WO2020095523A1 - Method for manufacturing hollow part - Google Patents

Method for manufacturing hollow part Download PDF

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Publication number
WO2020095523A1
WO2020095523A1 PCT/JP2019/034352 JP2019034352W WO2020095523A1 WO 2020095523 A1 WO2020095523 A1 WO 2020095523A1 JP 2019034352 W JP2019034352 W JP 2019034352W WO 2020095523 A1 WO2020095523 A1 WO 2020095523A1
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WO
WIPO (PCT)
Prior art keywords
hollow
foam
convex
lid
opening
Prior art date
Application number
PCT/JP2019/034352
Other languages
French (fr)
Japanese (ja)
Inventor
美徳 政次
Original Assignee
豊田合成株式会社
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Filing date
Publication date
Application filed by 豊田合成株式会社 filed Critical 豊田合成株式会社
Publication of WO2020095523A1 publication Critical patent/WO2020095523A1/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D22/00—Producing hollow articles
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent

Definitions

  • the present invention relates to a method for manufacturing a hollow part represented by a vehicle air conditioning duct.
  • hollow parts there is one in which two separate members are joined and integrated.
  • these joint-integrated hollow parts there are some which are required to have heat insulating properties such as air-conditioning ducts for vehicles.
  • heat insulating properties such as air-conditioning ducts for vehicles.
  • at least one of the above-mentioned two members is made of a porous body capable of retaining air therein, such as a nonwoven fabric, a woven fabric, or a foam. Is considered good.
  • hollow parts made of resin it is considered good to use foam as the porous body.
  • Patent Document 1 introduces a ventilation duct for an automobile, which is composed of a polyolefin crosslinked foamed laminate in which a foam layer and a resin layer are laminated.
  • a ventilation duct for an automobile which is composed of a polyolefin crosslinked foamed laminate in which a foam layer and a resin layer are laminated.
  • two polyolefin crosslinked foamed laminates are vacuum-formed and then laminated together, and two polyolefin crosslinked foamed laminates are simultaneously heated.
  • a compressed air vacuum forming method in which a mold is formed by compressed air and vacuum.
  • Patent Document 1 According to the manufacturing method introduced in Patent Document 1 described above, it is considered possible to manufacture a hollow part having heat insulating properties.
  • the manufacturing method when one of the two members is made of a non-foamed body, it is difficult to efficiently manufacture a hollow component having excellent shape and performance because the rigidity and the shrinkage rate of the two members are different.
  • a member obtained by shaping a foam will be referred to as a foam member
  • a member made of a non-foam member will be referred to as a non-foam member, as necessary.
  • the outer edge portion of the foamed member obtained by shaping the foam has an irregular shape. Become. Therefore, in this case, a step of trimming the outer edge portion of the foamed member is required to adjust the shape of the hollow component.
  • one of the two members is a foam member and the other is a non-foam member, it may be necessary to trim only the foam member. This is because, for example, when the non-foamed member is molded, the step itself of trimming the non-foamed member may be unnecessary.
  • the outer edge portion of the foamed member of the two members may be trimmed along the shape of the non-foamed member.
  • a new method for manufacturing a hollow part is desired, which can easily manufacture a hollow part having a regular shape.
  • the present invention has been made in view of the above circumstances, and an object of the present invention is to provide a new method for manufacturing a hollow part.
  • the method for manufacturing a hollow component of the present invention that solves the above problems, A method for producing a hollow component having a box-shaped foam hollow portion having an opening formed by forming a foam, and a lid portion made of a non-foam material and covering the opening of the foam hollow portion, A bonding step of covering the opening of the intermediate body of the foamed hollow portion having the opening with the lid portion and joining the peripheral edge portion of the opening and the lid portion in the intermediate body, Of the intermediate body, a trimming step of cutting off a surplus portion located radially outside the opening with respect to a portion joined to the lid portion, At least one of the intermediate body and the lid portion, a portion to be joined to the other, as a convex portion protruding toward the other, In the trimming step, the surplus portion is removed at a position adjacent to the convex portion on the outer side in the radial direction.
  • the hollow component manufacturing method of the present invention it is possible to easily manufacture a hollow component having a regular shape.
  • FIG. 3 is an explanatory view schematically showing how the hollow component of the first embodiment is mounted on a vehicle.
  • FIG. 3 is an explanatory view schematically showing a state in which the hollow component of Example 1 is cut along the vertical direction and the vehicle width direction.
  • FIG. 5 is an explanatory view schematically showing a state where the hollow component of Example 1 is being manufactured.
  • FIG. 5 is an explanatory view schematically showing a state where the hollow component of Example 2 is manufactured.
  • FIG. 9 is an explanatory view schematically showing a state where the hollow component of Example 3 is being manufactured. It is explanatory drawing explaining the other example of the convex curved part in the hollow component of Example 3.
  • FIG. 9 is an explanatory view schematically showing a state where the hollow component of Example 4 is being manufactured.
  • FIG. 11 is an explanatory view schematically showing the production of the hollow component of Example 5. It is explanatory drawing which represents typically the one aspect
  • the numerical range “ab” described in the present specification includes the lower limit a and the upper limit b in the range.
  • the upper limit value and the lower limit value, and the numerical values listed in the examples can be arbitrarily combined to form the numerical value range. Further, a numerical value arbitrarily selected from these numerical ranges can be set as a new upper and lower numerical value.
  • the foam hollow portion and the lid portion are joined by joining the two members of the foam hollow portion intermediate body and the lid portion and trimming the excess portion of the intermediate body. It is a method of manufacturing the hollow part.
  • the foam hollow portion corresponds to the above-mentioned foam member
  • the lid portion corresponds to the above non-foam member.
  • the method for manufacturing a hollow part of the present invention can be called a method for manufacturing a hollow part integrally joined.
  • the lid covers the opening of the hollow foam part and is joined to the peripheral edge of the opening. Further, in the method for manufacturing a hollow component of the present invention, a portion of at least one of the intermediate body of the foam hollow portion and the lid portion, which is joined to the other, is a convex portion protruding toward the other.
  • the surplus portion that is cut off in the trimming step is a portion of the intermediate body that is located outside the convex portion in the radial direction of the opening. Therefore, in the method for manufacturing a hollow component of the present invention, in the trimming step, the surplus portion may be cut off at a position adjacent to the convex portion on the outer side in the radial direction of the opening.
  • the convex portion is provided on at least one of the intermediate body and the lid portion and projects toward the other, the distance between the intermediate body and the lid portion is very short in the convex portion. Then, at the position adjacent to the convex portion, the distance between the intermediate body and the lid portion becomes large. That is, at a position adjacent to the convex portion, a gap is formed between the intermediate body and the lid portion.
  • the trimming step of cutting off only the foamed member without cutting the non-foamed member is easily performed. obtain.
  • a hollow component having a regular shape can be easily manufactured.
  • the foamed hollow portion and its intermediate may be collectively referred to simply as the foamed hollow portion, if necessary.
  • the foam hollow part is a box-shaped member formed by molding a foam and having an opening.
  • the shaping here means a molding method in which a material is deformed into a desired shape. It can be said that the foam hollow portion formed by shaping the foam body inherits the properties of the foam body.
  • the foam hollow part is a porous body. Therefore, the hollow component produced by the method for producing a hollow component of the present invention is provided with heat insulating properties, sound insulation properties, sound deadening properties, etc. due to the fact that the foam hollow portion is a porous body.
  • the foam may have a foam layer made of a known foam resin such as polyethylene foam or polyurethane foam.
  • the foam may have a non-porous layer such as a skin layer in addition to the foam layer. That is, the foam hollow portion may have a single-layer structure or a multi-layer structure.
  • the foam hollow portion formed by shaping the foam has a box shape having an opening.
  • the box shape here means that it has a U-shaped cross section.
  • the foam hollow part 102 may have a box shape in which four surfaces are closed by standing walls, or, as shown in FIG. 10, the foam hollow part 102 has a box in which two opposite surfaces are opened.
  • the shape may be a cut-out tubular shape that is cut along a direction orthogonal to the axial direction L.
  • the opening 120 of the foam hollow part 102 having a box shape is covered with the lid part 103. Then, at least one of the peripheral edge portion 121 of the opening 120 in the foam hollow portion 102 and the portion of the lid portion 103 facing the peripheral edge portion 121 is provided with a convex portion 131 projecting toward the other.
  • the protrusion 131 is provided on the peripheral portion 121 of the opening 120, that is, on the outer side in the radial direction of the opening 120.
  • a known method such as vacuum forming or a combination of vacuum forming and pressure forming may be used.
  • the foam a sheet-shaped, plate-shaped or the like may be used.
  • the opening of the foam hollow portion is referred to as a hollow opening, and is distinguished from other openings.
  • the lid part may be made of non-foamed material, and the lid part itself may have one or a plurality of openings.
  • the method for joining the foam hollow portion and the lid is not particularly limited, and therefore the material for the lid is not particularly limited either.
  • the lid may be made of metal or metal oxide.
  • a resin material is selected as the material of the lid portion. Preferably.
  • the lid part is made of non-foamed material, it can be said that it has higher rigidity than the foamed hollow part made of foamed material. That is, the lid portion can contribute to ensuring the rigidity of the hollow component as a whole.
  • a lid may be provided with a function as an attachment portion for attaching the hollow component to another member, or the lid may be used in combination with a part of the other member.
  • the lid may have any shape as long as it can cover the hollow opening.
  • the lid portion may have a simple flat plate shape, but may have a box shape like a foam hollow portion.
  • the hollow inside of the hollow component is mainly formed inside the box in the foam hollow.
  • the hollow inside of the hollow component includes the inside of the box in the foam hollow portion and the inside of the box in the lid. In this case, the inside of the box in the foam hollow portion and the inside of the box in the lid portion communicate with each other through the hollow opening. Since the lid portion is made of a non-foamed material, its shape may be given when it is molded by various molding methods typified by injection molding, extrusion molding, press molding and the like.
  • Adhesion as used herein may include both irreversible adhesion (ie, sticking) and reversible adhesion (ie, sticking).
  • the joined state of the foam hollow portion and the lid portion may be appropriately set depending on the application of the hollow component manufactured by the method for manufacturing a hollow component of the present invention and the performance required for the hollow component.
  • the hollow foam portion and the lid portion may be airtightly joined together or may be joined together with a gap.
  • a portion of at least one of the intermediate body and the lid portion that is joined to the other is a convex portion that projects toward the other.
  • the convex portion is provided at a position corresponding to the peripheral edge of the hollow opening and along the outer edge of the hollow opening.
  • the shape and the number of the convex portions may be appropriately provided depending on the joining state of the foam hollow portion and the lid portion required for the hollow component.
  • the convex portion may be provided on the intermediate body, the lid portion, or both the intermediate body and the lid portion. Since the intermediate body is formed of a foam, its rigidity tends to be lower than that of the lid portion. Therefore, considering that the shape of the convex portion is favorably maintained in the trimming step, it can be said that the convex portion is preferably provided on the lid portion.
  • the height of the convex portion is preferably in the range of 1 to 30 mm, more preferably in the range of 1 to 20 mm, and particularly preferably in the range of 2 to 10 mm.
  • the distance between the excision position of the surplus portion and the convex portion in the trimming step is preferably in the range of 2 to 50 mm, more preferably in the range of 3 to 30 mm, and in the range of 5 to 10 mm. Is particularly preferable.
  • the convex portion may be provided continuously over the entire circumference of the outer edge of the hollow opening, or may be provided intermittently.
  • the convex portion may be continuously provided over the entire circumference of the outer edge of the hollow opening.
  • the intermediate body and the lid portion can be airtightly joined over the entire circumference of the peripheral portion of the hollow opening.
  • the convex portion may be provided intermittently along the outer edge of the hollow opening.
  • the convex portion by providing the convex portion, a gap is formed between the intermediate body and the lid portion, which has an advantage of facilitating the trimming process.
  • the pitch between the adjacent convex portions is preferably small to some extent.
  • the preferable ranges of the pitch include 20 mm or less, 15 mm or less, 10 mm or less, and 5 mm or less.
  • the pitch of the adjacent convex portions here means the size of the gap between the adjacent convex portions.
  • the trimming process may be performed automatically using a known cutting device, or manually by an operator.
  • Two or more convex portions may be provided at intervals in the radial direction of the hollow opening.
  • the intermediate body and the lid portion By joining the intermediate body and the lid portion at the plurality of convex portions, there is an advantage that the intermediate body and the lid portion can be stably integrated.
  • the radial direction of the hollow opening may be simply abbreviated as the radial direction, if necessary.
  • the same protrusion as the protrusion may be further provided on the outside in the radial direction of the protrusion.
  • the protrusion is called a sub-projection. Similar to the convex portion, the sub-convex portion protrudes from one of the intermediate body and the lid portion toward the other, and may be provided on the same member as the convex portion of the intermediate body and the lid portion. It may be provided on a member different from the convex portion. That is, for example, when the convex portion is provided on the intermediate body, the auxiliary convex portion may be provided on the intermediate body or the lid portion.
  • the trimming process in the trimming process, the surplus portion of the intermediate body is cut off between the convex portion and the sub-convex portion. Since the convex portion and the sub convex portion function as two spacers, the gap between the intermediate body and the lid portion is sufficiently and stably ensured between the convex portion and the sub convex portion. Therefore, there is an advantage that the trimming process is further facilitated by cutting the surplus portion with the cutting position between the convex portion and the sub convex portion as the cutting position.
  • the convex portion and the sub-convex portion may have the same shape or different shapes.
  • the convex portion is a portion related to the bonding strength with the mating material, it is preferable that the convex portion is larger than the sub-convex portion in order to secure a large bonding strength.
  • the tops of the projections are flat.
  • the lid part is made of non-foamed material, while the foamed hollow part is obtained by shaping the foamed material as described above. Therefore, the foam hollow portion has lower rigidity than the lid portion and tends to be deformed. For this reason, when the hollow part is manufactured or used, if it is placed in an environment where the foam hollow part is easily deformed, only the foam hollow part may be deformed and separated from the joined lid part.
  • the hollow component when used as an air conditioning duct, the hollow component may expand during heating or the like, and the foamed hollow portion may peel off from the lid portion. Further, when the shaped intermediate body is joined to the lid portion before cooling, the intermediate body may be largely deformed and peeled off from the lid portion due to the difference in shrinkage rate between the two. In order to suppress such separation between the lid portion and the foam hollow portion, it is considered effective to suppress the deformation of the foam hollow portion.
  • the intermediate body In order to suppress the deformation of the foam hollow portion, it is preferable to provide the intermediate body with a buffer portion that can reduce the deformation. It is considered effective that the cushioning portion is configured by a curved portion that is raised toward the lid portion or is depressed toward the side opposite to the lid portion.
  • the curved portion protruding toward the lid portion is referred to as a convex curved portion
  • the curved portion depressed toward the opposite side of the lid portion is referred to as a concave curved portion. Since the convex curved portion and the concave curved portion are curved portions, that is, curved portions in a bow shape, they can be said to be easily deformed portions.
  • the curved portion of the intermediate body is deformed in preference to the other portions of the intermediate body. It can also be said that the intermediate body having the curved portion has a longer film length than the apparent outer shape.
  • the position of the buffer portion may be inside the radial direction of the convex portion, but for the purpose of efficiently absorbing or relaxing the force acting on the convex portion, the buffer portion is preferably provided in the vicinity of the convex portion, It is more preferable to provide it at a position adjacent to the convex portion on the inner side in the radial direction.
