JP6521368B2 - Vehicle cover - Google Patents

Description

  The present invention relates to a vehicle cover for covering a predetermined portion of an engine room, and more particularly to a vehicle cover having both sound absorption and design.

  In order to improve soundproofness and design in a vehicle engine room, various cover materials represented by an engine cover are put to practical use.

A conventional vehicle cover will be described based on the following figures.
FIG. 7 is a view for explaining the basic configuration of a conventional engine cover, and as shown in FIG. 7A, the engine cover 100 is made of a polypropylene base material 101 manufactured by injection molding, and FIG. As shown in b), the upper portion of the engine 103 (for example, a cylinder head cover, a power unit of a hybrid vehicle, and the like) is made of a sound absorbing material 102 such as urethane fixed to the back surface of the substrate 101 by ultrasonic fusion or hot melt. It is arranged in the engine room to cover the top etc. from the top.

  The surface 104 of the substrate 101 forms a design surface, while the sound absorbing material 102 absorbs engine noise. That is, the engine cover 100 is not only a designed part for improving the appearance of the engine room when the hood is opened, but also a sound absorbing part for reducing noise such as the engine 103 and the electric motor.

By the way, while weight reduction of a vehicle is calculated | required, the further weight reduction of the engine cover 100 is anticipated. However, in the engine cover 100, mere weight reduction is not easy because the necessary strength and sound absorbing performance are obtained by the constant mass of polypropylene and urethane. For example, if the thickness t of the base material 101 is 2.5 mm, the area density is 2500 g / m ² , and the mass of the sound absorbing material 102 is 35 g, the total mass of the engine cover 100 is 550 g.

  Therefore, it is conceivable to construct a laminate by a base material made of a fiber reinforced resin and a sound absorbing material such as a breathable film, and to reduce the weight of the engine cover by using this laminate. Conventionally, a vehicle floor undercover using such a laminate has been proposed (see, for example, Patent Document 1 (FIG. 2)).

  FIG. 8 is a view for explaining the basic configuration of a conventional floor undercover, and the floor undercover 110 is a protective cover for protecting the lower part of the vehicle body from stones and sand rolled up by tires, and comprises glass fiber and an olefin resin. A foaming agent is mixed, and a core material 111 which has been thermally expanded, a reinforcing layer 112 made of an olefin resin, and a road-side sound absorbing material 115 composed of a breathable film 113 and a non-woven fabric 114 are laminated.

  In the floor under cover 110, the sound transmitted from the road surface side to the vehicle interior is reduced by the action of the core material 111 and the road surface side sound absorbing material 115. Moreover, the core material 111 can be reduced in weight by reinforcing the core material 111 with glass fiber.

JP, 2009-298339, A

  Suppose that the technology disclosed in Patent Document 1 is applied to an engine cover. When a laminate such as the floor undercover 110 is used for the engine cover, it is possible to reduce the weight of the engine cover.

  However, the road-surface-side sound absorbing material 115 of the floor undercover 110 is obtained by sticking the air-permeable film 113 and the non-woven fabric 114 on the core material 111, and it is difficult to ensure the quality as a design part. This problem is not limited to the engine cover, but also occurs in various cover materials that cover locations around the engine in the engine room.

  The present invention has been made in view of such circumstances, and an object thereof is to provide a vehicle cover material which can achieve high designability and appropriate sound absorption performance, and can realize weight reduction.

In order to achieve such an object, the present invention is grasped by the following composition.
(1) The present invention relates to a vehicle cover material for covering a predetermined portion of an engine room, a base material made of a fiber reinforced resin, and a non-air-permeable thermal material provided on the upper side of the base material to form a design surface It has a surface of a plastic resin film or sheet, and a back surface of a breathable film or non-woven fabric provided on the lower side of the substrate.

(2) The present invention is characterized in that, in the constitution of (1), the base material is a glass fiber reinforced resin.

(3) The present invention is characterized in that in the configuration of (1) or (2), the base material is a fiber reinforced resin which is heat-foamed with a foaming agent.

(4) In the present invention, in any one of the constitutions (1) to (3), the skin material is an olefin resin or an olefin resin elastomer.

(5) In the present invention, in any one of the constitutions (1) to (3), the surface material is a nylon resin.

(6) The present invention is characterized in that in the configuration of any of (1) to (5), the design surface is embossed.

(7) The present invention is characterized in that in the configuration of any of (1) to (6), the back surface material is a film or nonwoven fabric having an air permeability of ^{3 to} 100 cm ³ / cm ² / sec.

