JP7171292B2 - deck board - Google Patents

Description

The present disclosure relates to deck boards.

2. Description of the Related Art Conventionally, as a deck board arranged in a luggage compartment of a vehicle, a deck board having a board body in which a skin material is laminated on a wooden hard board is known (see, for example, Patent Document 1). Further, a board placement portion of the vehicle on which a deck board is placed is provided with, for example, a storage recess opening upward, and a spare tire is stored in the storage recess. For this reason, the board mounting portion is provided with unevenness, and a raising material is assembled to the board body. In addition, a silencer and the like were also assembled to the board body.

Japanese Patent No. 5440851 (paragraphs [0019], [0027], [0028] and FIGS. 1, 2, 4)

It is desired to reduce the number of assembly man-hours by reducing or eliminating members such as raising materials and silencers for the above-described conventional deck board.

A first aspect of the invention, which has been made to solve the above problems, is a deck board arranged in a luggage compartment of a vehicle, which is formed by molding a laminated plate in which a plurality of sheets are laminated, and the laminated plate comprises a foam sheet having an open-cell structure, a pair of fiber sheets sandwiching the foam sheet, and a non-bonding fiber sheet sandwiching the upper fiber sheet of the pair of fiber sheets between the foam sheet and the foam sheet. and a breathable first panel.

A second aspect of the invention has a plate-like board main body and a support protrusion protruding from the lower surface of the board main body, and a portion of the board main body that overlaps the support protrusion in the thickness direction. is the deck board according to the first aspect , wherein the apparent density of the foam sheet is lower than that of the portion that does not overlap the support protrusion in the thickness direction.

In a third aspect of the invention, the laminated plate comprises the outermost surface of the laminated plate by sandwiching the fiber sheet disposed on the lower side of the pair of fiber sheets with the foam sheet. A deck board according to the first or second aspect , wherein a second face member is provided, said second face member being breathable.

A fourth aspect of the invention is the deck board according to any one of the first to third aspects, which has a skin material attached to the laminate from above.

According to a fifth aspect of the invention, the skin material is formed to have a size that protrudes from the laminated plate, and the protruding portion is wound around the lower surface side of the laminated plate , among the first to fourth aspects. A deck board according to any one aspect .

According to the first aspect of the invention, it is possible to reduce the man-hours for assembling members by reducing or eliminating at least one of the raising material and the silencer as follows. That is, in the first aspect of the invention, since the laminate includes the foam sheet having an open-cell structure, it is possible to shape the laminate by compressing the foam sheet. As a result, by shaping the laminated plate to form a protrusion that serves as a raising material on the lower surface of the deck board, it is possible to reduce or eliminate the raising material that is assembled to the laminated plate. It is possible to reduce the number of assembly man-hours. In addition, in the present invention, since it is possible to impart sound absorption to the entire deck board due to the sound absorption of the foam sheet, it is possible to reduce or eliminate the silencer to be assembled to the laminated plate, and reduce the number of man-hours for assembling the silencer. can be planned. Moreover, in the present invention, since the first face member is air-impermeable, it is possible for the first face member to insulate the sound generated below the deck board and transmitted through the deck board.

In the second aspect of the invention, the support protrusion protrudes from the lower surface of the plate-shaped board main body. Here, the apparent density of the foam sheet is lower in the portion of the board main body that overlaps the support protrusion in the thickness direction than in the portion that does not overlap the support protrusion in the thickness direction. That is, in the present invention, the support protrusion can be formed by compressing the portion of the foam sheet that does not overlap the support protrusion in the thickness direction. By using the supporting projections instead of the raising material, it is possible to reduce or eliminate the raising material, and it is possible to reduce the number of man-hours for assembling the member.

In the third aspect of the invention, since the second surface material forming the lower surface of the deck board has air permeability, the sound generated on the lower side of the deck board can easily enter the deck board, and sound absorption can be easily imparted. At the same time, it becomes possible to absorb sound in the entire deck board.

