WO2011052249A1 - 防音カバー及びその製造方法 - Google Patents
防音カバー及びその製造方法 Download PDFInfo
- Publication number
- WO2011052249A1 WO2011052249A1 PCT/JP2010/055690 JP2010055690W WO2011052249A1 WO 2011052249 A1 WO2011052249 A1 WO 2011052249A1 JP 2010055690 W JP2010055690 W JP 2010055690W WO 2011052249 A1 WO2011052249 A1 WO 2011052249A1
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- WO
- WIPO (PCT)
- Prior art keywords
- nut member
- cover
- cover body
- cavity
- mold
- Prior art date
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02B—INTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
- F02B77/00—Component parts, details or accessories, not otherwise provided for
- F02B77/11—Thermal or acoustic insulation
- F02B77/13—Acoustic insulation
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
- F02F7/00—Casings, e.g. crankcases or frames
- F02F7/006—Camshaft or pushrod housings
Definitions
- the present invention relates to a soundproof cover and a method for manufacturing the same, and particularly, to improve a soundproof cover in which a sound absorbing layer made of urethane foam is integrally formed on the back surface of a cover body, and to advantageously manufacture such a soundproof cover. And how to do.
- a soundproof cover for preventing leakage of noise generated in the engine may be further attached on the cylinder head cover.
- Some of such soundproof covers have various structures, and as one of them, a sound absorbing layer made of urethane foam is fixed to the back surface of the cover body made of a hard resin molded body.
- a sound absorbing layer made of urethane foam is fixed to the back surface of the cover body made of a hard resin molded body.
- the urethane resin composition is formed in the molding cavity portion located on the back side of the cover body in a state where the separately molded cover body is accommodated in the molding cavity of the molding die.
- a method of integrally forming a sound-absorbing layer made of urethane foam on the back surface of the cover body by filling an object and foam-molding is suitably employed. This is because the degree of freedom of shape of the sound absorbing layer can be advantageously increased.
- the nut member for screwing or bolting the bracket or the like is attached to the cover body of the soundproof cover with the seating surface facing the front side of the cover body. In other words, it is conceivable to bury the screw hole so as to open on the surface of the cover body and omit the through hole.
- the soundproof cover manufactured by the above-described preferred method that is, the sound absorbing layer made of urethane foam is integrally formed on the back surface of the cover body by foam molding of the urethane resin composition in the mold containing the cover body.
- the nut member is embedded in the soundproof cover, the following problems may occur.
- a nut member having screw holes that are open on both sides in the axial direction is usually used in consideration of economy and the like. Therefore, when the cover body in which such a nut member is embedded is accommodated in the molding cavity and the urethane resin composition is subjected to foam molding, the urethane resin composition flowing in the molding cavity is There was a risk of entering the hole from the opening on the end surface opposite to the seat surface. When this happens, there is a concern that the urethane foam solidified in the screw hole may cause a situation in which it is difficult to fasten a screw or a bolt to the nut member.
- the present invention was made in the background as described above, and the problem to be solved is that the sound absorbing layer made of urethane foam is in a mold that houses the cover body.
- the soundproof cover that is integrally formed on the back surface of the cover body by foam molding of the urethane resin composition, while maintaining excellent soundproofing performance sufficiently, other members are securely connected to the cover body by a screwed structure. It is to provide an improved structure so that it can be attached. Further, in the present invention, it is an object to provide a method for advantageously producing a soundproof cover having such an improved structure.
- the soundproof cover in order to solve the problem concerning the soundproof cover, it has a cover main body and a sound absorbing layer fixed to the back surface of the cover main body, and the cover main body is made of a hard resin.
- the soundproof cover comprising the urethane foam integrally formed on the back side of the cover body by foam molding of the urethane resin composition in the molding die containing the cover body, the sound absorbing layer comprising the molded body
- the nut member having screw holes that are open on both sides in the axial direction exposes the seating surface on one side in the axial direction to the surface of the cover body, and the screw hole opening on the one side in the axial direction is exposed on the surface of the cover body. It is embedded in the cover body in the opened state, and the screw hole opening on the other axial side of the nut member is closed by a closing part formed integrally with the cover body. Soundproof hippo And it is to its gist.
- the overall shape of the nut member embedded in the cover body is not particularly limited. Further, as a method of embedding the nut member in the cover body, a method of embedding the nut member in the cover body at the same time as forming the cover body by performing insert molding using the nut member as an insert product is advantageous. Can be employed. In addition, after the cover member is molded using a thermoplastic resin material, the cover member is partially heated to be in a plasticized state, and a nut member is pushed into the plasticized portion for embedding or heating. It is also possible to employ a method in which the nut member is pressed against a cover member made of a thermoplastic resin so that the cover member is partially plasticized and the nut member is embedded in the plasticized portion. Furthermore, it is also possible to adopt a method of embedding the nut member in the cover body by providing the cover member with a recess that can accommodate the nut member, and housing the nut member in the recess and fixing it.
- a configuration is adopted in which one end in the axial direction including the seating surface of the nut member protrudes from the surface of the cover body.
- the boss portion having a height larger than the height of the embedded portion of the nut member on the cover body integrally projects on the surface of the cover body.
- the nut member is embedded in the boss portion with the seating surface exposed to the protruding front end side of the boss portion, and the closing portion is a base of the boss portion. Consists of ends.
- an annular convex portion extending in a circumferential direction of the seat surface of the nut member is provided on a surface portion of the cover body located around the seat surface of the nut member. It is integrally formed.
- the overall shape of the annular protrusion formed on the surface of the cover body is not limited as long as it can surround the periphery of the seat surface of the nut member.
- the number of nut members embedded in the cover main body is not limited in any way, but when a plurality of nut members are embedded in the cover main body, the annular convex portion is a seating surface of the plurality of nut members. May be formed so as to surround each of them separately, or only one annular convex portion may be formed so as to surround all of the seating surfaces of the plurality of nut members.
- the height position of the seat surface of the nut member exposed on the surface side of the cover body is set to a position higher than the protruding tip portion of the annular protrusion. It is desirable that
- the nut member is harder than the cover body and is reduced in the axial direction by an axial force of a fastening member fastened to the nut member.
