the engagement hole 28 is bitten into the base materials 11 and 13, whereby the second shape holding member 25 is in the state of the first base material 11. Alternatively, the second base 13 is engaged. In addition, when the second shape holding member 25 is attached to the first base material 11 or the second base material 13, further improvement in mounting strength can be expected by using an appropriate adhesive.
[0013]
(About the molding of the first base material and the second base material)
The first base material 11 and the second base material 13 having the shapes as described above are formed into a predetermined shape by, for example, “pressure forming” or “vacuum forming” that has already been put to practical use as a known forming technique. Among these, the pressure forming method is a method of forming a hollow body by pressing two sheet materials against the inner surface (molding surface) of each corresponding mold using the pressure of compressed air. FIG. 14 is an explanatory view showing the process of forming the air guide duct 10 of this embodiment over time by using this compressed air forming method. That is, first, as shown in FIG. 10, the foamed resin sheet material 12 for molding the first base material 11 and the foamed resin sheet material 14 for molding the second base material 13 are required with the spacer 43 interposed therebetween. At the same time, the edge portions of the foamed resin sheet materials 12 and 14 are held by the clamps 45 and 45.
[0014]
In the first step, as shown in FIG. 11, the foamed resin sheet materials 12 and 14 set at the required intervals by the spacer 43 and the clamps 45 and 45 are preheated and softened by the heaters 46 and 46, and the spacer The compressed air is fed into a space 47 defined between the both foamed resin sheet materials 12 and 14 through the air ejection holes 44 formed in the nozzle 43, so that the both sheet materials 12 and 14 are appropriately expanded in a direction away from each other. Open and deform.
[0015]
Next, in the second step, as shown in FIGS. 12 (a) and 12 (b), the first shape holding member is formed on the molding surfaces 41a and 42a of the upper mold 41 and the lower mold 42 in advance. On the premise that 20 and the second shape holding member 25 are set, the upper mold 41 and the lower mold 42 are moved close to each other to clamp the mold. Further, by sending compressed air into the space 47, as shown in FIGS. 14 (a) and 14 (b), the upper foamed resin sheet material 12 is in close contact with the molding surface 41a of the upper mold 41, and The lower foamed resin sheet material 14 comes into close contact with the molding surface 42 a of the lower mold 42. Further, the contact surfaces 41b of the upper mold 41 and the contact surfaces 42b of the lower mold 42 are pressed near the outer peripheral edges of the both foamed resin sheet materials 12 and 14 to form the contact piece portions 11b and 13b. The sheet members 12 and 14 come to be joined to each other with the contact surfaces of the contact pieces 11b and 13b being self-fused. The upper die 41 and the lower die 42 in the molding die 40 are provided with air suction nozzles 48 and 48 connected to an air suction machine (not shown), and air in the molding die 40 is discharged from each nozzle 48. By sucking, the adhesion of the foamed resin sheet materials 12 and 14 to the molding surfaces 41a and 42a can be improved.
[0016]
Here, when the foamed resin sheet materials 12 and 14 are brought into close contact with the molding surfaces 41 a and 42 a of the upper mold 41 and the lower mold 42, they are also in contact with the first shape holding member 20 and the second shape holding member 25. It comes in close contact. At this time, in the first shape holding member 20, as shown in FIG. 7, the foamed resin sheet materials 12, 14 are deformed so as to wrap around the main body 21, so that the main body 21 bites into the sheet materials 12, 14. In this state, the first shape holding member 20 is attached to the corresponding sheet material 12, 14 so that it cannot be easily removed. On the other hand, in the second shape retaining member 25, the foamed resin sheet materials 12 and 14 bulge outwardly through the respective engagement holes 28 of the attachment portion 27, as shown in FIG. The bottom edge portion 28a is bitten into the sheet materials 12 and 14, and the second shape holding member 25 is attached to the corresponding sheet materials 12 and 14 and cannot be easily detached.
[0017]
When the molding of the foamed resin sheet materials 12 and 14 by the molding die 40 is completed and the sheet materials 12 and 14 are cooled and cured, as a third step, the upper die 41 and the lower die 42 are opened and joined to each other. The first base material 11 and the second base material 13 are removed from the mold 40. Then, as shown in FIG. 14, the air guide duct 10 with the first shape holding member 20 and the second shape holding member 25 as shown in FIG. Is done.
[0018]
In the above-described pressure forming, the first base material 11 and the second base material 13 are molded and joined simultaneously, and the first shape holding member 20 and the second shape holding member 25 are attached to the base materials 11 and 13. Can be performed at the same time, so that the forming operation can be greatly rationalized. In the pressure forming, it is desirable that the first base material 11 and the second base material 13 are made of the same material.