(8) The present invention is characterized in that, in any one of the constitutions (1) to (7), a coating layer which covers the upper surface of the skin material is provided.

(9) The invention is characterized in that, in any one of the constitutions (1) to (8), an adhesive layer is provided on at least one side of the surface material side and the back surface side of the base material. .

(10) In the configuration according to any one of (1) to (9), the present invention is formed by the first mold for forming the surface material side and the second mold for forming the back surface material side. The molded product is characterized in that it is vacuum molded in each of the first mold and the second mold.

  According to the present invention, it is possible to provide a vehicle cover material that can achieve high designability and appropriate sound absorption performance, and can realize weight reduction.

It is a perspective view of the front part of a vehicle, and is a figure showing the form where the hood was opened. It is a figure explaining the engine cover concerning the present invention, and (a) is a top view and (b) is a bb line sectional view of (a). (A) is an enlarged view of three parts of FIG.2 (b), (b) is a figure which shows the other example of (a). It is a table explaining composition of each class of an engine cover. It is a figure explaining the manufacturing method of an engine cover, (a) is a heating process, (b) is a raw material setting process, (c) is a figure explaining a formation process. It is a figure explaining the effect | action of an engine cover. It is a figure explaining the conventional engine cover, (a) is a top view and (b) is a bb line sectional view of (a). It is sectional drawing of the conventional floor undercover.

  Hereinafter, with reference to the accompanying drawings, modes for carrying out the present invention (hereinafter, referred to as “embodiments”) will be described in detail. In addition, the same number is attached | subjected to the same element through the whole description of embodiment.

  As shown in FIG. 1, the vehicle 10 includes a front body 11. The front body 11 includes a front fender 13 forming a side front of the vehicle body 12, a front mask 14 connecting the front fenders 13, and a hood 16 covering the front fender 13 and the front mask 14.

  Further, the front mask 14 is provided with a radiator grille 17 and headlights 18, 18. The front fender 13, the front mask 14, and the hood 16 form an engine room 22 for housing the engine 21. In the engine room 22, in addition to the engine 21, various storage bodies such as a power transmission device, an intake device, an exhaust device, electrical components and the like are disposed at predetermined places. The engine 21 includes not only a power source of an internal combustion engine but also a power source (for example, a power unit of a hybrid vehicle) in which an electric motor and the internal combustion engine are combined.

  In the engine compartment 22, an engine cover 30 covering the engine 21 from above, a room side cover 60 adjacent to both sides in the vehicle width direction of the engine cover 30, and a room disposed between the engine cover 30 and the front mask 14 A front cover 70 is provided.

  The engine cover 30, the room side cover 60, and the room front cover 70 correspond to the vehicle cover material of the present invention, and the upper surfaces thereof are designed surfaces 31, 61, 71 which have been subjected to embossing. It is formed. The patterns 31a and 31b formed by emboss processing can be selected from various patterns such as satin, sand blast, skin-like patterns, and geometric patterns.

  By arranging the engine cover 30, the room side cover 60, and the room front cover 70 in the engine room 22 in this manner, the entire upper part of the engine room 22 is covered with the design surfaces 31, 61, 71, so the decorativeness is high. The appearance of the engine room 22 is obtained.

Next, the entire configuration of the engine cover 30 will be described based on FIGS. 2 and 3.
As shown in FIG. 2A, the engine cover 30 has a substantially rectangular shape in a plan view. Further, as shown in FIG. 2B, the engine cover 30 includes a flat plate-like main body 32 and side walls 33 that are lowered from both ends of the main body 32 in the vehicle width direction.

  The thickness of each portion of the main body portion 32 is set in accordance with the required strength and sound absorption performance, or the position and shape of the upper portion of the engine 21. As a result, the thick portion 34 and the thin portion 35 are formed in the main body portion 32.

  As shown in FIG. 3A, the engine cover 30 is composed of a base 36, a surface material 37 provided on the upper side of the base 36, and a back surface 38 provided on the lower side of the base 36. Stacks.

  Further, as shown in FIG. 3 (b), in the engine cover 30, a coating layer 37 a may be provided to cover the upper surface of the skin material 37. In addition, the adhesive layers 39a and 39b may be provided on at least one side (both sides in this example) of the surface material 37 side and the back surface material 38 side of the base material 36.

Subsequently, the configuration of each layer of the engine cover 30 will be described based on the table of FIG.
As shown in FIG. 4, the coating layer 37 a is set as necessary, and has a function of protecting the surface material 37 to improve the appearance. For example, a urethane-based resin material can be used for the coating layer 37a.