- the biting protrusion is It will be comprised so that it may bite into the internal peripheral surface of the hole of this cover main body which embeds this nut member.
- the height position of the seat surface of the nut member exposed on the surface of the cover body is preferably set to a position higher than the protruding tip portion of the annular convex portion. In that case, it is desirable that the difference in height between the seat surface of the nut member and the projecting tip portion of the annular protrusion is larger than the reduction amount of the nut member due to the axial force of the bolt member. .
- the biting protrusion when the biting protrusion is formed on the outer peripheral surface of the nut member, the biting protrusion is advantageously formed in a spiral on the outer peripheral surface of the nut member on one end side in the axial direction.
- a first spiral biting ridge formed so as to extend in the direction, and a spiral in a direction opposite to the first spiral biting ridge is drawn on the outer peripheral surface of the nut member on the other end side in the axial direction.
- a second spiral biting ridge formed so as to extend in the circumferential direction.
- the above method for manufacturing the soundproof cover includes the following: (a) a first molding cavity having a shape corresponding to the cover body.
- a first forming mold having a dummy bolt which can be fastened to the nut member and made of an independent member separate from the first forming mold;
- a step of preparing an adsorbing means to be held by the mold and
- the dummy bolt is adsorbed to the first mold by the adsorbing means so as to protrude from the first cavity surface forming one molding cavity into the first molding cavity.
- the molten resin is injected and filled into the first molding cavity and solidified to form the cover body in the first molding cavity and embed the nut member in the cover body. And (c) opening the first mold in which the cover body is formed in the first molding cavity and opening the mold. At the time of opening, the holding state of the dummy bolt to the first mold due to the suction of the suction means is released, so that the cover body and the dummy bolt are taken out from the first mold together.
- a step of removing the dummy bolt from the nut member embedded in the cover body, and (d) using a second molding die having a second molding cavity having a shape corresponding to the sound absorbing layer After the bar main body is accommodated in the second molding cavity, the urethane resin composition is filled in the back side portion of the cover main body in the second molding cavity, and the urethane resin composition is foam-molded. And a step of integrally forming a sound-absorbing layer made of the urethane foam on the back side of the cover body.
- the nut member has an end surface opposite to the seat surface on the one axial side with respect to the bolt leg portion of the dummy bolt ( And the nut member is fastened to the dummy bolt and the nut member is fastened so that the seat surface on the other side in the axial direction) is substantially flush with the front end surface of the bolt leg.
- a closing portion forming cavity portion for forming the closing portion is formed on the tip end side of the bolt leg portion of the dummy bolt in the forming cavity. Configured to be formed.
- the end surface opposite to the seat surface of the nut member and the tip end surface of the bolt leg portion of the dummy bolt are flush with each other” means (A) the end surface of the nut member and the bolt leg portion. (B) The tip portion of the bolt leg is slightly pulled into the screw hole from the screw hole opening of the nut member, or the tip of the bolt leg. Although the portion slightly protrudes from the opening of the screw hole of the nut member and there is a slight step between the tip surface of the bolt leg and the end surface of the nut member, they are substantially flush. It shall include those made in a state that can be judged.
- a recess having a depth larger than the protruding height of the nut member into the first molding cavity is provided in the cavity surface portion of the nut member, and the whole nut member fastened to the dummy bolt or in the axial direction
- a portion other than the one end is disposed so as to protrude from the bottom surface of the recess into the recess, and a closed portion forming cavity portion for forming the closed portion is formed at the opening side portion of the recess.
- the nut member is inserted into the first molding cavity under the state where the nut member is disposed in the first molding cavity.
- An annular groove extending in the circumferential direction of the protruding portion of the nut member is formed in the first cavity surface portion located around the protruding portion, and the molten resin is injected and filled into the first molding cavity.
- the cover body is formed by embedding the nut member in the first molding cavity by being solidified and positioned around the seat surface of the nut member An annular convex portion extending in the circumferential direction of the seat surface of the nut member is integrally formed on the surface portion of the nut member, and then the cover body is formed at the tip portion of the annular convex portion in the second molding of the second mold.
- Contact with cavity surface In a state in which, after being housed in the second molding cavity, configured as foam molding of the urethane resin composition in said second mold cavity is performed.
- the dummy bolt is made of a ferromagnetic material
- the attracting means is a permanent magnet fixed to the first mold.
- the dummy bolt is held by the first mold by being attracted by the attracting means based on the attractive force of the permanent magnet, while the mold of the first mold is
- the cover body is opened, the cover body is released from the first cavity surface with a force larger than the attraction force of the permanent magnet to the dummy bolt, whereby the first bolt of the dummy bolt is attracted by the suction means. It will be comprised so that the holding state to the shaping
- the attracting means may be composed of an electromagnet other than the permanent magnet, or may be composed of a vacuum device (negative pressure generating device) that sucks air.
- a vacuum device negative pressure generating device
- the axial end including the seat surface of the nut member and the seat surface of the dummy bolt fastened to the nut member.
- An accommodating recess for accommodating the protruding portion from the first cavity surface, and the seat surface of the nut member is disposed deeper in the accommodating recess than the bottom surface of the annular groove. In this state, the dummy bolt is held by the first mold.
- the parts and members to be attached to the article covered by the soundproof cover are securely attached to the cover body by screwing or bolting the nut member embedded in the cover body. Can be attached to. Therefore, unlike the conventional soundproof cover, a through hole for inserting a boss portion provided in an article covered with the soundproof cover is advantageously omitted. Thereby, the leakage of sound from the gap between the inner peripheral surface of the through hole and the outer peripheral surface of the boss part can be effectively eliminated.
- a nut member embedded in the cover main body an economical merit can be ensured by using an inexpensive nut member having screw holes that are opened on both sides in the axial direction.
- the screw hole openings located on the back surface side of the cover body are closed by a closing part integrally formed with the cover body. ing.
- the urethane resin composition can be effectively prevented from entering the screw hole of the nut member from the screw hole opening on the back surface side of the cover body. .
- it can be prevented in advance that a situation in which it is difficult to fasten a screw, a bolt, or the like to the nut member due to the urethane foam solidified in the screw hole.