  • the preferable range of the distance between the convex portion and the buffer portion is within 50 mm, within 30 mm, and within 15 mm.
  • the distance between the convex portion and the buffer portion specifically means the distance between the top of the curved portion that is closest to the convex portion in the buffer portion and the top of the convex portion.
  • the distance between the convex portion and the buffer portion may exceed 0 mm.
  • the number of curved portions that the cushioning portion has is not limited, but it is more preferable that the cushioning portion has a convex curved portion, and the convex curved portion is adjacent to the convex portion inward in the radial direction. Is particularly preferable.
  • the cushioning portion is composed of a plurality of curved portions.
  • the plurality of curved portions preferably include at least one convex curved portion and at least one concave curved portion, and more preferably include a plurality of convex curved portions and a plurality of concave curved portions.
  • the convex portion is a portion that projects toward the other in at least one of the intermediate body and the lid portion, and thus may have the same curved shape as the curved portion.
  • the convex portion is not required to have the function of deforming. Therefore, the convex portion may have a protrusion shape in which a part of the surface is more protruded than the other portion, instead of the curved shape.
  • the method for manufacturing a hollow component according to the first embodiment is a method for manufacturing an air conditioning duct for a vehicle, which is a type of hollow component. Therefore, the hollow component of the first embodiment is a vehicle air conditioning duct.
  • FIG. 1 is an explanatory view schematically showing how the hollow component of the first embodiment is mounted on a vehicle.
  • FIG. 2 is an explanatory diagram schematically showing a state in which the hollow component of the first embodiment is cut along the vertical direction and the vehicle width direction.
  • FIG. 3 is an explanatory view schematically showing how the hollow component of Example 1 is manufactured.
  • the driver seat side and the passenger seat side mean the driver seat side and the passenger seat side shown in FIGS. 1 and 2.
  • the front and the rear mean the front and the rear shown in FIG. 1, and the upper and the lower mean the upper and the lower shown in FIG.
  • the driver's seat side-passenger seat side direction can be read as the vehicle width direction, and the front can be read as the front side of the vehicle traveling direction and the rear as the rear side of the vehicle traveling direction.
  • the hollow component 1 is integrally disposed in a vehicle center console box 90 disposed in a vehicle compartment, and is directed toward a thigh 93 of an occupant 92 seated on a seat 91. It is an air conditioning duct for blowing out the conditioned air 94.
  • the hollow component 1 has a substantially tubular shape extending in the substantially front-back direction.
  • the rear part of the hollow component 1 is arranged inside the center console box 90.
  • the front portion of the hollow component 1 is connected to a vehicle air conditioner (not shown) located in front of the center console box 90.
  • the hollow component 1 serves as a distribution path of the conditioned air 94 supplied to the vehicle compartment 95 by the vehicle air conditioner.
  • the hollow component 1 is composed of a foam hollow portion 2 and a lid portion 3.
  • the hollow component 1 is arranged below the console lid 96 in the center console box 90 and inside the side panel 97.
  • the foam hollow portion 2 of the hollow component 1 has a substantially U-shaped cross section that opens toward the driver's seat.
  • the opening of the foam hollow portion 2 is the hollow opening 20 described above.
  • a peripheral edge portion 21 of the hollow opening 20 in the foam hollow portion 2 extends in a substantially flat shape so as to be substantially flush with the hollow opening 20.
  • the hollow opening 20 of the foam hollow portion 2 is covered with the lid portion 3.
  • the lid portion 3 has a substantially plate shape and covers the hollow opening 20 from the driver's seat side.
  • a window-shaped blowout opening 30 is provided in the rear portion of the lid portion 3, and the surface of the lid portion 3 on the side of the hollow opening 20 protrudes toward the inside of the hollow opening 20 below the blowout opening 30. Ribs 35 are provided.
  • the blowout opening 30 is covered with a blowout member 6 that is separate from the hollow component 1.
  • the blowing member 6 has a lattice shape having a large number of openings.
  • the inner hollow 10 of the hollow component 1 serves as the flow path of the conditioned air 94 described above.
  • the conditioned air 94 flowing through the inner hollow 10 is straightened by the straightening ribs 35 extending in the front-rear direction, passes through the hollow openings 20 and the blowout openings 30, and further flows out into the vehicle compartment 95 through the lattice-shaped blowout members 6.
  • the intermediate body 29 of the foam hollow portion 2 and the lid portion 3 are joined.
  • the lid 3 was obtained by injection molding using polyethylene as a material.
  • the lid portion 3 is a non-foamed body unlike the foamed hollow portion 2 described later.
  • the lid portion 3 has a convex portion 31 protruding toward the intermediate body 29 at a position corresponding to the peripheral edge portion 21 of the hollow opening 20.
  • the convex portion 31 is arranged further outside in the radial direction than the outer edge 20p of the hollow opening 20, and is continuously formed along the outer edge 20p of the hollow opening 20.
  • an adhesive agent (not shown) is applied to the convex portions 31 of the lid portion 3, and the lid portion 3 is placed on one of the forming die (not shown) in the joining step. I went to
  • the intermediate body 29 of the foam hollow part 2 is formed by molding a foam, and has the same hollow opening 20 as the foam hollow part 2 as shown in FIG.
  • a sheet-shaped foamed polyethylene was used as the foamed material of the intermediate body 29.
  • the foamed polyethylene is foamed, unlike the material of the lid portion 3 which is a non-foamed body, because the foamed polyethylene is foamed with polyethylene as a base material.
  • the foam is placed in a vacuum forming mold (not shown) in a heated state, and the foam is shaped into a shape along the mold surface of the vacuum forming mold by drawing a vacuum in the vacuum forming mold to form a hollow foam.
  • Intermediate 29 of Part 2 was obtained.
  • the vacuum forming die was opened so that the intermediate body 29 remained in one die.
  • the portion of the intermediate body 29 facing the convex portion 31, that is, the peripheral portion of the hollow opening 20 of the intermediate body 29. 21 was adhered to the convex portion 31.
  • the integrated product of the intermediate body 29 and the lid portion 3 obtained in the joining step was taken out from the molding die and subjected to the following trimming step.
  • the trimming step the surplus portion 28 of the intermediate body 29 is cut out of the integrated product of the intermediate body 29 and the lid portion 3 obtained in the joining step. As shown in FIG. 3, a portion of the intermediate body 29, which is located on the outer side in the radial direction with respect to the portion joined to the lid portion 3, is an unnecessary portion of the hollow component 1. The part is the surplus part 28. In the trimming process, the surplus portion 28 is cut off to shape the integrated body of the intermediate body 29 and the lid portion 3.
  • the blade 80 of the cutter is applied to a position adjacent to the convex portion 31 on the outer side in the radial direction of the intermediate body 29, and the surplus portion 28 is cut off at the position. Since the convex portion 31 projects toward the intermediate body 29, a gap 15 is formed between the intermediate body 29 and the lid portion 3 at a position adjacent to the convex portion 31. Therefore, by cutting the surplus portion 28 at that position, it is possible to easily and accurately perform the trimming step of cutting only the intermediate 29 while suppressing cutting and damage of the lid 3.
  • the hollow component 1 of the example was obtained.
  • the foam hollow portion 2 in the hollow component 1 of the embodiment has a cut surface 19 at a position adjacent to the convex portion 31 on the outer side in the radial direction.
  • the lid portion has the sub-convex portion in addition to the convex portion, and the foam hollow portion has two buffer portions (first buffer portion, second buffer portion).
  • the hollow component is different from the hollow component manufacturing method and the hollow component of the first embodiment in that it has the following points, and the rest is substantially the same as the hollow component manufacturing method and the hollow component of the first embodiment.
  • FIG. 4 is an explanatory view schematically showing the manner of manufacturing the hollow component of Example 2.
  • the lid 3 has a sub-projection 33 on the outer side in the radial direction of the projection 31.
  • the convex portion 31 and the sub convex portion 33 have substantially the same shape, and the convex portion 31 and the sub convex portion 33 are arranged at intervals in the radial direction.
  • the intermediate body 29 has a first cushioning portion 22 and a second cushioning portion 23 inside the convex portion 31 in the radial direction.
  • the 1st buffer part 22 is provided in the substantially central part of the radial direction in the intermediate body 29, and has two concave curved parts 24a and one convex curved part 25a located between the two concave curved parts 24a.
  • Each concave curved portion 24a is a portion that is bent in a bow shape and is recessed in the opposite direction to the lid portion 3.
  • the convex curved portion 25a is a portion that is bent toward the lid 3 and that is bent toward the lid 3. Therefore, in the first buffer portion 22, the intermediate body 29 has a concavo-convex shape in which the portions that are curved in opposite directions are alternately continuous.
  • the second buffer portion 23 is provided at a position adjacent to the convex portion 31 inward in the radial direction.
  • the 2nd buffer part 23 has one convex curved part 25b.
  • the lid 3 has the sub-projection 33 in addition to the projection 31, as shown in FIG. 4, in the trimming step, the projection 31 and the sub-projection 33 are separated from each other. In between, the surplus portion 28 of the intermediate body 29 is cut off. At this time, the peripheral edge portion 21 of the hollow opening 20 in the intermediate body 29 is pressed against the lid portion 3 by the blade 80 of the cutter. However, since the peripheral edge portion 21 is supported by the convex portion 31 and the sub convex portion 33, the gap 15 between the intermediate body 29 and the lid portion 3 is sufficiently large between the convex portion 31 and the sub convex portion 33. And it is secured stably. Therefore, the surplus portion 28 is cut off easily and accurately.
  • the provision of the first buffer portion 22 in the intermediate body 29 suppresses the peeling of the intermediate body 29 from the lid 3. That is, the intermediate body 29 is made of foam, and is more likely to be thermally contracted than the lid portion 3 made of non-foam. For this reason, if the shaped intermediate body 29 is joined to the lid portion 3 before cooling, the shrinkage amount of the intermediate body 29 when cooled is much larger than the shrinkage amount of the lid portion 3. A difference may occur and the intermediate body 29 may peel off from the lid 3.
  • the contraction of the intermediate body 29 is absorbed by the expansion of the first cushioning portion 22 having the concave curved portion 24a and the convex curved portion 25a, and thus the lid portion 3 The peeling of the intermediate 29 from is suppressed.
  • the second cushioning portion 23 having the convex curved portion 25b is provided at a position adjacent to the convex portion 31 on the inner side in the radial direction, it acts on the joint portion of the lid portion 3 with the convex portion 31.
  • the acting force is alleviated by the deformation of the convex curved portion 25b.
  • the foam hollow portion 2 of the hollow component 1 may expand.
  • the convex curved portion 25b of the second cushioning portion 23 is deformed in the folding direction to impede the transmission of the force toward the convex portion 31. Therefore, the force acting on the adhesive (not shown) applied to the convex portion 31 is relaxed, and the peeling of the foam hollow portion 2 from the lid portion 3 is suppressed.
  • the flow passage cross-sectional area of the inner hollow 10 is sharply narrowed at a position adjacent to the convex portion 31 inward in the radial direction. This makes it difficult for the conditioned air 94 flowing through the inner hollow 10 to reach the convex portion 31, the amount of change in temperature of the convex portion 31 becomes small, and the deterioration of the adhesive applied to the convex portion 31 due to heat. Suppressed.
  • Example 3 In the hollow component manufacturing method and the hollow component according to the third embodiment, the shapes of the convex portion and the sub-convex portion, the first buffer portion is composed of two convex curved portions and one concave curved portion, and The method is substantially the same as the method for manufacturing the hollow part and the hollow part according to the second embodiment, except that the convex curved part in the second buffer part is largely raised.
  • FIG. 5 is an explanatory diagram that schematically shows how the hollow component of Example 3 is manufactured.
  • the tops of the convex portions 31 and the sub-convex portions 33 are flat, and the radial length of the convex portion 31 is the diameter of the sub-convex portion 33. Longer than direction length. Since the convex portion 31 has such a shape, a large area of the top portion of the convex portion 31, that is, a large bonding area between the intermediate body 29 and the lid portion 3 is ensured, and the intermediate body 29 and the lid portion 3 are made stronger. To join.
  • the hollow component manufacturing method according to the third embodiment is different from the hollow member according to the second embodiment in that the first cushioning portion 22 in the intermediate body 29 is composed of two convex curved portions 25a and one concave curved portion 24a. This is different from the method of manufacturing parts.
  • the first buffer portion 22 having the concave curved portion 24a and the convex curved portion 25a extends to form an intermediate body. Since the contraction of 29 is absorbed, peeling of the intermediate body 29 from the lid portion 3 is suppressed.
  • the convex curved portion 25b of the second buffer portion 23 is largely bulged toward the lid portion 3. Therefore, the flow passage cross-sectional area of the inner hollow 10 sharply narrows at a position adjacent to the convex portion 31 on the inner side in the radial direction.
  • the flow passage cross-sectional area of the portion adjacent to the convex portion 31 becomes smaller than that of the method for manufacturing the hollow component in the second embodiment, and The length of the narrow part also becomes longer.
  • the conditioned air 94 flowing through the inner hollow 10 is less likely to reach the convex portion 31, and the temperature change amount of the convex portion 31 is further reduced. As a result, deterioration of the adhesive applied to the convex portion 31 due to heat is further suppressed.
  • the convex curved portion 25a of the third embodiment has a gentle curved shape with a substantially arcuate cross section in the hollow interior 10 as shown in FIG. 5, but, for example, as shown in FIG. May be Also in this case, the contraction of the intermediate body 29 can be absorbed by the convex curved portion 25a. Further, by forming the bent convex curved portion 25a in the front-rear direction like the straightening rib 35, it is possible to impart a straightening function to the convex curved portion 25a.
  • Example 4 The hollow component manufacturing method and hollow component of Example 4 are different from those of Example 2 except that the convex portion and the sub-convex portion are provided in the intermediate body and the shape of the second buffer portion. It is almost the same as the hollow part.
  • FIG. 7 shows an explanatory view schematically showing the production of the hollow part of Example 4.
  • the convex portion 31 and the sub-convex portion 33 are provided on the intermediate body 29. Even in such a case, the gap 15 between the intermediate body 29 and the lid portion 3 is sufficiently and stably ensured between the convex portion 31 and the sub convex portion 33. Therefore, also in the method of manufacturing the hollow component according to the fourth embodiment, the surplus portion 28 is cut off easily and accurately.
  • the tops of the convex portions 31 and the sub-convex portions 33 are flat, and the radial length of the convex portions 31 is smaller than the radial length of the sub-convex portions 33. Is also long. Therefore, also in the method of manufacturing the hollow component according to the fourth embodiment, a large bonding area between the intermediate body 29 and the lid portion 3 is secured, and the intermediate body 29 and the lid portion 3 are more firmly joined.
  • the convex curved portion 25b of the second buffer portion 23 largely bulges toward the lid portion 3. .. Therefore, also in the hollow component manufacturing method and the hollow component of the fourth embodiment, the deterioration of the adhesive applied to the convex portion 31 due to heat is further suppressed.
  • Example 5 The method for manufacturing the hollow part and the hollow part according to the fifth embodiment are the same as the method for manufacturing the hollow part and the hollow part according to the third embodiment, except that the protrusion is provided on the intermediate body and the sub-projection is provided on the lid. Is almost the same as.
  • FIG. 8 is an explanatory diagram that schematically shows how the hollow component of Example 5 is manufactured.
  • the convex portion 31 is provided on the intermediate body 29, and the sub convex portion 33 is provided on the lid portion 3.
  • the convex portion 31 and the sub-convex portion 33 are arranged with a gap in the radial direction, and the sub-convex portion 33 is located outside the convex portion 31 in the radial direction.
  • the tops of the convex portions 31 and the sub convex portions 33 are flat, and the radial length of the convex portions 31 is longer than the radial length of the sub convex portions 33.
  • the surplus portion 28 can be easily and accurately cut off, similarly to the method of manufacturing the hollow component of the third embodiment.
  • the peeling of 29 is further suppressed.
  • peeling of the foam hollow portion 2 from the lid portion 3 is further suppressed.
  • Hollow part 2 Foamed hollow part 3: Lid part 19: Cut surface 20: Hollow opening (opening) 21: Peripheral part of hollow opening (opening) 22: First buffer part 23: Second buffer part 24a: Concave curve Part 25a, 25b: Convex curved part 28: Excess part 29: Intermediate body of foam hollow part 31: Convex part 33: Sub convex part 102: Foam hollow part 120: Opening 103: Lid part 122: Peripheral part 131 of opening: Convex