  The surface material 37 forms the design surface 31 (see FIG. 1), and is made of a non-air-permeable thermoplastic resin film or sheet. As the thermoplastic resin, an olefin resin represented by PP (polypropylene), an olefin resin elastomer (TPO), a nylon resin, or the like can be used. Moreover, as for the plate | board thickness of the skin material 37, about 0.2-1 mm is desirable.

  The adhesive layer 39a is a layer that adheres the base material 36 and the surface material 37, and is set as needed. For example, a PP-based resin material can be used for the adhesive layer 39a.

The base 36 is formed of a fiber reinforced resin formed by bonding reinforcing fibers with a resin binder, and may be formed of a fiber reinforced resin heated and foamed with a foaming agent according to the required specification. For example, a glass fiber reinforced resin in which glass fiber, PP (or PP fiber) and a foaming agent are combined, or a glass fiber reinforced resin in which glass fiber and PP (or PP fiber) are combined is used for the base 36 it can. The surface density of the base 36 is preferably 400 to 2000 g / m ² , and the thickness of the base 36 is preferably 1 to 30 mm.

  The adhesive layer 39 b is a layer that adheres the base 36 and the back surface material 38, and is set as needed. For example, a PP film or a PE (polyethylene) film can be used as the adhesive layer 39 b.

The backing material 38 is made of a breathable film or non-woven fabric, and for example, non-woven fabric made of PET (polyethylene terephthalate), non-woven fabric made of PP, PET film, PP film or the like can be used for the backing material 38. Moreover, as for the surface density of the back surface material 38, 10-200 g / m < ² > is desirable.

The air permeability of the backing material 38 is set from a suitable range for the engine noise according to the intake performance required of the engine cover 30. The present inventors examined the relationship between the air permeability of the back surface material 38 and the sound absorbing performance in order to determine the preferable range of the air permeability. As a result, by setting the air permeability of the back surface material 38 in the range of ³ to 100 cm ³ / cm ² / sec, it has been found that appropriate sound absorbing performance can be obtained in a wide range from the low frequency range to the high frequency range. The air permeability is a numerical value obtained by the Frazier method.

Next, a method of manufacturing the engine cover 30 will be described based on FIG.
The method of manufacturing the engine cover 30 includes a heating process of heating the laminated material 45, a material setting process of setting the heated laminated material 45 in a mold, and a forming process of press-forming the laminated material 45.

  As shown in FIG. 5 (a), in the heating step, the raw material 41 of the skin material, the raw material 42 of the base material, and the raw material 43 of the back surface material are manufactured in advance to form a laminated raw material 45 laminated. 45 is heated by the heater 46 to soften it. When a foaming agent is compounded to the base material 42, the base material 42 is sufficiently expanded by a thermal reaction.

  As shown in FIG. 5B, in the material setting step, the softened laminated material 45 is divided into an upper mold 47 (corresponding to the "first mold" according to the present invention) and a lower mold 48 (the present invention) Set in the space between the two molds. A pattern to be transferred to the surface (design surface) 52 a of the laminated material 45 is engraved on the molding surface 51 a of the upper mold 47. Further, a vacuum pump 53 is connected to each of the upper mold 47 and the lower mold 48 via a valve 54.

  As shown in FIG. 5C, in the forming step, while pressing the laminated material 45 with the upper die 47 and the lower die 48, the surface 52a side and the back surface 52b side of the laminated material 45 are vacuum drawn by the vacuum pump 53. Vacuum forming is performed along the forming surface 51a and the forming surface 51b. Thereby, the respective materials 41, 42 and 43 are pressure-bonded, and the main body 32, the side wall 33, the thick portion 34 and the thin portion 35 are formed, and a molded body of the engine cover 30 of a predetermined size is obtained. In the vacuum forming in the upper mold 47, the surface 52a of the laminated material 45 is in close contact with the forming surface 51a of the upper mold 47, so the embossed patterns 31a and 31b (see FIG. 2A) are clearly seen on the surface 52a. It is formed.

  In this manufacturing method, the laminated material 45 in which the respective materials 41, 42 and 43 are laminated is heated and molded, and in addition, a two-layer material in which the material 41 of the surface material and the material 42 of the substrate are stacked. After separately heating the material 43 of the back surface material, these two materials may be laminated and pressure bonded before the molding step. Further, in this example, in the forming step, the vacuum forming is performed by each of the upper mold 47 and the lower mold 48, but the vacuum forming may be performed by only the upper mold 47.