- the nut member is fastened to a dummy bolt made of an independent member separate from the mold, and is adsorbed to the first mold through the dummy bolt. Retained. And the cover main body which embeds a nut member is formed by performing injection molding in the state. Thereafter, after the cover main body is taken out of the first mold together with the dummy bolt, the dummy bolt is removed from the nut member embedded in the cover main body.
- the cover body when the cover body is formed, it is possible to advantageously prevent the molten resin injected into the first mold from entering the screw hole of the nut member by the dummy bolt. .
- the closing part that closes the screw hole opening located on the back side of the cover body is securely integrated with the cover body simultaneously with the formation of the cover body. It is formed.
- the dummy bolt is integrally formed with the first mold, after the cover body is molded, the entire first mold and the entire cover body are not rotated and each is simply small. If only the dummy bolt is rotated, the dummy bolt can be easily and quickly removed from the nut member embedded in the cover body. Thereby, simplification and efficiency improvement of the manufacturing process of the cover body can be realized advantageously.
- the soundproof cover exhibiting the excellent characteristics as described above can be manufactured very easily and efficiently.
- FIG. 3 is an explanatory view taken along the line BB in FIG. 2. It is the C section enlarged explanatory view of FIG. It is D arrow explanatory drawing of FIG. It is front explanatory drawing which shows the nut member embed
- FIG. 8 is an enlarged explanatory view of a portion E in FIG. 7.
- FIG. 8 is an explanatory diagram showing an example of a process performed when the soundproof cover shown in FIG. 1 is manufactured according to the method of the present invention, and includes a set of a nut member and a dummy bolt in the mold shown in FIG. 7. The attached body is shown.
- FIG. 10 shows the example of a process implemented following the process shown by FIG. 10, Comprising: The state which formed the cover main body in the shaping
- FIG. 16 is an explanatory diagram illustrating an example of steps performed when a soundproof cover having a structure different from that of the soundproof cover shown in FIG. 1 is manufactured according to the method of the present invention, corresponding to FIG. 15.
- FIG. 1 shows, as an embodiment of a soundproof cover having a structure according to the present invention, a soundproof cover that covers a cylinder head cover of an automobile engine in its top form.
- FIG. 2 shows a side view of such a soundproof cover
- FIG. 3 shows a longitudinal sectional view of the soundproof cover.
- the soundproof cover of this embodiment includes a cover body 10 and a sound absorbing layer 12.
- the cover body 10 as a whole has a longitudinal rectangular housing shape, and integrally includes a thin flat plate-like top plate portion 14 and a thin frame plate-like side wall portion 16. .
- the cover body 10 is formed by using a hard resin material, among them, a polyamide having excellent heat resistance and strength.
- the type of the resin material forming the cover body 10 is not particularly limited as long as it is a hard material. Conventionally, it is used as a material for forming a soundproof cover made of resin such as polyethylene terephthalate or polypropylene in addition to polyamide. Can be used as appropriate.
- the sound absorbing layer 12 has a longitudinal rectangular casing shape that is slightly smaller than the cover body 10 and has a thickness that is sufficiently thicker than the cover body 10.
- the sound absorbing layer 12 is composed of a soft urethane foam formed by foaming a urethane resin composition. Such a sound absorbing layer 12 is integrally bonded (fixed) to the back surface of the cover main body 10 on the surface thereof.
- the soundproof cover of the present embodiment is configured as an integrally joined product of the cover body 10 and the sound absorbing layer 12.
- a soundproof cover is disposed on the engine of the automobile so as to cover the entire upper portion of the cylinder head cover while bringing the back surface of the sound absorbing layer 12 into close contact with the surface of the cylinder head cover.
- the soundproof cover is bolted to the cylinder head cover via a rubber mount or the like as disclosed in, for example, Japanese Patent Application Laid-Open No. 2003-50585 and Japanese Patent Application Laid-Open No. 10-332076. Is done.
- the sound absorbing layer 12 has an apparent density of preferably about 0.06 to 0.12 g / cm 3 and a thickness of about 5 mm or more so that a sufficient sound absorbing function can be ensured. It is said that.
- three boss portions 18, 18, 18 are provided at the center portion in the width direction (vertical direction in FIG. 1) of the surface (upper surface) of the top plate portion 14. Are erected integrally at equal intervals in the length direction (left and right direction in FIG. 1).
- the three boss portions 18, 18, and 18 all have the same overall shape that is substantially cylindrical.
- one nut member 20 is embedded in each boss portion 18, one nut member 20 is embedded.
- the nut member 20 as a whole has a substantially cylindrical shape having a lower height and a smaller diameter than the boss portion 18, and the entire inner hole opens on both sides in the axial direction.
- a female screw hole 22 is provided.
- the nut member 20 is made of a relatively soft metal material such as brass. Thereby, as described later, when a bolt or the like screwed into the female screw hole 22 is sufficiently tightened, an axial compressive force acting on the nut member 20 based on an axial force of the bolt or the like is used. The nut member 20 expands in diameter while being reduced in the axial direction.
- the upper end surface of the nut member 20 is a seat surface 23, and the upper end portion including such a seat surface 23 is a large-diameter portion 24 having a larger diameter than other portions.
- Two small-diameter portions 26a and 26b are formed in the middle portion in the axial direction in the portion below the large-diameter portion 24 so as to be separated in the vertical direction (axial direction).
- the portions further lower than the portion 26b are an upper medium diameter portion 28a, an intermediate medium diameter portion 28b, and a lower medium diameter portion 28c, respectively.
- biting protrusions 30 are integrally formed on the outer peripheral surfaces of the upper intermediate diameter portion 28a and the intermediate intermediate diameter portion 28b.
- Each of the biting protrusions 30 has a trapezoidal longitudinal cross-sectional shape, and is formed of a ridge that spirally extends in the circumferential direction of the upper and middle intermediate diameter portions 28a, 28b.
- middle intermediate diameter part 28b are made into the direction where the extension direction to the circumferential direction extended helically is mutually opposite. .
- each biting projection 30 provided on the upper middle diameter portion 28a is the first spiral biting ridge, while each bit provided on the intermediate middle diameter portion 28b.