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Abstract

Provided is a novel method for manufacturing a hollow part. This method is used to manufacture a hollow part 1 having a box-shaped foamed hollow section 2 which is obtained by shaping a foamed body and which has an opening 20, and also having a cover section 3 comprising a non-foamed body and covering the opening 20 of the foamed hollow section 2. The method has: a joining step in which the opening 20 of an intermediate body 29 for the foamed hollow section 2 having the opening 20 is covered with the cover section 3, and the cover section 3 and the peripheral edge 21 of the opening 20 of the intermediate body 29 are joined; and a trimming step in which an excess section 28 located on the outside, in the radial direction of the opening 20, of the portion of the intermediate body 29, which is joined to the cover section 3, is cut off. The portion of the intermediate body 29 and/or the cover section 3, which is joined to the other, is formed as a protrusion section 31 protruding toward the other. In the trimming step, the excess section 28 is cut off at a position adjacent to the outside, in the radial direction, of the protrusion 31.

Description

中空部品の製造方法Manufacturing method of hollow parts
　本発明は、車両の空調用ダクトに代表される中空部品を製造する方法に関する。 The present invention relates to a method for manufacturing a hollow part represented by a vehicle air conditioning duct.
　中空部品の一種として、各々別体の２つの部材を接合し一体化したものがある。この種の接合一体型の中空部品のなかには、例えば車両の空調用ダクト等、断熱性を要求されるものがある。接合一体型の中空部品に断熱性を付与するためには、上記の２つの部材の少なくとも一方を、例えば不織布や織布、発泡体等の、内部に空気を保持し得る多孔体で構成するのが良いと考えられる。樹脂製の中空部品であれば、当該多孔体としては発泡体を用いるのが良いと考えられる。 As one type of hollow parts, there is one in which two separate members are joined and integrated. Among these joint-integrated hollow parts, there are some which are required to have heat insulating properties such as air-conditioning ducts for vehicles. In order to impart heat insulating properties to the joint-integrated hollow component, at least one of the above-mentioned two members is made of a porous body capable of retaining air therein, such as a nonwoven fabric, a woven fabric, or a foam. Is considered good. In the case of hollow parts made of resin, it is considered good to use foam as the porous body.
　特許文献１には、発泡体層と樹脂層とが積層されたポリオレフィン架橋発泡積層体からなる自動車用通気ダクトが紹介されている。当該特許文献１には、当該通気ダクトを製造する方法として、２枚のポリオレフィン架橋発泡積層体をそれぞれ真空成形した後で貼り合わせる方法、及び、２枚のポリオレフィン架橋発泡積層体を同時に加熱した後、金型内で圧空と真空により賦形する圧空真空成形法が例示されている。 Patent Document 1 introduces a ventilation duct for an automobile, which is composed of a polyolefin crosslinked foamed laminate in which a foam layer and a resin layer are laminated. In Patent Document 1, as a method for manufacturing the ventilation duct, two polyolefin crosslinked foamed laminates are vacuum-formed and then laminated together, and two polyolefin crosslinked foamed laminates are simultaneously heated. , A compressed air vacuum forming method in which a mold is formed by compressed air and vacuum.
特開２０１５－０３３８８１号公報JP, 2005-033881, A
　上記した特許文献１に紹介されている製造方法によると、断熱性が付与された中空部品を製造できると考えられる。しかし乍ら、当該製造方法において、２つの部材の一方が非発泡体からなる場合には、両者の剛性や収縮率が異なるために、形状や性能に優れる中空部品を効率良く製造するのは困難である。以下、必要に応じて、２つの部材のうち発泡体を賦形して得られた部材を発泡部材と称し、非発泡体からなる部材を非発泡部材と称する。 According to the manufacturing method introduced in Patent Document 1 described above, it is considered possible to manufacture a hollow part having heat insulating properties. However, in the manufacturing method, when one of the two members is made of a non-foamed body, it is difficult to efficiently manufacture a hollow component having excellent shape and performance because the rigidity and the shrinkage rate of the two members are different. Is. Hereinafter, of the two members, a member obtained by shaping a foam will be referred to as a foam member, and a member made of a non-foam member will be referred to as a non-foam member, as necessary.
　ところで、シート状や板状の発泡体を真空及び／又は圧空成形により賦形して、発泡部材を形成する場合、発泡体を賦形して得られた当該発泡部材の外縁部は不定形状となる。したがってこの場合には、中空部品の形状を整えるべく、当該発泡部材の外縁部をトリミングする工程が必要になる。上記した２つの部材のうち一方を発泡部材とし他方を非発泡部材とする場合には、発泡部材のみをトリミングする必要が生じる場合がある。例えば、非発泡部材が型成形される場合等には、当該非発泡部材をトリミングする工程自体が不要となる場合があるからである。 By the way, when a sheet-shaped or plate-shaped foam is shaped by vacuum and / or pressure forming to form a foamed member, the outer edge portion of the foamed member obtained by shaping the foam has an irregular shape. Become. Therefore, in this case, a step of trimming the outer edge portion of the foamed member is required to adjust the shape of the hollow component. When one of the two members is a foam member and the other is a non-foam member, it may be necessary to trim only the foam member. This is because, for example, when the non-foamed member is molded, the step itself of trimming the non-foamed member may be unnecessary.
　このような場合には、トリミング工程において、２つの部材のうち発泡部材の外縁部を、非発泡部材の形状に沿ってトリミングすれば良いと考えられる。しかし、このようなトリミング工程においては、非発泡部材を切断することなく発泡部材のみを切除する必要があるために、工程が非常に煩雑になる問題がある。
　このため、形状の整った中空部品を容易に製造し得る、中空部品の新規な製造方法が望まれている。 In such a case, it is considered that in the trimming step, the outer edge portion of the foamed member of the two members may be trimmed along the shape of the non-foamed member. However, in such a trimming process, since it is necessary to cut off only the foam member without cutting the non-foam member, there is a problem that the process becomes very complicated.
Therefore, a new method for manufacturing a hollow part is desired, which can easily manufacture a hollow part having a regular shape.
　本発明は、上記事情に鑑みてなされたものであり、中空部品の新規な製造方法を提供することを目的とする。 The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a new method for manufacturing a hollow part.
　上記課題を解決する本発明の中空部品の製造方法は、
　発泡体が賦形されてなり開口を有する箱状をなす発泡中空部と、非発泡体からなり前記発泡中空部の前記開口を覆う蓋部と、を有する中空部品を製造する方法であって、
　前記開口を有する前記発泡中空部の中間体の前記開口を、前記蓋部で覆い、前記中間体における前記開口の周縁部と前記蓋部とを接合させる接合工程と、
　前記中間体のうち、前記蓋部と接合する部分よりも前記開口の径方向の外側に位置する余剰部を切除するトリミング工程と、を有し、
　前記中間体と前記蓋部との少なくとも一方において、他方と接合する部分を、前記他方に向けて突起する凸部とし、
　前記トリミング工程において、前記凸部に対して前記径方向の外側に隣接する位置で、前記余剰部を切除する、製造方法である。 The method for manufacturing a hollow component of the present invention that solves the above problems,
A method for producing a hollow component having a box-shaped foam hollow portion having an opening formed by forming a foam, and a lid portion made of a non-foam material and covering the opening of the foam hollow portion,
A bonding step of covering the opening of the intermediate body of the foamed hollow portion having the opening with the lid portion and joining the peripheral edge portion of the opening and the lid portion in the intermediate body,
Of the intermediate body, a trimming step of cutting off a surplus portion located radially outside the opening with respect to a portion joined to the lid portion,
At least one of the intermediate body and the lid portion, a portion to be joined to the other, as a convex portion protruding toward the other,
In the trimming step, the surplus portion is removed at a position adjacent to the convex portion on the outer side in the radial direction.
　本発明の中空部品の製造方法によると、形状の整った中空部品を容易に製造し得る。 According to the hollow component manufacturing method of the present invention, it is possible to easily manufacture a hollow component having a regular shape.
実施例１の中空部品を車両に搭載した様子を模式的に表す説明図である。FIG. 3 is an explanatory view schematically showing how the hollow component of the first embodiment is mounted on a vehicle. 実施例１の中空部品を上下方向及び車幅方向に沿って切断した様子を模式的に表す説明図である。FIG. 3 is an explanatory view schematically showing a state in which the hollow component of Example 1 is cut along the vertical direction and the vehicle width direction. 実施例１の中空部品を製造している様子を模式的に表す説明図である。FIG. 5 is an explanatory view schematically showing a state where the hollow component of Example 1 is being manufactured. 実施例２の中空部品を製造している様子を模式的に表す説明図である。FIG. 5 is an explanatory view schematically showing a state where the hollow component of Example 2 is manufactured. 実施例３の中空部品を製造している様子を模式的に表す説明図である。FIG. 9 is an explanatory view schematically showing a state where the hollow component of Example 3 is being manufactured. 実施例３の中空部品における凸状湾曲部の他の例を説明する説明図である。It is explanatory drawing explaining the other example of the convex curved part in the hollow component of Example 3. 実施例４の中空部品を製造している様子を模式的に表す説明図である。FIG. 9 is an explanatory view schematically showing a state where the hollow component of Example 4 is being manufactured. 実施例５の中空部品を製造している様子を模式的に表す説明図である。FIG. 11 is an explanatory view schematically showing the production of the hollow component of Example 5. 本発明の中空部品の一態様を模式的に表す説明図である。It is explanatory drawing which represents typically the one aspect | mode of the hollow component of this invention. 本発明の中空部品の一態様を模式的に表す説明図である。It is explanatory drawing which represents typically the one aspect | mode of the hollow component of this invention.
　以下に、本発明を実施するための形態を説明する。なお、特に断らない限り、本明細書に記載された数値範囲「ａ～ｂ」は、下限ａ及び上限ｂをその範囲に含む。そして、これらの上限値及び下限値、ならびに実施例中に列記した数値も含めてそれらを任意に組み合わせることで数値範囲を構成し得る。さらに、これらの数値範囲内から任意に選択した数値を、新たな上限や下限の数値とすることができる。 A mode for carrying out the present invention will be described below. Unless otherwise specified, the numerical range “ab” described in the present specification includes the lower limit a and the upper limit b in the range. The upper limit value and the lower limit value, and the numerical values listed in the examples can be arbitrarily combined to form the numerical value range. Further, a numerical value arbitrarily selected from these numerical ranges can be set as a new upper and lower numerical value.
　本発明の中空部品の製造方法は、発泡中空部の中間体、及び、蓋部の２つの部材を接合させ、当該中間体の余剰部をトリミングすることで、発泡中空部と蓋部とが接合した中空部品を製造する方法である。当該２つの部材のうち、発泡中空部は上記した発泡部材に相当し、蓋部は上記した非発泡部材に相当する。本発明の中空部品の製造方法は、接合一体型の中空部品を製造する方法といい得る。 In the method for manufacturing a hollow component of the present invention, the foam hollow portion and the lid portion are joined by joining the two members of the foam hollow portion intermediate body and the lid portion and trimming the excess portion of the intermediate body. It is a method of manufacturing the hollow part. Of the two members, the foam hollow portion corresponds to the above-mentioned foam member, and the lid portion corresponds to the above non-foam member. The method for manufacturing a hollow part of the present invention can be called a method for manufacturing a hollow part integrally joined.
　蓋部は、発泡中空部の開口を覆うとともに、当該開口の周縁部に接合される。また、本発明の中空部品の製造方法においては、発泡中空部の中間体と、蓋部と、の少なくとも一方において、他方と接合する部分を、当該他方に向けて突起する凸部とする。トリミング工程で切除される余剰部は、中間体において当該凸部よりも開口の径方向の外側に位置する部分である。このため、本発明の中空部品の製造方法では、トリミング工程において、凸部に対して当該開口の径方向の外側に隣接する位置で、余剰部を切除すれば良い。 The lid covers the opening of the hollow foam part and is joined to the peripheral edge of the opening. Further, in the method for manufacturing a hollow component of the present invention, a portion of at least one of the intermediate body of the foam hollow portion and the lid portion, which is joined to the other, is a convex portion protruding toward the other. The surplus portion that is cut off in the trimming step is a portion of the intermediate body that is located outside the convex portion in the radial direction of the opening. Therefore, in the method for manufacturing a hollow component of the present invention, in the trimming step, the surplus portion may be cut off at a position adjacent to the convex portion on the outer side in the radial direction of the opening.
　凸部は、中間体又は蓋部の少なくとも一方に設けられ、他方に向けて突起するため、凸部においては、中間体と蓋部との距離は非常に近い。そして、凸部に隣接する位置においては、中間体と蓋部との距離は遠くなる。つまり、凸部に隣接する位置においては、中間体と蓋部との間に隙間が形成される。本発明の中空部品の製造方法においては、当該隙間の形成された部分で中間体の余剰部を切除するために、非発泡部材を切断することなく発泡部材のみを切除するトリミング工程を容易に行い得る。よって、本発明の中空部品の製造方法によると、形状の整った中空部品を容易に製造し得る。
　以下、必要に応じて、発泡中空部及びその中間体を総称して単に発泡中空部と称する場合がある。 Since the convex portion is provided on at least one of the intermediate body and the lid portion and projects toward the other, the distance between the intermediate body and the lid portion is very short in the convex portion. Then, at the position adjacent to the convex portion, the distance between the intermediate body and the lid portion becomes large. That is, at a position adjacent to the convex portion, a gap is formed between the intermediate body and the lid portion. In the method for manufacturing a hollow component of the present invention, in order to cut off the excess portion of the intermediate body at the portion where the gap is formed, the trimming step of cutting off only the foamed member without cutting the non-foamed member is easily performed. obtain. Therefore, according to the method for manufacturing a hollow component of the present invention, a hollow component having a regular shape can be easily manufactured.