[0019]
On the other hand, when the air guide duct 10 of this embodiment is formed using vacuum forming, the first base material 11 is removed from the foamed resin sheet material 12 using a vacuum forming die for the first base material 11. While molding, the second base material 13 is formed from the foamed resin sheet material 14 using a vacuum forming die for the second base material 13. In the next step, the contact piece portions 11b, 11b of the first base material 11 and the contact piece portions 13b, 13b of the second base material 13 are adhered to each other with an adhesive or the like. Two base materials 13 are joined in the longitudinal direction. When the first base material 11 and the second base material 13 are molded, the first shape holding member 20 and the second shape holding member 25 are set on the molding surface of each vacuum forming die. The shape holding members 20 and 25 can be attached to predetermined positions on the outer surface of the first base material 11 simultaneously with the molding of the first base material 11, and the shape holding members 20 and 25 can be attached simultaneously with the molding of the second base material 13. The second substrate 13 can be attached to a predetermined position on the outer surface. The first base material 11 and the third base material 13 are, for example, vibration welding (fusion), thermal welding (fusion) using a hot plate or the like, in addition to the above-described adhesive bonding using an adhesive, ultrasonic waves. It can be suitably joined also by a method such as welding (fusion).
[0020]
[Effect of the embodiment]
Next, the operation of the air guide duct of the present embodiment configured as described above will be described.
[0021]
The first base material 11 in the air guide duct 10 is integrally formed into a required shape from a foamed resin sheet material 12 made of polyethylene or polypropylene, and the second base material 13 is foamed of the same material such as polyethylene or polypropylene. The resin sheet material 14 is integrally formed into a required shape. In the case of molding by pressure forming, the first base material 11 and the second base material 13 are molded and joined at the same time, and the first shape holding member 20 and the second shape holding member 25 are mounted at the same time. The On the other hand, when forming by vacuum forming, the first base material 11 is formed, the first shape holding member 20 and the second shape holding member 25 are attached to the base material 11, the second base material 13 is formed and the first base material 11 is formed. After the first shape holding member 20 and the second shape holding member 25 are individually attached to the base material 13, the molded base materials 11 and 13 are joined to each other in a subsequent process.
[0022]
In the air guide duct 10 of the present embodiment formed by the pressure forming or the vacuum forming, the first base member 11 and the second base member 13 are extended to the outer surfaces of the main body portions 11a and 13a in the longitudinal direction. Since the shape holding members 20 and 20 are provided side by side, bending deformation and bending deformation in the longitudinal direction of the base materials 11 and 13 having elasticity, buckling deformation and the like can be suitably suppressed. Further, in the air guide duct 10 of the present embodiment, the second shape holding members 25 and 25 are attached to the respective end edges in the longitudinal direction of the first base material 11 and the second base material 13, so that they are formed at both ends. The shapes of the air inlet 15 and the air outlet 16 thus formed are also preferably maintained, and the air inlet 15 and the air discharge part 51 of the air conditioner unit 50 are connected and held, and the air outlet 16 and the air outlet 52 are connected. Is preferably connected and held. In addition, since both end portions of the first shape holding member 20 are fitted into the locking holes 29 of the second shape holding members 25 and 25, the first shape holding member 20 and the second shape holding members 25 and 25 are It is configured as a single member, and a suitable improvement in shape retention with respect to the corresponding first base material 11 and second base material 13 is achieved.
[0023]
The air guide duct 10 formed as described above aligns the brackets 22 and 22 formed on the first shape holding member 20 with predetermined positions on the inner back side of the vehicle interior member, and fixes, for example, screws. It is attached and fixed using a member. When this air guide duct 10 is installed inside the instrument panel, as shown in FIG. 9, the air inlet 15 is directly connected to the air outlet of the air outlet portion 51 of the air conditioner unit 50. At the same time, the air outlet 16 is connected to an air outlet 52 provided at a required position of the instrument panel.
[0024]