- the biting protrusion 30 is a second spiral biting ridge.
- Each of the biting protrusions 30 is easily formed by performing knurling or the like on the outer peripheral surfaces of the upper and middle intermediate diameter portions 28a and 28b, for example.
- the nut member 20 having such a structure is coaxially embedded in the boss portion 18 with the large-diameter portion 24 protruding from the tip surface.
- the bearing surface 23 of the nut member 20 by a dimension corresponding to the height of the large diameter portion 24 (dimension indicated by h 1 in FIG. 4), at a height position higher than the tip surface of the boss portion 18 , Exposed to the outside. Therefore, a bolt, a screw, or the like can be fastened to the female screw hole 22 of the nut member 20 embedded in the boss portion 18 through the upper opening (surface-side opening).
- the other members positioned around it are directed to the nut member 20 with respect to the boss portion 18. It can be attached by a screwing structure such as screwing or bolting.
- the lower middle diameter portion 28 c of the nut member 20 embedded in the boss portion 18 is disposed at the intermediate portion in the height direction of the boss portion 18.
- the lower opening (rear surface opening) of the female screw hole 22 of the nut member 20 is closed at the base side portion located below the nut member 20 of the boss portion 18.
- the base side portion of the boss portion 18 is a closing portion 34 that closes the lower opening of the female screw hole 22 of the nut member 20.
- the biting projections 30 provided on the upper surface of the nut member 20 and the outer peripheral surfaces of the intermediate medium diameter portions 28a and 28b are in a state of being bitten into the inner peripheral surface of the hole portion in which the nut member 20 of the boss portion 18 is embedded. ing.
- the biting protrusions 30 are integrally formed on the outer peripheral surface of the metal nut member 20, so that the hardness is sufficiently higher than that of the resin boss portion 18.
- the nut member 20 is embedded in the boss portion 18 in a state where the biting projections 30 are bitten into the inner peripheral surface of the hole portion of the boss portion 18 and the anchor effect by the biting projections 30 is exhibited. ing.
- the outer peripheral surface of the portion embedded in the boss portion 18 of the nut member 20 has a stepped shape in which the medium diameter portions 28a, 28b, 28c and the small diameter portions 26a, 26b are alternately arranged in the axial direction. As a result, the nut member 20 can be more reliably prevented from coming off from the boss portion 18.
- each biting protrusion 30 provided on the upper intermediate diameter portion 28a and the extending direction of each biting protrusion 30 provided on the intermediate intermediate diameter portion 28b are opposite to each other, the female It is possible to effectively prevent the nut member 20 from being rotated by tightening or loosening a bolt or the like in the screw hole 22.
- the nut member 20 expands in diameter while being reduced in the axial direction by sufficient tightening of a bolt or the like. Therefore, when a bolt or the like is sufficiently tightened with respect to the nut member 20 embedded in the boss portion 18, each biting protrusion 30 provided on the outer peripheral surface of the nut member 20 is expanded in diameter of the nut member 20.
- the anchor effect by the biting protrusion 30 is further advantageously enhanced by deeply biting into the inner peripheral surface of the hole of the boss 18 by an amount corresponding to the amount. As a result, the nut member 20 is more firmly fixed to the boss portion 18, and the nut member 20 can be more effectively prevented from coming out of the boss portion 18.
- the annular convex portion 36 is integrally formed on the tip surface of the boss portion 18 in which the nut member 20 is embedded.
- the annular convex portion 36 is formed of an annular ridge having a U-shaped or semi-elliptical cross-sectional shape.
- the annular convex portion 36 has an inner diameter that is larger than the large diameter portion 24 of the nut member 20 by a predetermined dimension, and is disposed so as to surround the large diameter portion 24 from the outside.
- the annular convex portion 36 is integrally projected from the tip surface portion of the boss portion 18 positioned around the seat surface 23 of the nut member 20 so as to extend in the circumferential direction of the seat surface 23. It is.
- such an annular protrusion 36 has a protruding height h 2 from the front end surface of the boss portion 18: a height from the front end surface of the boss portion 18 of the seat surface 23 of the nut member 20: It is smaller than h 1 (height of the large diameter portion 24 of the nut member 20). Accordingly, when a bolt or the like is screwed (fastened) into the female screw hole 22 of the nut member 20 embedded in the boss portion 18, the head of the bolt or the like comes into contact with the tip portion of the annular convex portion 36. Can be avoided and can be reliably brought into close contact with the seating surface 23 of the nut member 20 without being obstructed by the annular convex portion 36. As a result, at the time of tightening the bolt or the like to the nut member 20, the axial force of the bolt or the like can be ensured stably and reliably, so that the loosening of the bolt or the like can be advantageously prevented.
- the difference between the height of the seating surface 23 of the nut member 20 from the front end surface of the boss portion 18: h 1 and the projection height of the annular convex portion 36 from the front end surface of the boss portion 18: h 2 : h 1 -h 2 is not particularly limited.
- the difference between them: h 1 -h 2 is the reduction of the nut member 20 when the bolt is tightened. It is desirable that the value be larger than the amount. Therefore, specifically, the difference: h 1 -h 2 is preferably about 0.2 to 1.5 mm.
- the difference between the height: h 1 of the seat surface 23 of the nut member 20 from the front end surface of the boss portion 18 and the projection height: h 2 of the annular convex portion 36 from the front end surface of the boss portion 18: h 1 -h 2 is less than 0.2 mm, the head of the bolt or the like abuts against the annular protrusion 36 before the bolt or the like is sufficiently tightened when the bolt or the like is tightened to the nut member 20. As a result, there is a risk that the tightening of bolts and the like will be insufficient.
- the difference h 1 ⁇ h 2 is preferably about 0.2 to 1.5 mm.
- h 1 ⁇ h 2 is more preferably about 0.5 to 1.0 mm. 2 to 4 and drawings to be described later, the height position of the seating surface 23 of the nut member 20 and the height position of the tip of the annular convex portion 36 are exaggerated and are higher than the actual position. It should be understood that
- the urethane resin composition is foam-molded in a mold containing the cover body 10.