Hereinafter, the foamed hollow portion and its intermediate may be collectively referred to simply as the foamed hollow portion, if necessary.
　発泡中空部は、発泡体が賦形されてなり開口を有する箱状をなす部材である。ここでいう賦形とは、材料を変形させて望みの形状とする成形方法を意味する。発泡体が賦形されてなる発泡中空部は、発泡体の性状を引き継ぐといえる。 The foam hollow part is a box-shaped member formed by molding a foam and having an opening. The shaping here means a molding method in which a material is deformed into a desired shape. It can be said that the foam hollow portion formed by shaping the foam body inherits the properties of the foam body.
　発泡体が賦形されてなることから、発泡中空部は多孔体である。したがって、本発明の中空部品の製造方法で製造された中空部品には、発泡中空部が多孔体であることに由来する断熱性や遮音性、消音性等が付与される。 Since the foam is shaped, the foam hollow part is a porous body. Therefore, the hollow component produced by the method for producing a hollow component of the present invention is provided with heat insulating properties, sound insulation properties, sound deadening properties, etc. due to the fact that the foam hollow portion is a porous body.
　発泡体は、発泡ポリエチレンや発泡ポリウレタン等の既知の発泡樹脂を材料とする発泡層を有すれば良い。発泡体は、当該発泡層以外にも、表皮層等の非孔質の層を有しても良い。つまり、発泡中空部は１層構造であっても良いし、多層構造であっても良い。発泡体が賦形されてなる発泡中空部は、開口を有する箱状をなす。ここでいう箱状とは、断面Ｕ字状であることを意味する。 The foam may have a foam layer made of a known foam resin such as polyethylene foam or polyurethane foam. The foam may have a non-porous layer such as a skin layer in addition to the foam layer. That is, the foam hollow portion may have a single-layer structure or a multi-layer structure. The foam hollow portion formed by shaping the foam has a box shape having an opening. The box shape here means that it has a U-shaped cross section.
　図９に示すように、発泡中空部１０２は四面が立壁で塞がれた箱状をなしても良いし、図１０に示すように、発泡中空部１０２は対向する二面が開かれた箱状、つまり、軸方向Ｌに対して直交する方向に沿って切断された切り欠き筒状をなしても良い。
　何れの場合にも、箱状をなす発泡中空部１０２の開口１２０は、蓋部１０３で覆われる。そして、発泡中空部１０２における開口１２０の周縁部１２１と、蓋部１０３のうち当該周縁部１２１に対面する部分との少なくとも一方には、他方に向けて突起する凸部１３１が設けられる。凸部１３１は、開口１２０の周縁部１２１、すなわち、開口１２０の径方向の外側に設けられるともいい得る。
　発泡体を賦形して中間体とする方法としては、真空成形、真空成形と圧空成形との組み合わせ等、既知の方法を用いれば良い。発泡体としてはシート状、板状等の形状の物を用いれば良い。
　以下、当該発泡中空部の開口を中空開口と称し、他の開口と区別する。 As shown in FIG. 9, the foam hollow part 102 may have a box shape in which four surfaces are closed by standing walls, or, as shown in FIG. 10, the foam hollow part 102 has a box in which two opposite surfaces are opened. In other words, the shape may be a cut-out tubular shape that is cut along a direction orthogonal to the axial direction L.
In any case, the opening 120 of the foam hollow part 102 having a box shape is covered with the lid part 103. Then, at least one of the peripheral edge portion 121 of the opening 120 in the foam hollow portion 102 and the portion of the lid portion 103 facing the peripheral edge portion 121 is provided with a convex portion 131 projecting toward the other. It can be said that the protrusion 131 is provided on the peripheral portion 121 of the opening 120, that is, on the outer side in the radial direction of the opening 120.
As a method of shaping the foamed body into an intermediate, a known method such as vacuum forming or a combination of vacuum forming and pressure forming may be used. As the foam, a sheet-shaped, plate-shaped or the like may be used.
Hereinafter, the opening of the foam hollow portion is referred to as a hollow opening, and is distinguished from other openings.
　蓋部は、非発泡体からなれば良く、蓋部自体は１つ又は複数の開口を有しても良い。本発明の中空部品の製造方法において、発泡中空部と蓋部との接合方法は特に限定されないため、蓋部の材料についても又特に限定されない。例えば、蓋部は金属や金属酸化物等を材料としても良い。本発明の中空部品の製造方法で製造される中空部品が、車両に搭載される空調用ダクト等、軽量であることが要求される部材である場合には、蓋部の材料として樹脂材料を選択するのが好ましい。 The lid part may be made of non-foamed material, and the lid part itself may have one or a plurality of openings. In the method for manufacturing a hollow component of the present invention, the method for joining the foam hollow portion and the lid is not particularly limited, and therefore the material for the lid is not particularly limited either. For example, the lid may be made of metal or metal oxide. When the hollow component manufactured by the method for manufacturing a hollow component of the present invention is a member that is required to be lightweight, such as an air conditioning duct mounted on a vehicle, a resin material is selected as the material of the lid portion. Preferably.
　蓋部は、非発泡体からなるため、発泡体からなる発泡中空部よりも剛性の高い部分といい得る。つまり、蓋部は、中空部品全体としての剛性の確保に寄与し得る。このような蓋部には、中空部品を他部材に取り付けるための取付部分としての機能を付与しても良いし、或いは、蓋部を当該他部材の一部と併用しても良い。 Since the lid part is made of non-foamed material, it can be said that it has higher rigidity than the foamed hollow part made of foamed material. That is, the lid portion can contribute to ensuring the rigidity of the hollow component as a whole. Such a lid may be provided with a function as an attachment portion for attaching the hollow component to another member, or the lid may be used in combination with a part of the other member.
　蓋部は中空開口を覆い得る形状であれば良い。蓋部は単なる平板状をなしても良いが、発泡中空部のように箱状をなしても良い。蓋部が平板状をなす場合、中空部品の内部中空は、主として発泡中空部における箱の内部で構成される。また、蓋部が箱状をなす場合には、中空部品の内部中空は、発泡中空部における箱の内部と蓋部における箱の内部とで構成される。この場合、発泡中空部における箱の内部と、蓋部における箱の内部とは、中空開口を通じて連絡する。
　蓋部は非発泡体からなるため、射出成形、押出成形、プレス成形等に代表される各種の成形法によって成形する際に、その形状を付与すれば良い。 The lid may have any shape as long as it can cover the hollow opening. The lid portion may have a simple flat plate shape, but may have a box shape like a foam hollow portion. When the lid has a flat plate shape, the hollow inside of the hollow component is mainly formed inside the box in the foam hollow. When the lid has a box shape, the hollow inside of the hollow component includes the inside of the box in the foam hollow portion and the inside of the box in the lid. In this case, the inside of the box in the foam hollow portion and the inside of the box in the lid portion communicate with each other through the hollow opening.
Since the lid portion is made of a non-foamed material, its shape may be given when it is molded by various molding methods typified by injection molding, extrusion molding, press molding and the like.
　なお、発泡中空部と蓋部との接合方法としては、溶着、接着等の方法が挙げられる。ここでいう接着は、不可逆的な接着（すなわち固着）と、可逆的な接着（すなわち粘着）と、の両方を含み得る。
　発泡中空部と蓋部との接合状態は、本発明の中空部品の製造方法で製造される中空部品の用途や、当該中空部品に要求される性能に応じて適宜設定すれば良い。例えば、発泡中空部と蓋部とは、気密に接合されても良いし、隙間のあるように接合されても良い。 As a method of joining the foam hollow portion and the lid portion, a method such as welding or adhesion may be used. Adhesion as used herein may include both irreversible adhesion (ie, sticking) and reversible adhesion (ie, sticking).
The joined state of the foam hollow portion and the lid portion may be appropriately set depending on the application of the hollow component manufactured by the method for manufacturing a hollow component of the present invention and the performance required for the hollow component. For example, the hollow foam portion and the lid portion may be airtightly joined together or may be joined together with a gap.
　ところで、本発明の中空部品の製造方法では、中間体と蓋部との少なくとも一方において、他方と接合する部分を、当該他方に向けて突起する凸部とする。中間体と蓋部とを中空開口の周縁部で接合する都合上、凸部は、中空開口の周縁部に相当する位置に設けられ、かつ、中空開口の外縁に沿って設けられる。当該凸部の形状や数は、中空部品に要求される発泡中空部と蓋部との接合状態に応じて、適宜設ければ良い。 By the way, in the method for manufacturing a hollow component of the present invention, a portion of at least one of the intermediate body and the lid portion that is joined to the other is a convex portion that projects toward the other. For the convenience of joining the intermediate body and the lid at the peripheral edge of the hollow opening, the convex portion is provided at a position corresponding to the peripheral edge of the hollow opening and along the outer edge of the hollow opening. The shape and the number of the convex portions may be appropriately provided depending on the joining state of the foam hollow portion and the lid portion required for the hollow component.
　凸部は、中間体に設けても良いし、蓋部に設けても良いし、中間体と蓋部との両方に設けても良い。中間体は発泡体が賦形されてなるため、その剛性は蓋部よりも低い傾向にある。このため、トリミング工程において凸部の形状を良好に維持することを考慮すると、凸部は蓋部に設けるのが好ましいといえる。 The convex portion may be provided on the intermediate body, the lid portion, or both the intermediate body and the lid portion. Since the intermediate body is formed of a foam, its rigidity tends to be lower than that of the lid portion. Therefore, considering that the shape of the convex portion is favorably maintained in the trimming step, it can be said that the convex portion is preferably provided on the lid portion.
　なお、凸部の高さは１～３０ｍｍの範囲内であるのが好ましく、１～２０ｍｍの範囲内であるのがより好ましく、２～１０ｍｍの範囲内であるのが特に好ましい。トリミング工程における余剰部の切除位置と、凸部の距離は、２～５０ｍｍの範囲内であるのが好ましく、３～３０ｍｍの範囲内であるのがより好ましく、５～１０ｍｍの範囲内であるのが特に好ましい。 Note that the height of the convex portion is preferably in the range of 1 to 30 mm, more preferably in the range of 1 to 20 mm, and particularly preferably in the range of 2 to 10 mm. The distance between the excision position of the surplus portion and the convex portion in the trimming step is preferably in the range of 2 to 50 mm, more preferably in the range of 3 to 30 mm, and in the range of 5 to 10 mm. Is particularly preferable.
　また、凸部は中空開口の外縁の全周にわたって連続的に設けても良いし、断続的に設けても良い。
　例えば、発泡中空部と蓋部とを気密に接合する必要があれば、凸部は、中空開口の外縁の全周にわたって連続的に設けるのが良い。こうすることで、中空開口の周縁部の全周にわたって、中間体と蓋部とを気密に接合することができる。
　また、例えば、発泡中空部と蓋部とを、隙間のあるように接合する場合には、凸部は、中空開口の外縁に沿って断続的に設けても良い。 Further, the convex portion may be provided continuously over the entire circumference of the outer edge of the hollow opening, or may be provided intermittently.
For example, if it is necessary to join the foam hollow portion and the lid portion in an airtight manner, the convex portion may be continuously provided over the entire circumference of the outer edge of the hollow opening. By doing so, the intermediate body and the lid portion can be airtightly joined over the entire circumference of the peripheral portion of the hollow opening.
Further, for example, when the foam hollow portion and the lid portion are joined together with a gap, the convex portion may be provided intermittently along the outer edge of the hollow opening.
　何れの場合にも、凸部を設けることで、中間体と蓋部との間に隙間が形成されるため、トリミング工程が容易になる利点がある。なお、凸部を断続的に設ける場合、隣り合う凸部のピッチが過大であると、上記した中間体と蓋部との間の隙間が小さくなる可能性がある。このことを考慮すると、凸部を断続的に設ける場合に隣り合う凸部のピッチは、ある程度小さい方が好ましいといえる。具体的には、当該ピッチの好ましい範囲として、２０ｍｍ以下、１５ｍｍ以下、１０ｍｍ以下、５ｍｍ以下の各範囲が挙げられる。なお、ここでいう隣り合う凸部のピッチとは、隣り合う凸部同士の隙間の大きさを意味する。 In any case, by providing the convex portion, a gap is formed between the intermediate body and the lid portion, which has an advantage of facilitating the trimming process. When the convex portions are provided intermittently, if the pitch between the adjacent convex portions is excessively large, the gap between the intermediate body and the lid portion may become small. Considering this, it can be said that when the convex portions are intermittently provided, the pitch between the adjacent convex portions is preferably small to some extent. Specifically, the preferable ranges of the pitch include 20 mm or less, 15 mm or less, 10 mm or less, and 5 mm or less. The pitch of the adjacent convex portions here means the size of the gap between the adjacent convex portions.
　トリミング工程は、既知の切断装置を用いて自動的に行っても良いし、作業者が手動で行っても良い。 The trimming process may be performed automatically using a known cutting device, or manually by an operator.
　凸部は、中空開口の径方向に間隔をおいて２つ以上設けても良い。複数の凸部において中間体と蓋部とを接合することで、中間体と蓋部とを安定して一体化できる利点がある。
　以下、必要に応じて、中空開口の径方向を、単に径方向と略する場合がある。 Two or more convex portions may be provided at intervals in the radial direction of the hollow opening. By joining the intermediate body and the lid portion at the plurality of convex portions, there is an advantage that the intermediate body and the lid portion can be stably integrated.
Hereinafter, the radial direction of the hollow opening may be simply abbreviated as the radial direction, if necessary.
　凸部と同様の突起を、凸部の径方向外側に更に設けても良い。当該突起を副凸部と称する。副凸部は、凸部と同様に、中間体と蓋部との一方から他方に向けて突起するものであり、中間体と蓋部とのうち凸部と同じ部材に設けられても良いし、凸部と異なる部材に設けられても良い。つまり、例えば中間体に凸部を設ける場合、副凸部は中間体に設けても良いし蓋部に設けても良い。 The same protrusion as the protrusion may be further provided on the outside in the radial direction of the protrusion. The protrusion is called a sub-projection. Similar to the convex portion, the sub-convex portion protrudes from one of the intermediate body and the lid portion toward the other, and may be provided on the same member as the convex portion of the intermediate body and the lid portion. It may be provided on a member different from the convex portion. That is, for example, when the convex portion is provided on the intermediate body, the auxiliary convex portion may be provided on the intermediate body or the lid portion.