The deck board may have a skin material laminated to the laminate from above ( fourth aspect of the invention ), or may not have such a skin material. In the fifth aspect of the invention, by wrapping the skin material around the lower surface of the deck board, the edges of the laminate are covered and the appearance of the edges of the deck board can be improved.

1 is a rear perspective view of a vehicle fitted with a deck board according to an embodiment of the present disclosure; FIG. Front sectional view of deck board Enlarged cross-sectional view around the edge of the deck board Front cross-sectional view of a laminate before being pressed in a forming die Front sectional view of the laminate after being pressed in the forming die (A) A front cross-sectional view of the laminate before the skin material is attached, (B) A front cross-sectional view of the laminate after the skin material is attached. Front cross-sectional view of the skin material whose edge is wrapped around the laminate

As shown in FIG. 1, the deck board 10 of the present embodiment is arranged in a cargo room 90R of a vehicle 90. As shown in FIG. As shown in FIG. 2, a storage recess 92 that opens upward is provided at the bottom of a luggage compartment 90R of a vehicle 90, and a spare tire 93 is stored in the storage recess 92. As shown in FIG. In this embodiment, the opening edge 94 of the housing recess 92 and the spare tire 93 form a board placement portion 91 on which the deck board 10 is placed. In addition, in the example of this embodiment, the opening edge 94 of the housing recess 92 is higher than the upper surface of the spare tire 93 .

As shown in FIG. 3, the deck board 10 is formed by molding a laminated plate 20 in which a plurality of sheets are bonded together. As shown in the figure, the laminated plate 20 has a foam sheet 21 as a base material and a pair of fiber sheets 22, 22 bonded to both sides of the foam sheet 21 via a binder. . The foam sheet 21 is reinforced with a pair of fiber sheets 22,22.

The laminated plate 20 also has a first face member 23 and a second face member 24 sandwiching the fiber sheets 22 between the foam sheet 21 and the foam sheet 21 . The first face member 23 is arranged on the upper side, and the second face member 24 is arranged on the lower side. The first face member 23 and the second face member 24 are bonded to the fiber sheets 22, 22 with a binder impregnated in the fiber sheet 22. As shown in FIG.

A skin material 25 is attached to the laminated plate 20 from the upper side of the first surface material 23 . The skin material 25 is sized to protrude from the laminated plate 20, and the protruding portion 25E (in this embodiment, the entire outer end portion of the skin material 25) is the lower surface side of the laminated plate 20 (that is, the second surface). material 24 side) is wound and adhered.

Further, as shown in FIG. 2 , the deck board 10 includes a plate-like board body portion 11 and a plurality of supporting protrusions 12 projecting from the bottom surface of the board body portion 11 . The support protrusion 12 is placed on, for example, the spare tire 93 of the board placing portion 91 described above, and supports the board main body 11 in a state of being lifted from the spare tire 93 . Further, the outer edge of the board main body 11 is supported by the opening edge 94 of the housing recess 92 . As described above, in this embodiment, the support protrusion 12 serves as a raising member for raising the board main body 11 . In addition, the upper surface of the deck board 10 is flat.

As shown in FIG. 3, of the board main body 11, the overlapping portion 11A that overlaps the supporting protrusion 12 in the thickness direction has a larger thickness than the non-overlapping portion 11B that does not overlap the supporting protrusion 12 in the thickness direction. has a lower apparent density. The thickness of the board body portion 11 (non-overlapping portion 11B) is preferably 3 to 20 mm, more preferably 5 to 15 mm. Moreover, the projection length of the support protrusion 12 is preferably 2 to 30 mm, more preferably 5 to 20 mm.

Details of each sheet constituting the laminate 20, that is, the foam sheet 21, the fiber sheet 22, the first face member 23 and the second face member 24 are as follows.