- the sound absorbing layer 12 made of urethane foam is integrally formed on the back surface of the cover body 10.
- a first mold 38 having a structure as shown in FIG. 7 is used as an injection mold for injection molding the cover body 10. Is done.
- the first molding die 38 is attached to a fixed die 42 attached to a fixed platen 40 that is fixed in position and a movable platen 44 that is movable toward and away from the fixed platen 40.
- the movable mold 46 is disposed opposite to the fixed mold 42.
- a cavity forming recess 48 is provided on the surface of the first mold 38 facing the movable mold 46 of the fixed mold 42.
- the entire inner surface of the cavity forming recess 48 is a fixed mold side cavity surface 50 as a first cavity surface.
- the fixed mold side cavity surface 50 has a shape corresponding to the surface of the cover body 10.
- a cavity forming convex portion 52 that can enter the cavity forming concave portion 48 of the fixed die 42 is integrally provided on the surface of the movable die 46 that faces the fixed die 42.
- the entire outer surface of the cavity forming convex portion 52 is a movable mold side cavity surface 54 having a shape corresponding to the back surface of the cover body 10.
- a first molding cavity 56 is formed between the mold side cavity surface 54.
- the first molding cavity 56 has a shape corresponding to the outer shape of the cover body 10.
- the fixed platen 40 is provided with a sprue bush 58 that contacts a nozzle of an injection molding machine (not shown).
- a sub sprue 62 and a gate 63 are formed in the fixed mold 42 so as to communicate with the sprue 60 of the sprue bush 58 and open into the molding cavity 56.
- the molten resin material injected from the nozzle is guided into the first molding cavity 56 through the sprue 60, the sub sprue 62, and the gate 63.
- the fixed die 42 has a boss portion as a recess having an inner surface shape corresponding to the three boss portions 18, 18, 18 formed integrally with the cover body 10 at a substantially central portion of the fixed die side cavity surface 50.
- Three formation recesses 64 are provided in a line.
- each boss portion forming recess 64 is further provided with a housing recess 66 that opens at the center of the bottom surface.
- the housing recess 66 has a stepped cylindrical inner peripheral surface whose opening side is smaller in diameter than the bottom side.
- the large-diameter bottom portion of the housing recess 66 is a magnet housing portion 68, while the small-diameter opening-side portion is a dummy bolt housing portion 70.
- the permanent magnet 72 as an attraction means is each accommodated and arrange
- annular concave groove 74 is formed on the outer peripheral portion of the bottom surface of each boss forming recess 64 so as to extend in the circumferential direction of the opening of the housing recess 66.
- the annular concave groove 74 has an inner surface shape corresponding to the outer shape of the annular convex portion 36 formed integrally with the tip surface of the boss portion 18.
- the cover main body 10 is formed using the first mold 38 having such a structure.
- the operation is performed according to the following procedure.
- the dummy bolt 76 used here is formed using a ferromagnetic material that is attracted to the permanent magnet 72, and protrudes integrally from a substantially cylindrical large-diameter head 78 and a lower end of the head 78. And a small-diameter male screw portion 80.
- the head 78 of the dummy bolt 76 has an outer diameter that can be accommodated in the dummy bolt accommodating portion 70 of the accommodating recess 66 provided in the fixed die 42 of the first molding die 38, and the axial length of the dummy bolt accommodating portion 70.
- the axial length is shorter by a predetermined dimension than the thickness (depth).
- a recess is provided in the center of the end surface of the head portion 78 to reduce the area of the end surface.
- the area of the attracted surface of the dummy bolt 76 when the dummy bolt 76 is attracted to the permanent magnet 72 is reduced.
- the male screw portion 80 can be screwed into the female screw hole 22 of the nut member 20, and the axial length thereof is substantially the same as or slightly larger than the axial length of the nut member 20. It is set as a dimension (refer FIG. 12).
- the male threaded portion 80 of the dummy bolt 76 is screwed into the female threaded hole 22 of the nut member 20 from the opening that opens in the seat surface 23 of the large diameter portion 24. At this time, the male screw portion 80 is screwed into the female screw hole 22 until the lower end surface of the head portion 78 contacts the seat surface 23 of the nut member 20.
- three assembly bodies 82 in which the dummy bolts 76 are assembled to the nut member 20 are formed. In each of the assembled bodies 82, the male screw portion 80 is slightly protruded from the tip opening portion of the female screw hole 22 opposite to the seat surface 23 side.
- the front end surface of the male screw portion 80 and the front end surface of the nut member 20 opposite to the seating surface 23 side are substantially flush with each other.
- each assembly 82 is placed in each dummy bolt housing part 70 of each of the three housing recesses 66, 66, 66 of the fixed mold 42 with the first mold 38 opened.
- the head 78 of the dummy bolt 76 is inserted, and the end surface of the head 78 is attracted to the permanent magnet 72 housed in the magnet housing portion 68.
- the nut member 20 of each assembly 82 has the lower end surface of the large-diameter portion 24 (the end surface opposite to the seating surface 23 in contact with the head of the dummy bolt 76) of the boss portion forming recess 64. It is arranged at a position that is substantially flush with the bottom surface (see FIG. 12).
- the seat surface 23 is disposed at a position deeper than the bottom surface of the annular concave groove 74 in the dummy bolt housing portion 70 (see FIG. 12).
- the medium diameter portions 28a, 28b, 28c and the small diameter portions 26a, 26b of the nut member 20 are coaxially accommodated in the boss portion forming recess 64. Further, under such an arrangement state, the opening on the lower middle diameter portion 28 c side of the female screw hole 22 is arranged in the middle in the depth direction of the boss portion forming recess 64.
- the boss portion forming recess 64 has a depth larger than the height of the accommodating portion of the assembly 82 of the nut member 20 and the dummy bolt 76 into the boss portion forming recess 64. ing. And thereby, the opening part of the boss
- the side portion is a closed portion forming cavity portion 83 where the assembly 82 (the nut member 20 and the dummy bolt 76) does not exist.
- a portion other than the large diameter portion 24 including the seating surface 23 of each nut member 20 is positioned so as to protrude from the fixed mold side cavity surface 50 into the first molding cavity 56 (boss portion forming recess 64).