　この場合、トリミング工程では、凸部と副凸部との間で、中間体の余剰部を切除する。凸部及び副凸部は２つのスペーサとして機能するため、凸部と副凸部との間において、中間体と蓋部との間の隙間は充分にかつ安定して確保される。このため、当該凸部と副凸部との間を切除位置として余剰部を切除することで、トリミング工程が更に容易になる利点がある。 In this case, in the trimming process, the surplus portion of the intermediate body is cut off between the convex portion and the sub-convex portion. Since the convex portion and the sub convex portion function as two spacers, the gap between the intermediate body and the lid portion is sufficiently and stably ensured between the convex portion and the sub convex portion. Therefore, there is an advantage that the trimming process is further facilitated by cutting the surplus portion with the cutting position between the convex portion and the sub convex portion as the cutting position.
　凸部と副凸部とは、同じ形状であっても良いし、異なった形状であっても良い。但し、凸部は相手材との接合強度に関与する部分であるために、大きな接合強度を確保するためには、凸部は副凸部よりも大きいのが好ましい。具体的には、凸部の径方向の長さを、副凸部の径方向の長さよりも長くするのが好ましい。更に、相手材との接合強度を考慮すると、凸部の頂部は平面状をなすのが好ましい。 The convex portion and the sub-convex portion may have the same shape or different shapes. However, since the convex portion is a portion related to the bonding strength with the mating material, it is preferable that the convex portion is larger than the sub-convex portion in order to secure a large bonding strength. Specifically, it is preferable to make the radial length of the convex portion longer than the radial length of the sub-convex portion. Further, in consideration of the bonding strength with the mating material, it is preferable that the tops of the projections are flat.
　ところで、蓋部は非発泡体からなるのに対し、発泡中空部は既述したように発泡体を賦形して得られたものである。このため、発泡中空部は蓋部に比べて剛性が低く、変形し易い傾向にある。このため、中空部品の製造時や使用時に、発泡中空部が変形し易い環境下におかれると、発泡中空部のみが変形して、接合していた蓋部と剥離する可能性がある。 By the way, the lid part is made of non-foamed material, while the foamed hollow part is obtained by shaping the foamed material as described above. Therefore, the foam hollow portion has lower rigidity than the lid portion and tends to be deformed. For this reason, when the hollow part is manufactured or used, if it is placed in an environment where the foam hollow part is easily deformed, only the foam hollow part may be deformed and separated from the joined lid part.
　具体的には、中空部品を空調用ダクトとして用いる場合には、暖房時等に中空部品が膨張して、発泡中空部が蓋部から剥離する可能性がある。
　また、賦形後の中間体を冷却前に蓋部と接合させる場合等には、両者の収縮率の差により、中間体が大きく変形して蓋部から剥離する可能性がある。
　このような蓋部と発泡中空部との剥離を抑制するためには、発泡中空部の変形を抑制するのが有効と考えられる。 Specifically, when the hollow component is used as an air conditioning duct, the hollow component may expand during heating or the like, and the foamed hollow portion may peel off from the lid portion.
Further, when the shaped intermediate body is joined to the lid portion before cooling, the intermediate body may be largely deformed and peeled off from the lid portion due to the difference in shrinkage rate between the two.
In order to suppress such separation between the lid portion and the foam hollow portion, it is considered effective to suppress the deformation of the foam hollow portion.
　当該発泡中空部の変形を抑制するためには、中間体に、当該変形を和らげ得る緩衝部を設けるのが良い。緩衝部は、蓋部に向けて隆起するか、又は、蓋部とは逆側に向けて陥没する湾曲部で構成するのが有効と考えられる。蓋部に向けて隆起する湾曲部を凸状湾曲部と称し、蓋部とは逆側に向けて陥没する湾曲部を凹状湾曲部と称する。
　凸状湾曲部及び凹状湾曲部は、湾曲、すなわち、弓なりに曲がった部分であるため、変形し易い部分といえる。中間体における湾曲部は、中間体の他の部分に優先して変形するともいえる。また、湾曲部を有する中間体は、見掛けの外形よりも膜長が長いともいえる。このような湾曲部を有する緩衝部を中間体に設けることで、中間体における当該緩衝部以外の部分の変形を抑制または吸収でき、上記した剥離等を抑制できる利点がある。 In order to suppress the deformation of the foam hollow portion, it is preferable to provide the intermediate body with a buffer portion that can reduce the deformation. It is considered effective that the cushioning portion is configured by a curved portion that is raised toward the lid portion or is depressed toward the side opposite to the lid portion. The curved portion protruding toward the lid portion is referred to as a convex curved portion, and the curved portion depressed toward the opposite side of the lid portion is referred to as a concave curved portion.
Since the convex curved portion and the concave curved portion are curved portions, that is, curved portions in a bow shape, they can be said to be easily deformed portions. It can be said that the curved portion of the intermediate body is deformed in preference to the other portions of the intermediate body. It can also be said that the intermediate body having the curved portion has a longer film length than the apparent outer shape. By providing the intermediate body with the buffer portion having such a curved portion, it is possible to suppress or absorb the deformation of the portion other than the buffer portion in the intermediate body, and it is possible to suppress the above-described peeling and the like.
　緩衝部の位置は、凸部の径方向の内側であれば良いが、凸部に作用する力を効率良く吸収又は緩和する目的であれば、緩衝部は凸部の近傍に設けるのが好ましく、凸部に対して径方向の内側に隣接する位置に設けるのがより好ましい。この場合の凸部と緩衝部との距離の好ましい範囲として、５０ｍｍ以内、３０ｍｍ以内、１５ｍｍ以内の各範囲が挙げられる。なお、当該凸部と緩衝部との距離とは、具体的には、緩衝部において凸部の最も近くにある湾曲部の頂部と、凸部の頂部との距離を意味する。当該凸部と緩衝部との距離は、０ｍｍを超えれば良い。
　この場合の緩衝部が有する湾曲部の数は問わないが、当該緩衝部は凸状湾曲部を有するのがより好ましく、当該凸状湾曲部が凸部に対して径方向の内側に隣接するのが特に好ましい。 The position of the buffer portion may be inside the radial direction of the convex portion, but for the purpose of efficiently absorbing or relaxing the force acting on the convex portion, the buffer portion is preferably provided in the vicinity of the convex portion, It is more preferable to provide it at a position adjacent to the convex portion on the inner side in the radial direction. In this case, the preferable range of the distance between the convex portion and the buffer portion is within 50 mm, within 30 mm, and within 15 mm. Note that the distance between the convex portion and the buffer portion specifically means the distance between the top of the curved portion that is closest to the convex portion in the buffer portion and the top of the convex portion. The distance between the convex portion and the buffer portion may exceed 0 mm.
In this case, the number of curved portions that the cushioning portion has is not limited, but it is more preferable that the cushioning portion has a convex curved portion, and the convex curved portion is adjacent to the convex portion inward in the radial direction. Is particularly preferable.
　また、中間体全体の変形を抑制又は吸収する目的であれば、緩衝部は複数の湾曲部で構成されるのが好ましい。当該複数の湾曲部は、少なくとも１つの凸状湾曲部と、少なくとも１つの凹状湾曲部とを含むのが好ましく、複数の凸状湾曲部と複数の凹状湾曲部とを含むのがより好ましい。 Further, for the purpose of suppressing or absorbing the deformation of the entire intermediate body, it is preferable that the cushioning portion is composed of a plurality of curved portions. The plurality of curved portions preferably include at least one convex curved portion and at least one concave curved portion, and more preferably include a plurality of convex curved portions and a plurality of concave curved portions.
　なお、凸部は、中間体と蓋部との少なくとも一方において他方に向けて突起する部分であるため、湾曲部と同様の湾曲形状をなしても良い。しかし凸部には、湾曲部とは異なり、変形する機能は要求されないため、凸部は、湾曲形状でなく単に表面の一部が他の部分よりも出た突起状であっても良い。 Note that the convex portion is a portion that projects toward the other in at least one of the intermediate body and the lid portion, and thus may have the same curved shape as the curved portion. However, unlike the curved portion, the convex portion is not required to have the function of deforming. Therefore, the convex portion may have a protrusion shape in which a part of the surface is more protruded than the other portion, instead of the curved shape.
　以下、具体例を挙げて本発明の中空部品の製造方法を説明する。 The method for manufacturing the hollow component of the present invention will be described below with reference to specific examples.
　（実施例１）
　実施例１の中空部品の製造方法は、中空部品の一種である車両の空調用ダクトを製造する方法である。したがって、実施例１の中空部品は車両の空調用ダクトである。
　図１は実施例１の中空部品を車両に搭載した様子を模式的に表す説明図である。図２は実施例１の中空部品を上下方向及び車幅方向に沿って切断した様子を模式的に表す説明図である。図３は実施例１の中空部品を製造している様子を模式的に表す説明図である。以下の実施例において、運転席側、助手席側とは、図１及び図２に示す運転席側、助手席側を意味する。前、後とは図１に示す前、後を意味し、上、下とは図２に示す上、下を意味する。なお、運転席側－助手席側方向は、車両の車幅方向と読み替えることができ、前は車両進行方向の先側、後は車両進行方向の後側、と読み替えることができる。 (Example 1)
The method for manufacturing a hollow component according to the first embodiment is a method for manufacturing an air conditioning duct for a vehicle, which is a type of hollow component. Therefore, the hollow component of the first embodiment is a vehicle air conditioning duct.
FIG. 1 is an explanatory view schematically showing how the hollow component of the first embodiment is mounted on a vehicle. FIG. 2 is an explanatory diagram schematically showing a state in which the hollow component of the first embodiment is cut along the vertical direction and the vehicle width direction. FIG. 3 is an explanatory view schematically showing how the hollow component of Example 1 is manufactured. In the following examples, the driver seat side and the passenger seat side mean the driver seat side and the passenger seat side shown in FIGS. 1 and 2. The front and the rear mean the front and the rear shown in FIG. 1, and the upper and the lower mean the upper and the lower shown in FIG. The driver's seat side-passenger seat side direction can be read as the vehicle width direction, and the front can be read as the front side of the vehicle traveling direction and the rear as the rear side of the vehicle traveling direction.
　実施例１の中空部品１は、図１に示されるように車両室内に配設された車両のセンターコンソールボックス９０に一体に配設され、シート９１に着座した乗員９２の太腿９３に向けて空調空気９４を吹き出すための空調用ダクトである。図１に示すように、中空部品１は、略前後方向に延びる略筒状をなす。中空部品１の後部分は、センターコンソールボックス９０の内部に配置されている。中空部品１の前部分は、センターコンソールボックス９０の前方に位置する車両用空調装置（図略）に接続されている。中空部品１は、車両用空調装置が車両室内９５に供給する空調空気９４の流通経路となる。 As shown in FIG. 1, the hollow component 1 according to the first embodiment is integrally disposed in a vehicle center console box 90 disposed in a vehicle compartment, and is directed toward a thigh 93 of an occupant 92 seated on a seat 91. It is an air conditioning duct for blowing out the conditioned air 94. As shown in FIG. 1, the hollow component 1 has a substantially tubular shape extending in the substantially front-back direction. The rear part of the hollow component 1 is arranged inside the center console box 90. The front portion of the hollow component 1 is connected to a vehicle air conditioner (not shown) located in front of the center console box 90. The hollow component 1 serves as a distribution path of the conditioned air 94 supplied to the vehicle compartment 95 by the vehicle air conditioner.
　図２に示すように、中空部品１は、発泡中空部２と蓋部３とで構成されている。中空部品１は、センターコンソールボックス９０におけるコンソールリッド９６の下方かつサイドパネル９７の内方に配置されている。中空部品１の発泡中空部２は、運転席側に開口する断面略Ｕ字状をなす。当該発泡中空部２の開口は上記した中空開口２０である。発泡中空部２における中空開口２０の周縁部２１は、中空開口２０と略面一となるよう略平面状に延びる。 As shown in FIG. 2, the hollow component 1 is composed of a foam hollow portion 2 and a lid portion 3. The hollow component 1 is arranged below the console lid 96 in the center console box 90 and inside the side panel 97. The foam hollow portion 2 of the hollow component 1 has a substantially U-shaped cross section that opens toward the driver's seat. The opening of the foam hollow portion 2 is the hollow opening 20 described above. A peripheral edge portion 21 of the hollow opening 20 in the foam hollow portion 2 extends in a substantially flat shape so as to be substantially flush with the hollow opening 20.
　発泡中空部２の中空開口２０は蓋部３で覆われている。
　蓋部３は、略板状をなし、中空開口２０を運転席側から覆う。蓋部３における後部分には窓状の吹出開口３０が設けられ、蓋部３における中空開口２０側の面には、吹出開口３０よりも下側において中空開口２０の内部に向けて突起する整流リブ３５が設けられている。当該吹出開口３０は、中空部品１とは別体の吹出部材６で覆われている。当該吹出部材６は多数の開口を有する格子状をなす。中空部品１の内部中空１０は、既述した空調空気９４の流通経路となる。当該内部中空１０を流通する空調空気９４は、前後方向に延びる整流リブ３５によって整流され、中空開口２０及び吹出開口３０を通過し、更に格子状の吹出部材６を経て車両室内９５に流出する。 The hollow opening 20 of the foam hollow portion 2 is covered with the lid portion 3.