The foam sheet 21 is made of foam having an open cell structure. Specifically, in this embodiment, the foam sheet 21 is a rigid polyurethane foam. The thickness of the foam sheet 21 is preferably 5-50 mm, more preferably 10-40 mm. The overlapping portion 11A of the board body portion 11 may be thinner than the original thickness by compressing the foam sheet 21 by press molding, or if the foam sheet 21 is bonded to the fiber sheets 22, 22 It may not be compressed (it may have the same thickness as the original thickness). The non-overlapping portion 11B of the board body portion 11 is made thinner than the original thickness by compressing the foam sheet 21 by press molding. In addition, the thickness T1 (see FIG. 3) of the portion of the foam sheet 21 that forms the non-overlapping portion 11B is 0 relative to the thickness T2 of the portion of the foam sheet 21 that forms the supporting protrusion 12 and the overlapping portion 11A. 0.1 to 0.95 times, more preferably 0.2 to 0.5 times.

From the viewpoint of reinforcing the deck board 10, the foam sheet 21 preferably has a spring hardness test type C (JIS K7312:1996 Annex 2) of 30 or more, more preferably 35 or more. Moreover, it is preferable that the foam sheet 21 has air permeability. This makes it possible to impart sound absorption to the foam sheet 21 . The air permeability of the foam sheet 21 complies with JIS K6400-7 B method: 2012 when the thickness of the foam sheet 21 constituting the deck board 10 is 10 mm or more, and JIS K6400-7 B method: 2012 when it is less than 10 mm. Measured based on The permeation rate in accordance with JIS K6400-7 B method: 2012 at a thickness of 10 mm of the foam sheet 21 is preferably 1 to 10 ml/cm ² /s, more preferably 1 to 8 ml/cm ² /s. . If the foam sheet 21 has a permeation rate of less than 1 ml/cm ² /s, the high-frequency sound absorption is lowered. If the foam sheet 21 has a permeation rate higher than 10 ml/cm ² /s, the low-frequency sound absorption is lowered. In addition, when the thickness of the foam sheet 21 is less than 10 mm, the value of the permeation amount is a converted value converted so that the thickness becomes 10 mm. Specifically, if the thickness is X (mm) and the measured value of the ventilation rate is Y (ml/cm ² /s), then the conversion value (ml/cm ² /s) is Y*X/10, Calculate as

As the foam sheet 21, a sheet made of a known open-cell foam, such as polyurethane foam, can be used. The polyurethane foam may be a rigid polyurethane foam, a semi-rigid polyurethane foam, or a soft polyurethane foam. A foam is preferred. Further, by configuring the foam sheet 21 with a foam having an open-cell structure, it is possible to impart sound absorption to the foam sheet 21 . From the viewpoint of the heat insulation performance of the deck board 10, it is preferable that the foam sheet 21 is made of polyurethane foam.

Examples of the fiber sheet 22 include those made of fiber such as glass fiber, polyester fiber, polyamide fiber, acrylic fiber, vinylon fiber, carbon fiber, natural fiber (eg, cellulose nanofiber), Zylon (registered trademark), and the like. can be used. (Those fibers of various fiber lengths can also be used without any particular limitation.) From the viewpoint of the effect of reinforcing the deck board, the fibers constituting the fiber sheet 22 are glass fibers. is preferred. Such fiber sheets may also be in the form of, for example, woven fabrics, knitted fabrics, non-woven fabrics, and the like.

When the fiber sheet 22 is a glass fiber sheet, it may be a glass mat obtained by processing glass fibers into felt, or may be a glass cloth obtained by weaving glass fibers in a grid pattern. From the viewpoint of formability of the laminate 20, such a glass fiber sheet is preferably a glass mat, more preferably a chopped strand mat.

Examples of the binder described above include those made of thermosetting resins. Examples of such binders include liquid isocyanates, which are inexpensive and have good adhesion. Liquid isocyanates are those that cure by reaction with water in the presence of heat and a catalyst to function as adhesives. Examples of liquid isocyanates include aromatic TDI (toluene diisocyanate), polymeric MDI (4,4′ diphenylmethane diisocyanate), NDI (1,5-naphthalene diisocyanate), TODI (tolyzine diisocyanate), PPDI (paraphenylene diisocyanate), XDI (xylylene diisocyanate), TMXDI (tetramethylxylene diisocyanate), and modified products thereof (specifically, various modifications such as urethane modification, allophanate modification, biuret modification, carbodiimide/uretonimine modification, etc. but preferably polymeric MDI, modified TDI, modified MDI, or a mixture thereof. As these liquid isocyanates, those having a viscosity of 3 to 300 cP are more preferable because they are excellent in permeability and coating properties. Among these, polymeric MDI has a low vapor pressure and a good affinity with glass fibers, and is suitable in terms of reactivity, adhesiveness, and workability. The types of these liquid isocyanates are appropriately selected according to the adhesiveness, reactivity, strength of the laminated plate 20, workability, and the like.