The operation and effects of the engine cover 30 described above will be described.
As shown in FIG. 6, since the air permeability of the back surface material 38 is set from an appropriate range ( ^{3 to} 100 cm ³ / cm ² / sec), the sound from the engine 21 in a wide range from the low frequency range to the high frequency range Is incident on the back surface material 38 (arrow (1)), and is well absorbed by the back surface material 38 and the base 36 (arrow (2)). Furthermore, when the base material 36 is a fiber reinforced resin which is heat-foamed with a foaming agent, the base material 36 is a porous body having a large thickness, and the sound absorbing performance is further enhanced. In addition, since the skin material 37 is made non-air-permeable, in addition to the sound absorption effect of the back surface material 38 and the base material 36, the sound absorption effect due to the film vibration of the skin material 37 can also be obtained.

Further, since the base material 36 is made of fiber reinforced resin, weight reduction of the engine cover 30 can be realized. For example, when the surface density of the base material 36 is set to 1000 g / m ² , the surface density of the surface material 37 to 400 g / m ² , and the surface density of the back surface material 38 to 100 g / m ² , the total mass of the engine cover 30 is 300 g Can be reduced to Thereby, the weight reduction of the engine cover 30 can be realized significantly, as compared with the total mass 550 g of the conventional engine cover 100 (see FIG. 7B).

  Further, when the surface material 37 is made of an olefin resin having high transferability in embossing, for example, an olefin resin elastomer, the patterns 31a and 31b (see FIG. 2A) are formed more clearly on the design surface 31. Be done. As a result, the design of the engine cover 30 can be further enhanced.

  Further, in the forming step, the laminated material 45 is vacuum formed in each of the upper mold 47 and the lower mold 48, so that the skin material 37 and the base material 36 can be pressure-bonded better, and the forming time and cooling time Can also be shortened.

  Although the configuration of the engine cover 30 has been described in the embodiment, the basic configuration of the engine cover 30 is the same for the room side cover 60 (see FIG. 1) and the room front cover 70 (see FIG. 1).

  Although the present invention has been described above using the embodiment, it goes without saying that the technical scope of the present invention is not limited to the scope described in the above embodiment. It will be apparent to those skilled in the art that various changes or modifications can be added to the above embodiment. It is also apparent from the scope of the claims that the embodiments added with such alterations or improvements can be included in the technical scope of the present invention.

30 Engine cover (cover for vehicle)
31 design surface 36 base material 37 skin material 37a coating layer 38 back surface material 39a adhesive layer 39b adhesive layer 47 upper mold (first mold)
48 Lower mold (second mold)
60 Room side cover (cover for vehicle)
61 Design surface 70 Room front cover (cover for vehicle)
71 Design surface

Claims (4)

In a vehicle cover material that covers a predetermined portion of an engine room,
A substrate,
And table skin material impermeable to form a design surface disposed above said substrate,
And back surface member that is provided on the lower side of the substrate,
A first adhesive layer which is a polypropylene-based resin provided between the substrate and the skin material;
A second adhesive layer which is a polypropylene film or a polyethylene film provided between the substrate and the back surface material;
A coating layer made of a urethane resin material covering the upper surface of the surface material;
I have a,
The base material is a fiber reinforced resin composed of glass fiber and polypropylene, a fiber reinforced resin composed of glass fiber and polypropylene fiber, a foamed fiber reinforced resin composed of glass fiber, polypropylene and a foaming agent, and a glass fiber, polypropylene fiber and a foaming agent Fiber reinforced resin selected from foamed fiber reinforced resins, having a thickness of 1 to 30 mm, and an area density of 400 to 2000 g / m ² ,
The skin material is a nylon resin film or a nylon resin sheet having a thickness of 0.2 to 1 mm,
The back surface member is made of polyethylene terephthalate nonwoven fabric or polyethylene terephthalate film, air permeability is 3~100cm ³ / ^cm 2 · sec, a vehicle cover member, wherein the surface density of 10 to 200 g / ^{m 2} . The vehicle cover material according to claim 1, wherein the base material is a fiber reinforced resin composed of glass fiber and polypropylene fiber or a foamed fiber reinforced resin composed of glass fiber, polypropylene fiber and a foaming agent . The vehicle cover material according to any one of claims 1 and 2 , wherein the design surface is embossed. It is a method of manufacturing the cover material for vehicles according to any one of claims 1 to 3, and sets the material of the cover material for vehicles between the first mold and the second mold. A method of manufacturing a cover material for a vehicle comprising: a material setting step; and a forming step of performing vacuum forming on the material in a state where the first mold and the second mold are combined. .

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