- the dummy bolt 76 (assembled body 82) is attracted to the fixed mold 42 by the permanent magnet 72 and held.
- the molten resin material is injected and filled into the first molding cavity 56 from the nozzle 84 of the injection molding machine (not shown) through the sprue 60, the sub sprue 62, and the gate 63 of the fixed mold 42. Solidify.
- the cover body 10 is formed in the first molding cavity 56, and the three boss portions 18, 18, 18 protrude integrally on the surface of the cover body 10.
- one nut member 20 is coaxially embedded in each boss portion 18 provided on the surface of the cover body 10 in a state where the dummy bolts 76 are fastened and assembled. To do.
- each boss portion 18 In the nut member 20 embedded in each boss portion 18, only the large-diameter portion 24 protrudes from the protruding front end surface of the boss portion 18, while the portions other than the large-diameter portion 24. (Each medium diameter portion 28a, 28b, 28c and each small diameter portion 26a, 26b) are embedded in the boss portion 18.
- the large-diameter portion 24 side opening of the female screw hole 22 is open on the surface side of the cover body 10, while the lower middle-diameter portion 28 c side opening of the female screw hole 22 is the base of the boss portion 18. It is blocked at the side part.
- the seating surface 23 which consists of the end surface of the large diameter part 24 is exposed to the surface of the cover main body 10 in the position higher than the front end surface of the boss
- hub part 18 (refer FIG. 13).
- a boss portion 18 formed in the closed portion molding cavity portion 83 is formed on the back surface side of the cover body 10 so as to close the lower middle diameter portion 28 c side opening portion of the female screw hole 22 of the nut member 20.
- the cover body 10 integrally having the three boss portions 18, 18, 18 is formed, and at the same time, the annular shape is formed in the annular groove 74 of each boss portion forming recess 64.
- An annular convex portion 36 to be presented is integrally formed on the outer peripheral portion of the tip surface of each boss portion 18.
- the annular convex portion 36 is provided so as to surround the seat surface 23 of the nut member 20 embedded in each boss portion 18 from the outside, and the height position of the tip portion thereof is the height position of the seat surface 23. The position is lower.
- the mold opening force of the first mold 38 is set to be larger than the attracting force with which each permanent magnet 72 attracts each dummy bolt 76. Further, the cover body 10 is in close contact with the movable mold side cavity surface 54 of the movable mold 46 with a force larger than such an adsorption force. Therefore, although not shown, when the first molding die 38 is opened, the attractive force of each permanent magnet 72 to each dummy bolt 76 is released without performing any special operation other than the mold opening. The mold is opened while the cover body 10 is in close contact with the movable mold side cavity surface 54.
- the cover main body 10 is moved to the first molding die in a state where the dummy bolts 76 are screwed to the nut members 20 embedded in the boss portions 18 respectively. 38.
- the cover main body 10 is in close contact with the movable mold side cavity surface 54 of the movable mold 46.
- the cover main body 10 is It is easily released from the movable mold 46.
- the dummy bolts 76 are removed from the nut members 20 of the cover main body 10, respectively.
- the dummy bolt 76 is made of an independent member that is separate from the first mold 38. Therefore, unlike the case where the dummy bolt 76 is provided integrally with the fixed mold 42, for example, the dummy bolt 76 is simply performed without performing any major work such as rotating the entire fixed mold 42. The dummy bolts 76 can be easily removed from the nut members 20 only by rotating the 76 one by one.
- the cover body 10 is set on the second mold 86 for molding the sound absorbing layer 12.
- the second molding die 86 used here is fixedly attached to a fixed die 94 attached to a fixed platen 92 that is fixed in position and a movable platen 88 that is movable toward and away from the fixed platen 92. It has a mold 94 and a movable mold 90 arranged opposite to the mold 94.
- a cavity forming convex portion 96 is integrally provided on the surface of the second mold 86 facing the fixed mold 94 of the movable mold 90. As will be described later, a pressing projection 95 for pressing the cover body 10 so as not to move when the cover body 10 is set on the second mold 86 is applied to the outer surface of the cavity forming convex portion 96. In the position corresponding to the boss portion 18 of the cover main body 10, each is integrally projected. The entire outer surface of the cavity forming convex portion 96 is a movable mold side cavity surface 98 having a shape corresponding to the back surface of the sound absorbing layer 12.
- a cavity forming concave portion 100 into which the cavity forming convex portion 96 of the movable die 90 can enter is provided on the surface of the fixed die 94 facing the movable die 90.
- the entire inner surface of the cavity forming recess 100 is a fixed mold side cavity surface 102 having a shape corresponding to the surface of the cover body 10.
- the second molding cavity 104 has a shape corresponding to the outer shape of the target soundproof cover.
- the fixed die 94 has a boss portion accommodating recess having an inner surface shape corresponding to the three boss portions 18, 18, 18 formed integrally with the cover main body 10 at a substantially central portion of the fixed die side cavity surface 102.
- Three 112 are provided in a line.
- each of the boss receiving recesses 112 is further provided with a circular central recess 114 that opens at the center of the bottom surface.
- the central recess 114 is larger than the outer diameter of the large diameter portion 24 of the nut member 20 embedded in the boss portion 18, and is larger than the inner diameter of the annular convex portion 36 provided on the outer peripheral portion of the tip surface of the boss portion 18.
- FIGS. 14 and 15 illustrate the second molding die 86 having the above-described structure in a second molding cavity 104 formed inside the second molding die 86 in a closed state.
- the cover body 10 is set on the fixed mold 94.
- the cover main body 10 is set to the fixed mold 94 in an open state.
- FIGS. 14 and 15 illustrate the housing position of the cover main body 10 in the second molding cavity 104 in FIGS.
- the state in which the cover body 10 is set in the fixed mold 94 is shown in the closed state.
- the liquid urethane resin composition 116 is placed in the cavity forming recess 100 of the fixed mold 94 in the urethane resin composition foam injection device. Cast from an injection nozzle (not shown).
- the movable mold 90 and the fixed mold 94 are closed to form the second molding cavity 104, and the back surface side of the cover body 10 in the second molding cavity 104.