The first surface member 23 is composed of a resin film having no air permeability. As a result, it is possible to provide the deck board 10 with sound insulation against sounds coming from below the deck board 10 . The first surface material 23 is preferably a resin film having a smooth surface from the viewpoint of adhesiveness to the skin material 25 and adhesiveness to the binder. Examples of resins constituting the resin film include resins such as polypropylene, polyethylene terephthalate, and nylon.

The second face member 24 is composed of a nonwoven fabric sheet. Specifically, the second face member 24 is made of a spunlaced nonwoven fabric, a spunbonded nonwoven fabric, a needle-punched nonwoven fabric, or the like. The air permeability of the second face member 24 (based on JIS L1096 A method (Fragile type method): 2010) is preferably 10 to 200 cm ³ /cm ² ·s. If the air permeability of the second surface material 24 is lower than 10 cm ³ /cm ² ·s, the sound absorption of the deck board 10 will decrease, and if it is higher than 200 cm ³ /cm ² ·s, the binder will flow out from the second surface material 24. Exudation may easily occur. In order to facilitate shaping into the laminate 20, the tensile elongation at break of the second face material 24 (based on JIS L1913 general nonwoven fabric test method 6.3 Tensile strength and elongation rate) is preferably 20% or more. . In this embodiment, since the second face member 24 has air permeability, the sound generated on the lower side of the deck board 10 can easily enter the deck board 10, and the entire deck board 10 can easily absorb the sound. ing. Examples of fibers constituting the non ^- woven fabric include natural fibers such as wool and cotton, and synthetic fibers such as polyester fibers and polypropylene fibers.

As the skin material 25, a fiber sheet such as felt may be used, or a synthetic leather, genuine leather, resin film, or the like may be used.

The deck board 10 is manufactured as follows. In order to manufacture the deck board 10, first, a plurality of sheets forming the laminate 20 are prepared. Specifically, in the example of the present embodiment, a foam sheet 21 made of rigid polyurethane foam, a pair of fiber sheets 22, 22 made of glass fiber, a first surface material 23 made of a resin film, and a second sheet made of a nonwoven fabric sheet. A two-sided material 24 is prepared. A binder is applied to the foam sheet 21 and/or each fiber sheet 22 in advance. The foam sheet 21 made of rigid polyurethane foam preferably has an apparent core density (in accordance with JIS K7222:2012) of 20 to 90 kg/m ³ , more preferably 30 to 80 kg/m ³ .

Then, the foam sheet 21, the pair of fiber sheets 22, 22, the first face member 23 and the second face member 24 are laminated. Specifically, each fiber sheet 22 is superimposed on the foam sheet 21 from the outside. Further, the first face member 23 and the second face member 24 are superimposed from the outside of each fiber sheet 22 .

Next, a sheet group 26G in which the foam sheet 21, the pair of fiber sheets 22, 22, the first surface member 23 and the second surface member 24 are superimposed is cut to a length corresponding to the luggage compartment 90R, and shown in FIG. Hot press molding is performed by the molding die 30 shown. The molding die 30 is composed of a lower mold 31 having a flat molding surface and an upper mold 32 having a plurality of molding recesses 32U for forming the support protrusions 12 on the molding surface. It should be noted that the molding surface of the lower mold 31 has a flat portion 32H except for the portion where the molding recess 32U is formed.