Then, when the operation of the air conditioner unit 50 is started by a required operation on the air conditioning control operation panel disposed on the instrument panel, the conditioned air adjusted to a predetermined temperature in the air conditioner unit 50 is converted into the air discharge part. The gas flows out of the air flow passage 17 from the air flow inlet 51 through the air flow inlet 15. Thereafter, the temperature-controlled air that has moved through the air flow passage 17 of the air guide duct 10 is passed through the air outlet 16 to the air outlet 52 and then blown out from the outlet of the air outlet 52 into the passenger compartment. become.
[0025]
In the air guide duct 10 of the present embodiment configured as described above, the first base material 11 and the second base material 13 constituting the entire duct 10 have the foamed resin sheet material 12 excellent in heat insulation effect and sound absorption effect, 14. Therefore, even if the temperature difference between the inside of the air flow passage 17 in the air guide duct 10 and the inner back side of the vehicle interior member (the outside of the air guide duct 10) is large, condensation occurs on the outer surface of the air guide duct 10. In addition, the generation and dripping of water droplets due to this dew condensation are also suitably prevented. Further, since water droplets do not drip on the harness or the in-vehicle device disposed inside the vehicle interior member, there is no short circuit or malfunction or failure of the in-vehicle device. Furthermore, rusting of steel parts such as a vehicle body due to dripping of water droplets can be suitably prevented.
[0026]
In addition, since the first base material 11 and the second base material 13 are also excellent in sound absorption effect, for example, even if another member (harness or the like) is in contact with any of the base materials 11 and 13, abnormal noise is generated. Occurrence is preferably prevented. Further, since the operating noise of the blower driven in the air conditioner unit 50 is absorbed to some extent by the first base material 11 and the second base material 13, the operating noise of the blower is occupant via the air blowing part 52. Leakage into the room is also preferably prevented. On the other hand, since the foamed resin sheet materials 12 and 14 themselves are lightweight, the air guide duct 10 of the embodiment formed thereby is significantly lighter than the air guide duct formed by the conventional blow molding (40 %).
[0027]
[Example of change]
FIG. 15 is a schematic perspective view of an air guide duct according to a modified example of the present invention. An air guide duct 35 of this modified example is based on the air guide duct 10 of the above-described embodiment, and is a first unit. The material 11 and the second base material 13 extend substantially along the outer surface shape of the base material 11, 13 across the first shape holding member 20 at a substantially central position in the longitudinal direction of the main body portions 11 a, 13 a. The third shape holding member 36 is additionally mounted. Therefore, in the air guide duct 35, the substantially central portion in the longitudinal direction is held by the third shape holding member 36. Therefore, the shape is formed by suitably suppressing torsional deformation in the circumferential direction around the longitudinal axis. It becomes possible to hold. The third shape holding member 36 can be mounted simultaneously with the molding of the first base material 11 and the second base material 13, similarly to the first shape holding member 20 and the second shape holding member 25. Here, the same shape as the second shape holding member 25 is illustrated. That is, injection molding is performed using polyethylene or the like as a material, and a plurality of engaging holes 37 are formed at required intervals in the longitudinal direction so that the engaging holes 37 and the foamed resin sheet materials 12 and 14 are engaged. Attachment to the base materials 11 and 13 is suitably achieved.
[0028]
FIG. 16 exemplifies a modified example of the first shape holding member 20, and as shown in FIGS. 16 (a) and 16 (b), the base materials 11 and 13 to be mounted at appropriate positions of the main body 21 are shown. A bent portion 24 displaced to the back side is formed. Thereby, in the first shape holding member 20 of the modified example attached to the first base material 11 or the second base material 13, as shown in FIG. The foamed resin sheet materials 12 and 14 are projected to the outside of the bent portion 24, and the engaging force at the bent portion 24 is greatly increased. The prevention of removal is suitably achieved.
[0029]
In the embodiment and the modified example, the first shape holding member 20 is exemplified by a wire-like wire member having a circular cross section made of steel or the like, but the form of the first shape holding member 20 is limited to this. Instead, for example, it may be an integrally formed product of an elongated rod shape or an elongated plate shape made of polyethylene or the like. Here, in the case of an elongated rod shape, the cross-sectional shape is not limited to the circular shape, and as long as the cross-sectional shape expands appropriately from the outer surface of the base material 11 or 13 to the inner direction, an inverted triangle or trapezoid is used. Also good. In the case of an elongated plate shape, engagement holes similar to those of the second shape holding member 25 are formed in the longitudinal direction at required intervals, and the engagement holes and the foamed resin sheet material are under engagement. It is good also as a form to mount. When the first shape holding member 20 is made of resin, the second shape holding members 25 and 25 and the first shape holding member 20 can be integrally molded as resin parts made of the same material. Thus, since it is configured as a single member, parts management and handling become easy.