- the liquid urethane resin composition 116 is foamed.
- the sound absorbing layer 12 is integrally foam-molded with respect to the back surface of the cover body 10 to obtain an integrally molded product of the cover body 10 and the sound absorbing layer 12.
- the surface of the cover main body 10 is pressed against the movable mold side cavity surface 102 of the movable mold 90 by the pressing projection 95 of the movable mold 90, and an annular shape provided on the tip surface of each boss portion 18.
- the tip portion of the convex portion 36 is pressed against the outer peripheral portion of the bottom surface of the boss portion accommodating recess 112.
- the liquid urethane resin composition 116 in the second molding cavity 104 moves from the opening of the injector (not shown) to the surface side of the cover body 10. Even if such urethane resin composition 116 wraps around, the surface of the cover body 10 is pressed against the movable mold side cavity surface 102.
- the function as a seal portion for sealing between the front end surface of each boss portion 18 and the bottom surface of the boss portion accommodating recess 112 is advantageously exhibited.
- the urethane resin composition 116 can be effectively prevented from entering the female screw hole 22 from the opening of the female screw hole 22 of the nut member 20 that opens at the front end surface of the boss portion 18.
- the opening portion of the female screw hole 22 of the nut member 20 on the back surface side of the cover body 10 is closed by the closing portion 34 formed of the base portion of the boss portion 18. Further, the urethane resin composition 116 does not enter.
- an inexpensive nut provided with screw holes that are open on both sides in the three boss portions 18, 18, 18 that are integrally projected on the surface of the cover body 10.
- One member 20 is embedded in each.
- other members positioned around the soundproof cover are screwed or bolted to the nut member 20 with respect to the boss portion 18. It can be attached by a screwing structure such as.
- the soundproof cover of the present embodiment unlike the conventional soundproof cover in which the through hole through which the boss part protruding from the cylinder head cover is inserted is provided in the cover body, such a through hole is omitted. Can be done. Therefore, sound leakage from the engine side through such a through hole can be advantageously prevented, and as a result, excellent soundproof performance can be more fully exhibited.
- the urethane foam that has entered and solidified into the female screw hole 22 of the nut member 20 may cause a situation in which it is difficult to fasten screws, bolts, or the like to the nut member 20. Can be prevented in advance. And as a result, the attachment by the screwing structure with respect to the boss
- the annular convex portion 36 extending in the circumferential direction of the seat surface 23 of the nut member 20 is integrally formed on the tip surface of the boss portion 18 of the cover body 10.
- the seat surface 23 is formed so as to surround the seat surface 23 of the nut member 20 from the outside on the bottom surface of the boss portion accommodating recess 112 that accommodates the boss portion 18 of the cover body 10.
- the seal protrusion 122 extending in the circumferential direction is provided, the annular convex portion (36) can be omitted from the tip surface of the boss portion 18.
- the specific overall shape thereof is particularly limited if the annular convex portion 36 has a closed shape extending in the circumferential direction of the seat surface 23 of the nut member 20. is not.
- the cross-sectional shape of the annular protrusion 36 is not limited to the illustrated one, and various polygonal shapes, shapes in which the ridgeline is a curved line, and the like can be appropriately employed.
- the thickness of the cover main body 10 is made larger than the height of the portion of the nut member 20 embedded in the cover main body 10, and the nut member of the cover main body 10 portion where the nut member 20 is embedded.
- the portion on the back side from 20 is the closed portion 34.
- the nut member 20 has an end portion on the seating surface 23 side of the nut member 20 (in the above embodiment, a large diameter).
- the part 24) does not necessarily have to protrude from the surface of the cover body 10.
- the nut member 20 may be embedded in the cover body 10 with the seating surface 23 being flush with the surface of the cover body 10.
- the seat surface 23 of the nut member 20 is disposed at a position that is substantially flush with the bottom surface of the boss forming recess 64 of the first molding die 38. The entire nut member 20 is accommodated in the boss portion forming recess 64.
- biting protrusion 30 formed on the outer peripheral surface of the nut member 20 is not essential in the present invention, when the biting protrusion 30 is formed, the overall shape and the cross-sectional shape other than those exemplified are not shown. Shape can be adopted. That is, as the overall shape of the biting protrusion 30, for example, a convex shape independent of each other can be appropriately adopted in addition to the convex shape extending in the circumferential direction of the nut member. As the cross-sectional shape, various polygonal shapes, shapes in which the ridgeline is a curved line, and the like can be variously adopted.
- the present invention includes a soundproof cover that covers a cylinder head cover of an automobile engine and a manufacturing method thereof, and a sound absorption layer made of urethane foam is integrally formed on the back surface of a cover body made of a hard resin molded body.
- the present invention can also be advantageously applied to various types of soundproof covers and methods for manufacturing such soundproof covers.