In the heat press molding of the sheet group 26G, first, the heated molding die 30 is opened, the sheet group 26G is set between the lower die 31 and the upper die 32, and then the molding die 30 is opened. After closing, the sheet group 26G is hot-pressed. Then, the laminated plate 20 is formed from the sheet group 26G, and the laminated plate 20 is shaped to form the board body portion 11 and the support protrusions 12 (see FIG. 5). At this time, the portion of the laminated plate 20 that overlaps the flat portion 32H of the upper mold 32 in the thickness direction is compressed more than the portion that overlaps the molding recess 32U of the upper mold 32 in the thickness direction. The apparent density of is increased.

Note that the binder applied to the foam sheet 21 and/or each fiber sheet 22 permeates into the fiber sheet 22 before hot press molding is performed, and the one fiber sheet 22 and the first fiber sheet 22 are separated by heat curing of the permeated binder. The face material 23 is adhered, and the other fiber sheet 22 and the second face material 24 are adhered. At this time, the first face member 23 and the second face member 24 prevent the binder from leaking to the outside of the laminate plate 20 and prevent the binder from adhering to the molding surface of the molding die 30. .

When the hot press molding is completed, the laminated plate 20 is removed from the molding die 30 and trimmed appropriately.

Next, as shown in FIG. 6A, a skin material 25 is prepared. Specifically, as the skin material 25, a material having a size protruding from the entire outer edge portion of the laminated plate 20 is prepared. Then, as shown in FIG. 6B, the skin material 25 is attached to the first surface material 23 of the laminated plate 20 with an adhesive or the like so that the entire outer edge of the skin material 25 protrudes. be. Next, as shown in FIG. 7 , the protruding portion 25E of the skin material 25 protruding from the laminated plate 20 is wound around the second surface member 24 side of the laminated plate 20 . The protruding portion 25E is attached to the second surface member 24 by, for example, an adhesive. By the above, the deck board 10 shown in FIG. 2 is completed.

The configuration of the deck board 10 according to the present embodiment and the method for manufacturing the deck board 10 have been described above. Next, the effect of the deck board 10 and its manufacturing method will be described. According to the deck board 10 of the present embodiment, by reducing or eliminating at least one of the raising material and the silencer as follows, it is possible to reduce the man-hours for assembling the members. That is, in the deck board 10 , the laminated plate 20 includes the foam sheet 21 having an open cell structure, so that the laminated plate 20 can be shaped by compressing the foam sheet 21 . As a result, by shaping the laminated plate 20 to form the support protrusion 12 that serves as a raising material on the lower surface of the deck board, it is possible to reduce or eliminate the raising material that is assembled to the laminated plate 20. , the number of man-hours required for assembling the raising material can be reduced. In addition, in the present embodiment, since the foam sheet 21 can impart sound absorption to the deck board 10, it is possible to reduce or eliminate the silencer to be assembled to the laminated plate 20, thereby reducing the number of man-hours for assembling the silencer. be able to. Moreover, in the present embodiment, since the first face member 23 is non-breathable, it is possible to provide sound insulation against sounds coming from the lower side of the deck board.

In this embodiment, the support protrusion 12 protrudes from the lower surface of the plate-like board main body 11 . Here, the foam sheet 21 has a lower apparent density in the portion of the board main body 11 that overlaps the support protrusion 12 in the thickness direction than the portion that does not overlap the support protrusion 12 in the thickness direction. That is, in the present embodiment, the support protrusions 12 can be formed by compressing the portions of the foam sheet 21 that do not overlap the support protrusions 12 in the thickness direction. By using the support protrusion 12 instead of the raising material, it is possible to reduce or eliminate the raising material, and it is possible to reduce the number of man-hours for assembling the members. Moreover, since the supporting projections 12 are provided integrally with the deck board 10, it is possible to prevent a decrease in productivity due to incorrect mounting of the raising material.