The lid portion 3 has a substantially plate shape and covers the hollow opening 20 from the driver's seat side. A window-shaped blowout opening 30 is provided in the rear portion of the lid portion 3, and the surface of the lid portion 3 on the side of the hollow opening 20 protrudes toward the inside of the hollow opening 20 below the blowout opening 30. Ribs 35 are provided. The blowout opening 30 is covered with a blowout member 6 that is separate from the hollow component 1. The blowing member 6 has a lattice shape having a large number of openings. The inner hollow 10 of the hollow component 1 serves as the flow path of the conditioned air 94 described above. The conditioned air 94 flowing through the inner hollow 10 is straightened by the straightening ribs 35 extending in the front-rear direction, passes through the hollow openings 20 and the blowout openings 30, and further flows out into the vehicle compartment 95 through the lattice-shaped blowout members 6.
　実施例１の中空部品１の製造方法を以下に説明する。 The method for manufacturing the hollow component 1 of Example 1 will be described below.
　（接合工程）
　接合工程では図３に示すように、発泡中空部２の中間体２９と蓋部３とを接合させる。
　実施例１の中空部品１の製造方法においては、ポリエチレンを材料として射出成形することで蓋部３を得た。当該蓋部３は、後述する発泡中空部２とは異なり、非発泡体である。
　蓋部３は、図３に示すように、中空開口２０の周縁部２１に相当する位置に、中間体２９に向けて突起する凸部３１を有する。凸部３１は、中空開口２０の外縁２０ｐよりも更に径方向の外側に配置され、中空開口２０の外縁２０ｐに沿って連続的に形成されている。実施例１の中空部品１の製造方法では、蓋部３の凸部３１に図略の接着剤を塗布し、当該蓋部３を図略の成形型の一方に載置した状態で、接合工程に供した。 (Joining process)
In the joining step, as shown in FIG. 3, the intermediate body 29 of the foam hollow portion 2 and the lid portion 3 are joined.
In the method of manufacturing the hollow component 1 of Example 1, the lid 3 was obtained by injection molding using polyethylene as a material. The lid portion 3 is a non-foamed body unlike the foamed hollow portion 2 described later.
As shown in FIG. 3, the lid portion 3 has a convex portion 31 protruding toward the intermediate body 29 at a position corresponding to the peripheral edge portion 21 of the hollow opening 20. The convex portion 31 is arranged further outside in the radial direction than the outer edge 20p of the hollow opening 20, and is continuously formed along the outer edge 20p of the hollow opening 20. In the method for manufacturing the hollow component 1 according to the first embodiment, an adhesive agent (not shown) is applied to the convex portions 31 of the lid portion 3, and the lid portion 3 is placed on one of the forming die (not shown) in the joining step. I went to
　発泡中空部２の中間体２９は、発泡体が賦形されてなるものであり、図３に示すように、発泡中空部２と同じ中空開口２０を有する。中間体２９の材料である発泡体としては、シート状の発泡ポリエチレンを用いた。参考までに、当該発泡ポリエチレンは、基材であるポリエチレンを発泡剤により発泡させたものであるため、非発泡体である蓋部３の材料とは異なり、発泡体である。 The intermediate body 29 of the foam hollow part 2 is formed by molding a foam, and has the same hollow opening 20 as the foam hollow part 2 as shown in FIG. A sheet-shaped foamed polyethylene was used as the foamed material of the intermediate body 29. For reference, the foamed polyethylene is foamed, unlike the material of the lid portion 3 which is a non-foamed body, because the foamed polyethylene is foamed with polyethylene as a base material.
　発泡体を加熱状態で図略の真空成形型に配置し、当該真空成形型内で真空引きすることにより、発泡体を当該真空成形型の型面に沿った形状に賦形して、発泡中空部２の中間体２９を得た。賦形後、中間体２９が一方の型に残るように、真空成形型を型開きした。中間体２９が残った方の型と、上記の蓋部３が載置された型とを組み合わせて新たな成形型とし、当該成形型を型締めすることで、中間体２９と蓋部３とを位置決めし、密着させた。既述したように、蓋部３の凸部３１には接着剤が塗布されているため、中間体２９のうち凸部３１に対面する部分、すなわち、中間体２９のうち中空開口２０の周縁部２１は凸部３１に接着された。
　接合工程で得られた中間体２９と蓋部３との一体品を、成形型から取り出して、以下のトリミング工程に供した。 The foam is placed in a vacuum forming mold (not shown) in a heated state, and the foam is shaped into a shape along the mold surface of the vacuum forming mold by drawing a vacuum in the vacuum forming mold to form a hollow foam. Intermediate 29 of Part 2 was obtained. After the shaping, the vacuum forming die was opened so that the intermediate body 29 remained in one die. By combining the mold on which the intermediate body 29 remains and the mold on which the lid portion 3 is placed to form a new molding die, and clamping the molding die, the intermediate body 29 and the lid portion 3 are separated. Was positioned and brought into close contact. As described above, since the convex portion 31 of the lid 3 is coated with the adhesive, the portion of the intermediate body 29 facing the convex portion 31, that is, the peripheral portion of the hollow opening 20 of the intermediate body 29. 21 was adhered to the convex portion 31.
The integrated product of the intermediate body 29 and the lid portion 3 obtained in the joining step was taken out from the molding die and subjected to the following trimming step.
　（トリミング工程）
　トリミング工程では、接合工程で得られた中間体２９と蓋部３との一体品のうち、中間体２９の余剰部２８を切除する。
　図３に示すように、中間体２９のうち蓋部３と接合する部分よりも径方向の外側に位置する部分は、中空部品１に不要な部分である。当該部分が余剰部２８である。トリミング工程では、当該余剰部２８を切除することで、中間体２９と蓋部３との一体品を整形する。 (Trimming process)
In the trimming step, the surplus portion 28 of the intermediate body 29 is cut out of the integrated product of the intermediate body 29 and the lid portion 3 obtained in the joining step.
As shown in FIG. 3, a portion of the intermediate body 29, which is located on the outer side in the radial direction with respect to the portion joined to the lid portion 3, is an unnecessary portion of the hollow component 1. The part is the surplus part 28. In the trimming process, the surplus portion 28 is cut off to shape the integrated body of the intermediate body 29 and the lid portion 3.
　具体的には、中間体２９のうち凸部３１に対して径方向の外側に隣接する位置に、カッターの刃８０をあてがい、当該位置で余剰部２８を切除する。凸部３１は中間体２９に向けて突起しているため、凸部３１に隣接する位置においては、中間体２９と蓋部３との間には隙間１５が形成されている。このため、当該位置で余剰部２８を切除することで、蓋部３の切断及び損傷を抑制しつつ、中間体２９のみを切除するトリミング工程を、容易にかつ精度高く行うことが可能である。 Specifically, the blade 80 of the cutter is applied to a position adjacent to the convex portion 31 on the outer side in the radial direction of the intermediate body 29, and the surplus portion 28 is cut off at the position. Since the convex portion 31 projects toward the intermediate body 29, a gap 15 is formed between the intermediate body 29 and the lid portion 3 at a position adjacent to the convex portion 31. Therefore, by cutting the surplus portion 28 at that position, it is possible to easily and accurately perform the trimming step of cutting only the intermediate 29 while suppressing cutting and damage of the lid 3.
　以上の工程により、実施例の中空部品１を得た。なお、実施例の中空部品１における発泡中空部２は、図２に示すように、凸部３１に対して径方向の外側に隣接する位置に切断面１９を有する。 Through the above steps, the hollow component 1 of the example was obtained. In addition, as shown in FIG. 2, the foam hollow portion 2 in the hollow component 1 of the embodiment has a cut surface 19 at a position adjacent to the convex portion 31 on the outer side in the radial direction.
　（実施例２）
　実施例２の中空部品の製造方法及び中空部品は、蓋部が凸部に加えて副凸部を有する点、及び、発泡中空部が２つの緩衝部（第１緩衝部、第２緩衝部）を有する点において実施例１の中空部品の製造方法及び中空部品と相違し、その余は実施例１の中空部品の製造方法及び中空部品と概略同じである。
　実施例２の中空部品を製造している様子を模式的に表す説明図を図４に示す。 (Example 2)
In the hollow component manufacturing method and the hollow component according to the second embodiment, the lid portion has the sub-convex portion in addition to the convex portion, and the foam hollow portion has two buffer portions (first buffer portion, second buffer portion). The hollow component is different from the hollow component manufacturing method and the hollow component of the first embodiment in that it has the following points, and the rest is substantially the same as the hollow component manufacturing method and the hollow component of the first embodiment.
FIG. 4 is an explanatory view schematically showing the manner of manufacturing the hollow component of Example 2.
　以下、実施例２の中空部品の製造方法及び中空部品について、実施例１と相違する点を中心として説明する。 Hereinafter, the hollow part manufacturing method and the hollow part according to the second embodiment will be described focusing on the differences from the first embodiment.
　図４に示すように、蓋部３は、凸部３１の径方向の外側に副凸部３３を有する。凸部３１と副凸部３３とは略同形であり、凸部３１と副凸部３３とは径方向に間隔をおいて配置されている。 As shown in FIG. 4, the lid 3 has a sub-projection 33 on the outer side in the radial direction of the projection 31. The convex portion 31 and the sub convex portion 33 have substantially the same shape, and the convex portion 31 and the sub convex portion 33 are arranged at intervals in the radial direction.
　中間体２９は、凸部３１よりも径方向の内側に、第１緩衝部２２及び第２緩衝部２３を有する。第１緩衝部２２は、中間体２９における径方向の略中央部分に設けられ、２つの凹状湾曲部２４ａと、当該２つの凹状湾曲部２４ａの間に位置する１つの凸状湾曲部２５ａとを有する。各凹状湾曲部２４ａは、蓋部３に対して逆方向に向けて陥没する、弓なりに曲がった部分である。凸状湾曲部２５ａは、蓋部３に向けて隆起する、弓なりに曲がった部分である。したがって、第１緩衝部２２において、中間体２９は、互いに逆方向に弓なりに曲がった部分が交互に連続する凹凸形状をなす。 The intermediate body 29 has a first cushioning portion 22 and a second cushioning portion 23 inside the convex portion 31 in the radial direction. The 1st buffer part 22 is provided in the substantially central part of the radial direction in the intermediate body 29, and has two concave curved parts 24a and one convex curved part 25a located between the two concave curved parts 24a. Have. Each concave curved portion 24a is a portion that is bent in a bow shape and is recessed in the opposite direction to the lid portion 3. The convex curved portion 25a is a portion that is bent toward the lid 3 and that is bent toward the lid 3. Therefore, in the first buffer portion 22, the intermediate body 29 has a concavo-convex shape in which the portions that are curved in opposite directions are alternately continuous.
　第２緩衝部２３は、凸部３１に対して径方向の内側に隣接する位置に設けられている。第２緩衝部２３は１つの凸状湾曲部２５ｂを有する。 The second buffer portion 23 is provided at a position adjacent to the convex portion 31 inward in the radial direction. The 2nd buffer part 23 has one convex curved part 25b.
　実施例２の中空部品の製造方法では、蓋部３が凸部３１に加えて副凸部３３を有するため、図４に示すように、トリミング工程では、凸部３１と副凸部３３との間で、中間体２９の余剰部２８を切除する。このとき、中間体２９における中空開口２０の周縁部２１は、カッターの刃８０によって蓋部３に向けて押しつけられる。しかし、当該周縁部２１は凸部３１及び副凸部３３によって支えられるため、凸部３１と副凸部３３との間においては、中間体２９と蓋部３との間の隙間１５は充分にかつ安定して確保される。このため、余剰部２８の切除は容易にかつ精度高く行われる。 In the method for manufacturing the hollow component according to the second embodiment, since the lid 3 has the sub-projection 33 in addition to the projection 31, as shown in FIG. 4, in the trimming step, the projection 31 and the sub-projection 33 are separated from each other. In between, the surplus portion 28 of the intermediate body 29 is cut off. At this time, the peripheral edge portion 21 of the hollow opening 20 in the intermediate body 29 is pressed against the lid portion 3 by the blade 80 of the cutter. However, since the peripheral edge portion 21 is supported by the convex portion 31 and the sub convex portion 33, the gap 15 between the intermediate body 29 and the lid portion 3 is sufficiently large between the convex portion 31 and the sub convex portion 33. And it is secured stably. Therefore, the surplus portion 28 is cut off easily and accurately.
　また、実施例２の中空部品１の製造方法では、中間体２９に第１緩衝部２２を設けたことで、蓋部３からの中間体２９の剥離が抑制される。
　つまり、中間体２９は発泡体からなり、非発泡体からなる蓋部３に比べて熱収縮し易い。このため、賦形後の中間体２９を、冷却前に、蓋部３に接合させると、冷却される際の中間体２９の収縮量が蓋部３の収縮量を大きく上回るため、双方に寸法差が生じて、中間体２９が蓋部３から剥離する可能性がある。しかし、実施例２の中空部品の製造方法においては、凹状湾曲部２４ａ及び凸状湾曲部２５ａを有する第１緩衝部２２が伸びることで中間体２９の収縮が吸収されるために、蓋部３からの中間体２９の剥離が抑制される。 In addition, in the method for manufacturing the hollow component 1 according to the second embodiment, the provision of the first buffer portion 22 in the intermediate body 29 suppresses the peeling of the intermediate body 29 from the lid 3.
That is, the intermediate body 29 is made of foam, and is more likely to be thermally contracted than the lid portion 3 made of non-foam. For this reason, if the shaped intermediate body 29 is joined to the lid portion 3 before cooling, the shrinkage amount of the intermediate body 29 when cooled is much larger than the shrinkage amount of the lid portion 3. A difference may occur and the intermediate body 29 may peel off from the lid 3. However, in the method for manufacturing the hollow component according to the second embodiment, the contraction of the intermediate body 29 is absorbed by the expansion of the first cushioning portion 22 having the concave curved portion 24a and the convex curved portion 25a, and thus the lid portion 3 The peeling of the intermediate 29 from is suppressed.
　また、凸状湾曲部２５ｂを有する第２緩衝部２３が凸部３１に対して径方向の内側に隣接する位置に設けられていることで、蓋部３の凸部３１との接合部に作用する力は、当該凸状湾曲部２５ｂが変形することで緩和される。例えば、暖房時に、中空部品１の内部中空１０を温かい空調空気９４が流通する場合には、中空部品１の発泡中空部２が膨張する場合がある。この場合、第２緩衝部２３の凸状湾曲部２５ｂが折り畳まれる方向に変形して、凸部３１に向かう力の伝達を阻害する。このため、凸部３１に塗布された接着剤（図略）に作用する力が緩和され、蓋部３からの発泡中空部２の剥離が抑制される。 In addition, since the second cushioning portion 23 having the convex curved portion 25b is provided at a position adjacent to the convex portion 31 on the inner side in the radial direction, it acts on the joint portion of the lid portion 3 with the convex portion 31. The acting force is alleviated by the deformation of the convex curved portion 25b. For example, when warm conditioned air 94 flows through the inner hollow 10 of the hollow component 1 during heating, the foam hollow portion 2 of the hollow component 1 may expand. In this case, the convex curved portion 25b of the second cushioning portion 23 is deformed in the folding direction to impede the transmission of the force toward the convex portion 31. Therefore, the force acting on the adhesive (not shown) applied to the convex portion 31 is relaxed, and the peeling of the foam hollow portion 2 from the lid portion 3 is suppressed.