[0030]
Further, the second shape holding member 25 is not limited to an integrally molded product made of polyethylene, and may be a wire-like wire member having a circular cross section made of steel or the like, similar to the first shape holding member 20. . In this case, since the first shape holding member 20 and the second shape holding member 25 are made of steel of the same material, the second shape holding members 25 and 25 are welded to both ends of the first shape holding member 20. If they are joined, the parts 20 and 25 are configured as a single member, so that parts management and handling become easy. Further, when the first shape holding member 20 is made of resin, the third shape holding member 36 and the first shape holding member 20 are integrated as a resin part made of the same material. While being able to be molded, the third shape holding member 36 may be a wire-like wire member having a circular cross section made of steel or the like. In this case, the third shape holding member 36 and the first shape holding member may be used. Since the member 20 is made of steel of the same material, the member 20 can be configured as a single member by welding the members 36 and 20 together. On the other hand, the bracket 22 provided on the first shape holding member 20 may be provided on the second shape holding member 25 or the third shape holding member 36.
[0031]
The air guide ducts 10 and 35 in the embodiment and the modified example are preferably applied to air guide ducts disposed on the inner back side of various vehicle interior members such as an instrument panel, a floor console, a pillar garnish, and a ceiling panel. Can do.
[0032]
【The invention's effect】
As described above, in the air guide duct according to the present invention, the first base material and the second base material constituting the entire duct are formed from the foamed resin sheet material that is excellent in the heat insulating effect and the sound absorbing effect. Therefore, even if the temperature difference between the inside of the air flow passage in the air guide duct and the inner back side of the vehicle interior member (outside of the air guide duct) is large, condensation does not occur on the outer surface of the air guide duct. At the same time, the generation and dripping of water droplets due to this condensation is also preferably prevented, so that short-circuits caused by dripping water drops on harnesses and in-vehicle devices arranged inside the vehicle interior members and malfunctions of in-vehicle devices and There is an advantage that it is possible to suitably prevent the occurrence of failure and the like, and the occurrence of rust of steel parts such as a vehicle body due to the dripping of water droplets. Moreover, since the first base material and the second base material are excellent in sound absorption effect, for example, even if other members (harness etc.) are in contact with any of these base materials, the generation of abnormal noise is suitably prevented. On the other hand, since the operating noise of the blower driven in the air conditioner unit is absorbed by the first base material and the second base material, the operating noise of the blower may leak into the passenger compartment through the air blowing part. There is also an advantage of being suitably prevented. In addition, the weight can be significantly reduced as compared with a conventional blow-molded air guide duct.
[0033]
  The air guide duct of the present invention is provided on the outer surfaces of the first base material and the second base material,In the middle part in the short directionExtending in the longitudinal directionFormSince the shape holding member is mounted, there is a beneficial effect that it is possible to suitably suppress bending deformation and bending deformation in the longitudinal direction of the base material having elasticity, buckling deformation due to this, and the like. In addition, the second base material has a second end on each longitudinal edge of the first base material and the second base material.ofIf the shape holding member is attached, the shape of the air inlet and the air outlet formed at both ends is also suitably maintained, and the air inlet and the air conditioner unit are connected and held, and the air outlet is There is also an advantage that the connection and holding of the air blowing part can be suitably performed. Further, a third intermediate portion is provided in the longitudinal intermediate portion of the first base material and the second base material.ofIf the shape holding member is attached, it becomes possible to suppress the torsional deformation of each base material. For the first base