In this embodiment, since the second surface member 24 forming the lower surface of the deck board 10 has air permeability, the deck board 10 can be provided with sound absorbing properties for sound from the lower side of the deck board 10. If the overlapping portion 11A of the board main body portion 11 and the support protrusion 12 are formed by hot press molding so as not to compress the foam sheet 21, the cells of the hard polyurethane foam constituting the foam sheet 21 are hardly crushed. Therefore, the sound absorbing property can be further enhanced. In addition, in the conventional deck board 10, since the silencers were scattered, there was a large variation between the sound absorbing part and the non-sound absorbing part, but in the deck board 10 of the present embodiment, the entire deck board 10 Since it is possible to impart sound absorbing properties to the structure, it is possible to reduce variations in sound absorbing properties.

Furthermore, in this embodiment, by wrapping the skin material 25 around the lower surface side of the deck board 10, the edge of the laminated plate 20 is covered and the appearance of the edge of the deck board can be improved. Further, by wrapping the skin material 25 around the lower surface side of the deck board 10 , the skin material 25 can be made difficult to peel off from the laminate plate 20 .

[Other embodiments]
(1) In the above-described embodiment, the deck board 10 may be configured to include only the first face member 23 out of the first face member 23 and the second face member 24 .

(2) In the above embodiment, in the deck board 10, the second surface member 24 may be impermeable. An example of this case is a configuration in which the second surface member 24 is made of a resin film.

(3) In the above embodiment, the portion of the skin material 25 that is wrapped around the second surface member 24 side of the laminate 20 is the entire outer end of the skin material 25, but only a part of it. good too. Further, the outer edge of the skin material 25 does not have to be wrapped around the second surface material 24 side of the laminate 20 . In this case, the skin material 25 should have substantially the same size as the laminated plate 20 when viewed from the thickness direction of the deck board 10 .

(4) In the above embodiment, a plurality of foam sheets 21 may be laminated. At that time, the resin types and properties (density, hardness, air permeability, thickness, etc.) of the foam sheets 21 may be the same or different. Moreover, the fiber sheet 22 may be sandwiched between the plurality of foam sheets 21 .

(5) In the above-described embodiment, one pair of the fiber sheets 22 sandwiching the foam sheet 21 was arranged, but two or more pairs may be arranged, and the foam sheet 21 may be arranged in one or the other direction in the thickness direction. A plurality of only may be arranged. When a plurality of fiber sheets 22 are provided, the types (type of fiber, fiber length, etc.) and properties (basis weight, thickness, etc.) of the fiber sheets 22 may be the same or different. Alternatively, a plurality of fiber sheets 22 may be arranged only on the portion where the support projections 12 are formed.

(6) In the above embodiment, the upper surface of the deck board 10 is formed flat, but the upper surface of the deck board 10 may be partially or wholly provided with a curved portion, an uneven portion, or the like.

(7) The deck board 10 may be configured without the skin material 25 . In this case, since the skin material 25 itself becomes unnecessary, it becomes unnecessary to attach the skin material 25 to the laminated board 20, and the deck board 10 can be easily formed.

REFERENCE SIGNS LIST 10 deck board 11 board main body 12 support protrusion 20 laminated plate 21 foam sheet 22 fiber sheet 23 first surface material 24 second surface material 25 skin material

Claims (5)

A deck board arranged in the luggage compartment of a vehicle,
A laminated plate is formed by laminating multiple sheets,
The laminate includes
a foam sheet having an open-cell structure;
a pair of fiber sheets sandwiching the foam sheet;
and a non-breathable first face member sandwiching the upper fiber sheet of the pair of fiber sheets with the foam sheet. a plate-shaped board main body;
a support protrusion protruding from the lower surface of the board main body,
2. The foam sheet has a lower apparent density in a portion of the board main body overlapping the supporting protrusion in the thickness direction than in a portion not overlapping the supporting protrusion in the thickness direction. Deck board as described. The laminated plate is provided with a second face material that constitutes the outermost surface of the laminated plate by sandwiching the fiber sheet arranged on the lower side of the pair of fiber sheets and the foam sheet. ,
The deck board according to claim 1 or 2, wherein said second face material has air permeability. 4. Deck board according to any one of the preceding claims, comprising a skin material laminated to the laminate from above. 5. The deck board according to claim 4 , wherein said skin material is formed in a size protruding from said laminated plate, and the protruding portion is wound around the lower surface side of said laminated plate.

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