　更に、第２緩衝部２３の凸状湾曲部２５ｂによって、内部中空１０の流路断面積は、凸部３１に対して径方向の内側に隣接する位置において、急激に狭くなる。このことにより、内部中空１０を流通する空調空気９４が凸部３１に到達し難くなり、凸部３１の温度変化量が小さくなり、ひいては、凸部３１に塗布された接着剤の熱による劣化が抑制される。 Further, due to the convex curved portion 25b of the second buffer portion 23, the flow passage cross-sectional area of the inner hollow 10 is sharply narrowed at a position adjacent to the convex portion 31 inward in the radial direction. This makes it difficult for the conditioned air 94 flowing through the inner hollow 10 to reach the convex portion 31, the amount of change in temperature of the convex portion 31 becomes small, and the deterioration of the adhesive applied to the convex portion 31 due to heat. Suppressed.
　（実施例３）
　実施例３の中空部品の製造方法及び中空部品は、凸部及び副凸部の形状、第１緩衝部が２つの凸状湾曲部と１つの凹状湾曲部とで構成されていること、及び、第２緩衝部における凸状湾曲部が大きく隆起していること以外は実施例２の中空部品の製造方法及び中空部品と概略同じである。
　実施例３の中空部品を製造している様子を模式的に表す説明図を図５に示す。 (Example 3)
In the hollow component manufacturing method and the hollow component according to the third embodiment, the shapes of the convex portion and the sub-convex portion, the first buffer portion is composed of two convex curved portions and one concave curved portion, and The method is substantially the same as the method for manufacturing the hollow part and the hollow part according to the second embodiment, except that the convex curved part in the second buffer part is largely raised.
FIG. 5 is an explanatory diagram that schematically shows how the hollow component of Example 3 is manufactured.
　以下、実施例３の中空部品の製造方法及び中空部品について、実施例２と相違する点を中心として説明する。 Hereinafter, the hollow part manufacturing method and the hollow part according to the third embodiment will be described focusing on the differences from the second embodiment.
　図５に示すように、実施例３の中空部品の製造方法では、凸部３１及び副凸部３３の頂部は平面状をなし、凸部３１の径方向の長さは副凸部３３の径方向の長さよりも長い。凸部３１がこのような形状であるため、凸部３１における頂部の面積、つまり、中間体２９と蓋部３との接着面積が大きく確保され、中間体２９と蓋部３とはより強固に接合する。
　つまり、実施例３の中空部品の製造方法では、蓋部３からの中間体２９の剥離がより一層抑制され、実施例３の中空部品では、蓋部３からの発泡中空部２の剥離がより一層抑制される。 As shown in FIG. 5, in the method for manufacturing a hollow component according to the third embodiment, the tops of the convex portions 31 and the sub-convex portions 33 are flat, and the radial length of the convex portion 31 is the diameter of the sub-convex portion 33. Longer than direction length. Since the convex portion 31 has such a shape, a large area of the top portion of the convex portion 31, that is, a large bonding area between the intermediate body 29 and the lid portion 3 is ensured, and the intermediate body 29 and the lid portion 3 are made stronger. To join.
That is, in the hollow component manufacturing method of the third embodiment, peeling of the intermediate body 29 from the lid portion 3 is further suppressed, and in the hollow component of the third embodiment, peeling of the foam hollow portion 2 from the lid portion 3 is further suppressed. It is further suppressed.
　また、実施例３の中空部品の製造方法は、中間体２９における第１緩衝部２２が２つの凸状湾曲部２５ａと１つの凹状湾曲部２４ａとで構成されている点で実施例２の中空部品の製造方法と相違する。
　しかし、実施例３の中空部品の製造方法においても、実施例２の中空部品の製造方法と同様に、凹状湾曲部２４ａ及び凸状湾曲部２５ａを有する第１緩衝部２２が伸びることで中間体２９の収縮が吸収されるために、蓋部３からの中間体２９の剥離が抑制される。 The hollow component manufacturing method according to the third embodiment is different from the hollow member according to the second embodiment in that the first cushioning portion 22 in the intermediate body 29 is composed of two convex curved portions 25a and one concave curved portion 24a. This is different from the method of manufacturing parts.
However, also in the method of manufacturing the hollow component of the third embodiment, as in the method of manufacturing the hollow component of the second embodiment, the first buffer portion 22 having the concave curved portion 24a and the convex curved portion 25a extends to form an intermediate body. Since the contraction of 29 is absorbed, peeling of the intermediate body 29 from the lid portion 3 is suppressed.
　また、実施例３の中空部品の製造方法においては、第２緩衝部２３の凸状湾曲部２５ｂが蓋部３に向けて大きく隆起している。このため、内部中空１０の流路断面積は、凸部３１に対して径方向の内側に隣接する位置において、急激に狭くなる。実施例３の中空部品の製造方法では、実施例２の中空部品の製造方法に比べて、この凸部３１に隣接する部分の流路断面積は更に狭くなり、かつ、当該流路断面積の狭い部分の長さも更に長くなる。
　このことにより、実施例３の中空部品の製造方法においては、内部中空１０を流通する空調空気９４はより一層凸部３１に到達し難くなり、凸部３１の温度変化量がより一層小さくなり、ひいては、凸部３１に塗布された接着剤の熱による劣化がより一層抑制される。 In addition, in the method of manufacturing the hollow component according to the third embodiment, the convex curved portion 25b of the second buffer portion 23 is largely bulged toward the lid portion 3. Therefore, the flow passage cross-sectional area of the inner hollow 10 sharply narrows at a position adjacent to the convex portion 31 on the inner side in the radial direction. In the method for manufacturing the hollow component of the third embodiment, the flow passage cross-sectional area of the portion adjacent to the convex portion 31 becomes smaller than that of the method for manufacturing the hollow component in the second embodiment, and The length of the narrow part also becomes longer.
As a result, in the method for manufacturing a hollow component according to the third embodiment, the conditioned air 94 flowing through the inner hollow 10 is less likely to reach the convex portion 31, and the temperature change amount of the convex portion 31 is further reduced. As a result, deterioration of the adhesive applied to the convex portion 31 due to heat is further suppressed.
　なお実施例３の凸状湾曲部２５ａは、図５に示すように、中空内部１０において断面略円弧状となる緩やかな湾曲形状をなすが、例えば図６に示すように、曲率の大きな屈曲形状であっても良い。この場合にも、当該凸状湾曲部２５ａによって中間体２９の収縮を吸収できる。また、当該屈曲形状の凸状湾曲部２５ａを、整流リブ３５と同様に前後方向に延びる形状とすることで、凸状湾曲部２５ａに整流機能を付与することもできる。 The convex curved portion 25a of the third embodiment has a gentle curved shape with a substantially arcuate cross section in the hollow interior 10 as shown in FIG. 5, but, for example, as shown in FIG. May be Also in this case, the contraction of the intermediate body 29 can be absorbed by the convex curved portion 25a. Further, by forming the bent convex curved portion 25a in the front-rear direction like the straightening rib 35, it is possible to impart a straightening function to the convex curved portion 25a.
　（実施例４）
　実施例４の中空部品の製造方法及び中空部品は、凸部及び副凸部が中間体に設けられていること、及び第２緩衝部の形状以外は、実施例２の中空部品の製造方法及び中空部品と概略同じである。
　実施例４の中空部品を製造している様子を模式的に表す説明図を図７に示す。 (Example 4)
The hollow component manufacturing method and hollow component of Example 4 are different from those of Example 2 except that the convex portion and the sub-convex portion are provided in the intermediate body and the shape of the second buffer portion. It is almost the same as the hollow part.
FIG. 7 shows an explanatory view schematically showing the production of the hollow part of Example 4.
　以下、実施例４の中空部品の製造方法及び中空部品について、実施例２と相違する点を中心として説明する。 Hereinafter, the hollow part manufacturing method and the hollow part according to the fourth embodiment will be described focusing on the differences from the second embodiment.
　図７に示すように、実施例４の中空部品の製造方法では、凸部３１及び副凸部３３が中間体２９に設けられている。このような場合にも、凸部３１と副凸部３３との間において、中間体２９と蓋部３との間の隙間１５は、充分にかつ安定して確保される。このため、実施例４の中空部品の製造方法においても、余剰部２８の切除は容易にかつ精度高く行われる。 As shown in FIG. 7, in the method of manufacturing a hollow component according to the fourth embodiment, the convex portion 31 and the sub-convex portion 33 are provided on the intermediate body 29. Even in such a case, the gap 15 between the intermediate body 29 and the lid portion 3 is sufficiently and stably ensured between the convex portion 31 and the sub convex portion 33. Therefore, also in the method of manufacturing the hollow component according to the fourth embodiment, the surplus portion 28 is cut off easily and accurately.
　また、実施例４の中空部品の製造方法においても、凸部３１及び副凸部３３の頂部は平面状をなし、凸部３１の径方向の長さは副凸部３３の径方向の長さよりも長い。このため実施例４の中空部品の製造方法においても、中間体２９と蓋部３との接着面積が大きく確保され、中間体２９と蓋部３とはより強固に接合する。 Also in the method for manufacturing the hollow component of Example 4, the tops of the convex portions 31 and the sub-convex portions 33 are flat, and the radial length of the convex portions 31 is smaller than the radial length of the sub-convex portions 33. Is also long. Therefore, also in the method of manufacturing the hollow component according to the fourth embodiment, a large bonding area between the intermediate body 29 and the lid portion 3 is secured, and the intermediate body 29 and the lid portion 3 are more firmly joined.
　更に、実施例４の中空部品の製造方法においては、実施例３の中空部品の製造方法と同様に、第２緩衝部２３の凸状湾曲部２５ｂが蓋部３に向けて大きく隆起している。このため、実施例４の中空部品の製造方法及び中空部品においても、凸部３１に塗布された接着剤の熱による劣化が更に抑制される。 Furthermore, in the method of manufacturing the hollow component of the fourth embodiment, similarly to the method of manufacturing the hollow component of the third embodiment, the convex curved portion 25b of the second buffer portion 23 largely bulges toward the lid portion 3. .. Therefore, also in the hollow component manufacturing method and the hollow component of the fourth embodiment, the deterioration of the adhesive applied to the convex portion 31 due to heat is further suppressed.
　（実施例５）
　実施例５の中空部品の製造方法及び中空部品は、凸部が中間体に設けられ、副凸部が蓋部に設けられていること以外は、実施例３の中空部品の製造方法及び中空部品と概略同じである。
　実施例５の中空部品を製造している様子を模式的に表す説明図を図８に示す。 (Example 5)
The method for manufacturing the hollow part and the hollow part according to the fifth embodiment are the same as the method for manufacturing the hollow part and the hollow part according to the third embodiment, except that the protrusion is provided on the intermediate body and the sub-projection is provided on the lid. Is almost the same as.
FIG. 8 is an explanatory diagram that schematically shows how the hollow component of Example 5 is manufactured.
　以下、実施例５の中空部品の製造方法及び中空部品について、実施例３と相違する点を中心として説明する。 Hereinafter, the hollow part manufacturing method and the hollow part according to the fifth embodiment will be described, focusing on the differences from the third embodiment.
　図８に示すように、実施例５の中空部品の製造方法では、凸部３１が中間体２９に設けられ、副凸部３３が蓋部３に設けられている。
　しかし、実施例５の中空部品の製造方法においても、当該凸部３１と副凸部３３とは径方向に間隔をおいて配置され、副凸部３３は凸部３１よりも径方向の外側に位置する。また、凸部３１及び副凸部３３の頂部は平面状であり、凸部３１の径方向の長さは副凸部３３の径方向の長さよりも長い。
　したがって、実施例５の中空部品の製造方法においても、実施例３の中空部品の製造方法と同様に、余剰部２８の切除を容易にかつ精度高く行うことができ、蓋部３からの中間体２９の剥離がより一層抑制される。当然乍ら、実施例５の中空部品においても、蓋部３からの発泡中空部２の剥離はより一層抑制される。 As shown in FIG. 8, in the method for manufacturing a hollow component according to the fifth embodiment, the convex portion 31 is provided on the intermediate body 29, and the sub convex portion 33 is provided on the lid portion 3.
However, also in the method of manufacturing the hollow component according to the fifth embodiment, the convex portion 31 and the sub-convex portion 33 are arranged with a gap in the radial direction, and the sub-convex portion 33 is located outside the convex portion 31 in the radial direction. To position. The tops of the convex portions 31 and the sub convex portions 33 are flat, and the radial length of the convex portions 31 is longer than the radial length of the sub convex portions 33.
Therefore, also in the method of manufacturing the hollow component of the fifth embodiment, the surplus portion 28 can be easily and accurately cut off, similarly to the method of manufacturing the hollow component of the third embodiment. The peeling of 29 is further suppressed. As a matter of course, also in the hollow component of the fifth embodiment, peeling of the foam hollow portion 2 from the lid portion 3 is further suppressed.
　本発明は、上記し且つ図面に示した実施形態にのみ限定されるものではなく、要旨を逸脱しない範囲内で適宜変更して実施できる。また、実施形態を含む本明細書に示した各構成要素は、それぞれ任意に抽出し組み合わせて実施できる。 The present invention is not limited to the embodiments described above and shown in the drawings, and can be appropriately modified and implemented without departing from the scope of the invention. In addition, each component shown in the present specification including the embodiment can be arbitrarily extracted and combined.
１：中空部品　　　　　　　　　２：発泡中空部
３：蓋部　　　　　　　　　　　１９：切断面
２０：中空開口（開口）　　　　２１：中空開口（開口）の周縁部
２２：第１緩衝部　　　　　　　２３：第２緩衝部
２４ａ：凹状湾曲部　　　　　　２５ａ、２５ｂ：凸状湾曲部
２８：余剰部　　　　　　　　　２９：発泡中空部の中間体
３１：凸部　　　　　　　　　　３３：副凸部
１０２：発泡中空部　　　　　　１２０：開口
１０３：蓋部　　　　　　　　　１２２：開口の周縁部
１３１：凸部