material and the second base materialFormShaped holding member, secondofShape retaining member and thirdofThe mounting of the shape holding member can be performed at the same time as pressure forming or vacuum forming for forming the respective substrates, so that the rationalization and efficiency of manufacturing are not impaired. Moreover,Since the shape holding member, the second shape holding member, and the third shape holding member are engaged with the first base material and the second base material in a state of being bitten, they can be easily detached from these base materials. do not do. Furthermore,When the materials of the shape holding members are the same, it is possible to configure each member by welding or integrally forming them, and there is an advantage that parts management and handling are easy.
[Brief description of the drawings]
FIG. 1 is a schematic perspective view of an air guide duct according to a preferred embodiment of the present invention.
FIG. 2 is an exploded perspective view of the air guide duct shown in FIG.
FIG. 3 is a schematic perspective view of a first shape holding member.
4A is a cross-sectional view taken along line III-III in FIG. 3, and FIG. 4B is a cross-sectional view taken along line IV-IV in FIG.
FIG. 5 is a schematic perspective view of a second shape holding member.
6A is a cross-sectional view taken along the line VV of FIG. 5, and FIG. 6B is a cross-sectional view taken along the line VI-VI of FIG.
7 shows a state in which the first shape holding member is attached to the substrate, (a) is a sectional view taken along line VII-VII in FIG. 1, (b) is a sectional view taken along line VIII-VIII in FIG. It is a principal part enlarged view of (b).
8A and 8B show the mounting state of the second shape holding member on the substrate, where FIG. 8A is a cross-sectional view taken along the line IX-IX in FIG. 1, FIG. It is a principal part enlarged view of (b).
FIG. 9 is an exploded perspective view showing an embodiment of an air guide duct that connects an air discharge portion of an air conditioner unit and an air blowing portion installed in a vehicle interior member.
FIG. 10 is an explanatory diagram of a process of forming the first base material and the second base material constituting the air guide duct by pressure forming, and positioning the two foamed resin sheet materials with a spacer therebetween with a clamp The gripping state is shown.
FIG. 11 is an explanatory view of a first step of forming the first base material and the second base material constituting the air guide duct by pressure forming, and between two foamed resin sheet materials fixed with a spacer interposed therebetween. While the compressed air is sent into the space, both the foamed resin sheet materials are preheated by the heater.
FIG. 12 is an explanatory view of a second step of forming the first base material and the second base material constituting the air guide duct by pressure forming, and (a) shows the first shape holding member and the second step on the forming surface. Cross-sectional view of the main part showing from the back side the state in which the upper mold and the lower mold of the molding die set with the shape-holding member are brought close to each other from the up-down direction of the heated both foamed resin sheet material, (b) is the state of (a) It is principal part sectional drawing shown from a side surface and a front side.
FIG. 13 is an explanatory view of a third step of forming the first base material and the second base material constituting the air guide duct by pressure forming, and (a) shows that the upper die and the lower die are clamped The principal part sectional view which shows the state where the foaming resin sheet material adhered to each molding surface of the upper mold and the lower mold from the back side, (b) is the principal part sectional view which shows the state of (a) from the side and front side is there.
14A and 14B show a first base material and a second base material molded from two foamed resin sheet materials, and FIG. 14A is a main part sectional view showing a state in which an unnecessary part is cut from the back side, and FIG. FIG. 4 is a cross-sectional view of a main part showing a state in which an unnecessary part is removed from a side surface and a front side.
FIG. 15 is a schematic perspective view of an air guide duct according to a modified example, in which twist deformation is also suppressed by newly installing a third shape holding member in addition to the first shape holding member and the second shape holding member. This is an example of a possible form.
16A is a cross-sectional view showing a state where the first shape holding member according to the modified example is mounted on a base material, and FIG. 16B is an enlarged view of a main part of FIG. FIG. 6 is a cross-sectional view taken along line YY of (b).
[Explanation of symbols]
  11 First base material
  11a body
  12 Foamed resin sheet material
  13 Second base material
  13a body
  14 Foamed resin sheet material
  15 Air inlet
  16 Air outlet
  17 Air flow passage
  20 First shape holding member (shape holding member)
  22 Bracket (Mounting tool)
  25 Second shape holding member
  36 Third shape retaining member
  52 Air outlet
  50 Air conditioner unit