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- Combustion & Propulsion (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
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Abstract
Description
18 ボス部 20 ナット部材
22 雌ネジ孔 23 座面
30 食い込み突起 34 閉塞部
36 環状凸部 38 第一の成形型
56 第一の成形キャビティ 72 永久磁石
76 ダミーボルト 83 閉塞部成形キャビティ部分
86 第二の成形型 104 第二の成形キャビティ
116 ウレタン樹脂組成物
Claims (10)
- カバー本体と、該カバー本体の裏面に固着された吸音層とを有しており、該カバー本体が、硬質の樹脂成形体からなる一方、該吸音層が、該カバー本体を収容した成形型内でのウレタン樹脂組成物の発泡成形により、該カバー本体の裏面側に一体形成されたウレタン発泡体からなる防音カバーにおいて、
軸方向両側に開口するネジ孔を備えたナット部材が、軸方向一方側の座面を該カバー本体の表面に露呈させて、軸方向一方側のネジ孔開口部を前記カバー本体の表面において開口させた状態で、該カバー本体に埋設されていると共に、該ナット部材の軸方向他方側のネジ孔開口部が、該カバー本体に一体形成された閉塞部にて閉塞されていることを特徴とする防音カバー。 - 前記ナット部材の前記座面を含む軸方向一端部が、前記カバー本体の表面から突出している請求項1に記載の防音カバー。
- 前記カバー本体の表面に、該カバー本体への前記ナット部材の埋設部分の高さよりも大きな高さを有するボス部が一体的に突設されて、該ボス部に対して、該ナット部材が、前記座面を該ボス部の突出先端面側に露呈させた状態で埋設されていると共に、前記閉塞部が、該ボス部の基端部にて構成されている請求項1又は請求項2に記載の防音カバー。
- 前記ナット部材の前記座面の周囲に位置する前記カバー本体の表面部分に、該ナット部材の座面の周方向に延びる環状凸部が一体形成されている請求項1乃至請求項3のうちの何れか1項に記載の防音カバー。
- 前記ナット部材が、前記カバー本体よりも硬質で、且つ該ナット部材に締結される締結部材の軸力により軸方向に縮小しつつ、拡径する材料を用いて形成されていると共に、該ナット部材の外周面に食い込み突起が形成されて、該ナット部材が該締結部材の軸力により拡径したときに、該食い込み突起が、該ナット部材を埋設する該カバー本体の穴部の内周面に食い込むようになっている請求項1乃至請求項4のうちの何れか1項に記載の防音カバー。
- 前記食い込み突起が、前記ナット部材の軸方向一端部側の外周面に、螺旋を描いて周方向に延びるように形成された第一の螺旋状食い込み凸条と、該ナット部材の軸方向他端部側の外周面に、該第一の螺旋状食い込み凸条とは逆方向の螺旋を描いて周方向に延びるように形成された第二の螺旋状食い込み凸条とにて構成されている請求項5に記載の防音カバー。
- 請求項1に記載の防音カバーの製造方法であって、
前記カバー本体に対応した形状の第一の成形キャビティを有する第一の成形型と、前記ナット部材に締結可能で、且つ該第一の成形型とは別個の独立した部材からなるダミーボルトと、該ダミーボルトを吸着して、該第一の成形型に保持させる吸着手段とを準備する工程と、
前記ダミーボルトに前記ナット部材を締結すると共に、該ナット部材の全体又は前記座面を含む軸方向一端部以外の部位が、前記第一の成形キャビティを形成する第一のキャビティ面から該第一の成形キャビティ内に突出して配置されるように、該ダミーボルトを、該第一の成形型に対して、前記吸着手段により吸着させて、保持せしめた後、溶融樹脂を該第一の成形キャビティ内に射出充填して、固化させることにより、前記カバー本体を該第一の成形キャビティ内で形成すると共に、前記ナット部材を該カバー本体に埋設し、更に、前記閉塞部を該カバー本体に一体形成する工程と、
前記第一の成形キャビティ内で前記カバー本体が形成された前記第一の成形型を型開きすると共に、かかる型開き時に、前記吸着手段の吸着による前記ダミーボルトの該第一の成形型への保持状態が解除されることにより、該カバー本体と該ダミーボルトとを該第一の成形型から一緒に取り出した後、該カバー本体に埋設された前記ナット部材から該ダミーボルトを取り外す工程と、
前記吸音層に対応した形状の第二の成形キャビティを有する第二の成形型を用い、前記カバー本体を該第二の成形キャビティ内に収容した後、前記ウレタン樹脂組成物を、該第二の成形キャビティにおける該カバー本体の裏面側の部分に充填して、該ウレタン樹脂組成物の発泡成形を行うことにより、前記ウレタン発泡体からなる吸音層を該カバー本体の裏面側に一体形成する工程と、
を含むことを特徴とする防音カバーの製造方法。 - 前記ナット部材が、前記ダミーボルトのボルト脚部に対して、前記軸方向一方側の座面とは反対側の端面を該ボルト脚部の先端面と面一と為すように螺合されて、該ダミーボルトに該ナット部材が締結されるようになっていると共に、該ナット部材が締結された該ダミーボルトが前記第一の成形型に保持された状態下で、前記第一の成形キャビティ内における該ダミーボルトのボルト脚部の先端側に、前記閉塞部を成形するための閉塞部成形キャビティ部分が形成されるようになっている請求項7に記載の防音カバーの製造方法。
- 前記ナット部材の全体又は前記座面を含む軸方向一端部以外の部位が前記第一の成形キャビティ内に突出する前記第一のキャビティ面部分に、該第一の成形キャビティ内への該ナット部材の突出高さよりも大きな深さを有する凹所が設けられて、前記ダミーボルトに締結された該ナット部材の全体又は軸方向一端部以外の部位が、該凹所の底面から該凹所内に突出して配置されると共に、該凹所の開口側部分にて、前記閉塞部を成形するための閉塞部成形キャビティ部分が形成されるようになっている請求項7又は請求項8に記載の防音カバーの製造方法。
- 前記ナット部材が前記第一の成形キャビティ内に配置された状態下で、該第一の成形キャビティ内への該ナット部材の突出部分の周囲に位置する該第一のキャビティ面部分に、該ナット部材の突出部分の周方向に延びる環状凹溝が形成されており、前記溶融樹脂が該第一の成形キャビティ内に射出充填されて、固化されることによって、該第一の成形キャビティ内で、前記カバー本体が、該ナット部材を埋設して形成されると共に、該ナット部材の前記座面の周囲に位置する該カバー本体の表面部分に、該ナット部材の座面の周方向に延びる環状凸部が一体形成され、その後、該カバー本体が、該環状凸部の先端部位を前記第二の成形型の第二の成形キャビティ面に接触させた状態で、前記第二の成形キャビティ内に収容された後、該第二の成形キャビティ内での前記ウレタン樹脂組成物の発泡成形が行われるようになっている請求項7乃至請求項9のうちの何れか1項に記載の防音カバーの製造方法。
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DE112010000443B4 (de) | 2014-10-23 |
JPWO2011052249A1 (ja) | 2013-03-14 |
CN102396023B (zh) | 2013-06-05 |
US8336671B2 (en) | 2012-12-25 |
DE112010000443T5 (de) | 2012-10-25 |
CN102396023A (zh) | 2012-03-28 |
US20120168246A1 (en) | 2012-07-05 |
JP5432244B2 (ja) | 2014-03-05 |
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