  1: Hollow part 2: Foamed hollow part 3: Lid part 19: Cut surface 20: Hollow opening (opening) 21: Peripheral part of hollow opening (opening) 22: First buffer part 23: Second buffer part 24a: Concave curve Part 25a, 25b: Convex curved part 28: Excess part 29: Intermediate body of foam hollow part 31: Convex part 33: Sub convex part 102: Foam hollow part 120: Opening 103: Lid part 122: Peripheral part 131 of opening: Convex

Claims (6)

  1. 　発泡体が賦形されてなり開口を有する箱状をなす発泡中空部と、非発泡体からなり前記発泡中空部の前記開口を覆う蓋部と、を有する中空部品を製造する方法であって、
    　前記開口を有する前記発泡中空部の中間体の前記開口を、前記蓋部で覆い、前記中間体における前記開口の周縁部と前記蓋部とを接合させる接合工程と、
    　前記中間体のうち、前記蓋部と接合する部分よりも前記開口の径方向の外側に位置する余剰部を切除するトリミング工程と、を有し、
    　前記中間体と前記蓋部との少なくとも一方において、他方と接合する部分を、前記他方に向けて突起する凸部とし、
    　前記トリミング工程において、前記凸部に対して前記径方向の外側に隣接する位置で、前記余剰部を切除する、中空部品の製造方法。     A method for producing a hollow component having a box-shaped foam hollow portion having an opening formed by forming a foam, and a lid portion made of a non-foam material and covering the opening of the foam hollow portion,
    A bonding step of covering the opening of the intermediate body of the foamed hollow portion having the opening with the lid portion and joining the peripheral edge portion of the opening and the lid portion in the intermediate body,
    Of the intermediate body, a trimming step of cutting off a surplus portion located radially outside the opening with respect to a portion joined to the lid portion,
    At least one of the intermediate body and the lid portion, a portion to be joined to the other, as a convex portion protruding toward the other,
    In the trimming step, the method for manufacturing a hollow component, wherein the surplus portion is cut off at a position adjacent to the convex portion on the outer side in the radial direction.
  2. 　前記凸部の前記径方向の外側に、前記他方に向けて突起する副凸部を設け、
    　前記トリミング工程において、前記凸部と前記副凸部との間で前記余剰部を切除する、請求項１に記載の中空部品の製造方法。     On the outer side of the convex portion in the radial direction, a sub-convex portion protruding toward the other is provided,
    The method for manufacturing a hollow component according to claim 1, wherein, in the trimming step, the surplus portion is cut off between the convex portion and the sub convex portion.
  3. 　前記凸部の前記径方向の長さは、前記副凸部の前記径方向の長さよりも長い、請求項２に記載の中空部品の製造方法。 The method for manufacturing a hollow component according to claim 2, wherein the radial length of the convex portion is longer than the radial length of the sub convex portion.
  4. 　前記中間体は、前記凸部よりも前記径方向の内側に、前記蓋部に向けて隆起する凸状湾曲部及び／又は前記蓋部とは逆側に向けて陥没する凹状湾曲部を有する緩衝部を有する、請求項１～請求項３の何れか一項に記載の中空部品の製造方法。 The intermediate body has a convex curved portion that is bulged toward the lid portion and / or a concave curved portion that is depressed toward the opposite side of the lid portion, inside the convex portion in the radial direction. The method for manufacturing a hollow component according to any one of claims 1 to 3, which has a portion.
  5. 　前記緩衝部は、前記凸状湾曲部を有し、前記凸部に対して前記径方向の内側に隣接する位置に設けられる、請求項４に記載の中空部品の製造方法。 The method for manufacturing a hollow component according to claim 4, wherein the buffer portion has the convex curved portion and is provided at a position adjacent to the convex portion on the inner side in the radial direction.
  6. 　発泡体が賦形されてなり開口を有する箱状をなす発泡中空部と、非発泡体からなり前記発泡中空部の前記開口を覆い前記開口の周縁部で前記発泡中空部に接合されている蓋部と、を有し、
    　前記発泡中空部と前記蓋部との少なくとも一方において、他方と接合する部分は、前記他方に向けて突出する凸部で構成され、
    　前記発泡中空部は、前記凸部に対して前記開口の径方向の外側に隣接する位置に切断面を有する、中空部品。

          A box-shaped foam hollow portion having an opening formed by forming a foam body, and a lid formed of a non-foam body that covers the opening of the foam hollow portion and is joined to the foam hollow portion at a peripheral portion of the opening. And a section,
    In at least one of the foam hollow portion and the lid portion, a portion joined to the other is formed by a convex portion protruding toward the other,
    The said foam hollow part is a hollow component which has a cut surface in the position adjacent to the outer side of the said protrusion in the radial direction of the said opening.

PCT/JP2019/034352 2018-11-05 2019-09-02 Method for manufacturing hollow part WO2020095523A1 (en)

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Citations (5)

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JP2002321284A (en) * 2001-04-25 2002-11-05 Toyo Seikan Kaisha Ltd Container sealing method
JP2011131776A (en) * 2009-12-25 2011-07-07 Kyoraku Co Ltd Floor duct and carrier
JP2012158141A (en) * 2011-02-02 2012-08-23 Teijin Ltd Fiber-reinforced plastic joined body and joining method
JP2015045494A (en) * 2013-07-30 2015-03-12 キョーラク株式会社 Duct and manufacturing method thereof
JP2018069557A (en) * 2016-10-28 2018-05-10 株式会社イノアックコーポレーション Compact with stamp and manufacturing method of compact with stamp

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2002321284A (en) * 2001-04-25 2002-11-05 Toyo Seikan Kaisha Ltd Container sealing method
JP2011131776A (en) * 2009-12-25 2011-07-07 Kyoraku Co Ltd Floor duct and carrier
JP2012158141A (en) * 2011-02-02 2012-08-23 Teijin Ltd Fiber-reinforced plastic joined body and joining method
JP2015045494A (en) * 2013-07-30 2015-03-12 キョーラク株式会社 Duct and manufacturing method thereof
JP2018069557A (en) * 2016-10-28 2018-05-10 株式会社イノアックコーポレーション Compact with stamp and manufacturing method of compact with stamp

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