Claims

Arranged inside various vehicle interior members installed in the passenger compartment of the vehicle, the air conditioning unit (50) provided in the vehicle and the air blowing part (52) are connected to each other to control the temperature-controlled air. In the air guide duct that guides to the blowout part (52),
It is molded as a half when the duct is divided in the longitudinal direction from the foam resin sheet material (12, 14) of the required thickness, and the air flow passage (17) is formed inside by correspondingly joining each other in the longitudinal direction. A first base material (11) and a second base material (13) which are defined and have air inlets (15) and air outlets (16) at both end edges;
A shape-retaining member (20) provided in the longitudinal direction at an intermediate portion in the short direction of the main body portions (11a, 13a) of the first base material (11) and the second base material (13) ,
The air guide duct, wherein the shape holding member (20) has a shape that expands inward from the outer surface of the first base material (11) or the second base material (13) .

The shape holding member (20) is provided with a fixture (22) extending outward from the outer surface of the first base material (11) and the second base material (13), and the fixture (22) is used. The air guide duct according to claim 1, wherein both the base members (11, 13) can be attached to the inside of the vehicle interior member.

A second shape retaining member (25) surrounding the air inlet (15) and the air outlet (16) is attached to the edge of the first base (11) and the second base (13). The air guide duct according to claim 1 or 2.

The second shape retaining member (25, 25) and the shape retaining member (20) are made of the same material, and the second shape retaining member (25, 25) is at both ends of the shape retaining member (20). The air guide duct according to claim 3, which is joined to the air guide duct.

The second shape holding member (25, 25) and the shape holding member (20) are made of the same material, and the second shape holding member (25, 25) and the shape holding member (20) are integrally formed. The air guide duct according to claim 3.

The first base material (11) and the second base material (13) extend along the outer surface shape of the base material (11, 13) at required positions in the longitudinal direction, intersecting the shape holding member (20). air guide duct according to any one of claims 1 to 3 third shape retaining member (36) mounted to stationary.

The third shape retaining member (36) and the shape retaining member (20) are made of the same material, and the third shape retaining member (36) is joined to a required position of the shape retaining member (20). The air guide duct according to claim 6.

The third shape retaining member (36) and the shape retaining member (20) are made of the same material, and the third shape retaining member (36) and the shape retaining member (20) are integrally formed. 6. The air guide duct according to 6.

Before Stories second shape holding member (25) and the third shape retaining member (36), the cross-sectional shape expanding toward the inside from the outer surface of the first base member (11) or second substrate (13) air guide duct according to any one of claims 6-8 for chromatic.

The air guide duct according to any one of claims 1 to 9, wherein the first base material (11) and the second base material (13) are molded and joined in the longitudinal direction simultaneously by pressure forming.

The air according to any one of claims 1 to 9, wherein the first base material (11) and the second base material (13) are both formed individually by vacuum forming and then joined in the longitudinal direction. Guide duct.

The shaped Joho support member (20), a second shape-retaining member (25) and the third shape retaining member (36) comprises a molding of the first base member (11) and the second substrate (13) The air guide duct according to claim 9 , wherein the air guide duct is mounted on the outer surface of the base material (11, 13) at the same time.

It said first base member (11) and the second substrate (13) constituting the foamed resin sheet material (12, 14), an air guide duct of claim 1 wherein the material of the foamed polyethylene or foamed polypropylene emissions.