WO2022102410A1 - フェンダーライナー及びその製造方法、並びに車両 - Google Patents
フェンダーライナー及びその製造方法、並びに車両 Download PDFInfo
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- WO2022102410A1 WO2022102410A1 PCT/JP2021/039703 JP2021039703W WO2022102410A1 WO 2022102410 A1 WO2022102410 A1 WO 2022102410A1 JP 2021039703 W JP2021039703 W JP 2021039703W WO 2022102410 A1 WO2022102410 A1 WO 2022102410A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- foam
- layer
- fender liner
- mixed layer
- resin composition
- Prior art date
Links
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- 239000006260 foam Substances 0.000 claims abstract description 110
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
- B29C39/02—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles
- B29C39/10—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. casting around inserts or for coating articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/0001—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor characterised by the choice of material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
- B29C45/14795—Porous or permeable material, e.g. foam
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
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Definitions
- This disclosure relates to a fender liner, a manufacturing method thereof, and a vehicle.
- the fender liner is arranged in a curved shape along the outer circumference of the tire of the vehicle to prevent foreign matter such as pebbles that are flipped up when the vehicle is running from colliding with the vehicle body (hereinafter, also referred to as chipping). Further, the fender liner includes a non-woven fabric or the like, and absorbs the running noise of a vehicle, the collision noise of a foreign substance, and the like (see Patent Document 1).
- the conventional fender liner includes non-woven fabric and the like.
- the foamed layer is superior in sound absorption and shape retention to the non-woven fabric, but is inferior in strength.
- One aspect of the present disclosure provides a technique for improving the strength of a fender liner including a foam layer.
- the fender liner is arranged in a curved shape along the outer circumference of the tire of the vehicle.
- the fender liner includes a first foam layer and a mixed layer.
- the first foam layer is formed of the first foam.
- the mixed layer contains a first nonwoven fabric and a second foam foamed inside the first nonwoven fabric. The first foam forming the first foam layer leads to the second foam contained in the mixed layer.
- the foam layer of the fender liner can be reinforced with a mixed layer, and the strength of the fender liner can be improved.
- FIG. 1 is a diagram showing a lower structure of a vehicle on which a fender liner according to an embodiment is mounted.
- 2A is a cross-sectional view showing a laminated structure according to an embodiment
- FIG. 2B is a cross-sectional view showing a laminated structure according to a first modification
- FIG. 2C is a second modification. It is sectional drawing which shows the laminated structure which concerns on an example.
- FIG. 3 is a flowchart showing a method of manufacturing a fender liner according to an embodiment.
- FIG. 4 is a cross-sectional view showing an example of S102 in FIG.
- FIG. 5 is a cross-sectional view showing an example of S105 in FIG. FIG.
- FIG. 6 is a cross-sectional view showing an example of S106 of FIG.
- FIG. 7 is a diagram showing an example of the relationship between the surface density and the tensile strength.
- FIG. 8 is a diagram showing an example of the relationship between the thickness of the nonwoven fabric before compounding and the strength improvement rate A.
- FIG. 9 is a diagram showing an example of the relationship between the thickness of the nonwoven fabric before compounding and the strength improvement rate B.
- Nonwoven fabric is defined as follows in Japanese Industrial Standards JIS L 0222: 2001. A fiber sheet, web or bat in which the fibers are oriented in one direction or randomly, and the fibers are bonded by entanglement and / or fusion and / or adhesion. However, paper, woven fabrics, knitted fabrics, tufts and velvet felt are excluded.
- the fender liner 1 according to the embodiment will be described with reference to FIG.
- the white arrow indicates the traveling direction of the vehicle
- the left side is the front side of the vehicle
- the right side is the rear side of the vehicle.
- the fender liner 1 is arranged inside the tire house 31.
- the tire house 31 is a space for accommodating the tire 2 of the vehicle body 3.
- the fender liner 1 is arranged in a curved shape along the outer circumference of the tire 2.
- the fender liner 1 forms a certain gap or more with the tire 2 so as not to come into contact with the tire 2.
- the fender liner 1 prevents foreign matter such as pebbles that are flipped up while the vehicle is running from colliding with the vehicle body 3. Further, the fender liner 1 absorbs the running sound of the vehicle, the collision sound of foreign matter, and the like.
- the fender liner 1 is attached to the vehicle body 3 with, for example, a pin and a washer.
- the fender liner 1 includes at least a first foam layer 11 and a mixed layer 12.
- the first foam layer 11 and the mixed layer 12 are each formed in a curved shape along the outer circumference of the tire 2 of the vehicle.
- the first foam layer 11 is formed of the first foam.
- the first foam forming the first foam layer 11 leads to the second foam contained in the mixed layer 12.
- the first foam and the second foam are simultaneously molded with the same resin composition and are continuously molded.
- the mixed layer 12 includes a first nonwoven fabric and a second foam foamed inside the second nonwoven fabric. That is, the mixed layer 12 is a composite of the first non-woven fabric and the second foam.
- the first foam layer 11 does not contain a non-woven fabric.
- the fender liner 1 may further include a nonwoven fabric layer 13 on the opposite side of the first foamed layer 11 with respect to the mixed layer 12.
- the nonwoven fabric layer 13 is formed of a second nonwoven fabric connected to the first nonwoven fabric contained in the mixed layer 12.
- the first non-woven fabric and the second non-woven fabric are originally one non-woven fabric 6 (see FIGS. 4 and 5).
- the portion of the nonwoven fabric 6 impregnated with the resin composition is the first nonwoven fabric, and the portion of the nonwoven fabric 6 remaining without being impregnated with the resin composition is the second nonwoven fabric.
- the non-woven fabric layer 13 does not contain foam.
- the resin composition is injected into the internal space 56 with the non-woven fabric 6 installed in the internal space 56 of the molding die 5 shown in FIG. 4 and the like, and the non-woven fabric 6 is impregnated with the resin composition. It is obtained by foaming the resin composition and then solidifying the resin composition.
- the resin composition is impregnated from one side (for example, the upper surface) of the nonwoven fabric 6 toward the opposite surface (for example, the lower surface) of the nonwoven fabric 6.
- the fender liner 1 shown in FIG. 2 (A) When the impregnation of the resin composition stops in the middle of the nonwoven fabric 6, the fender liner 1 shown in FIG. 2 (A) is obtained.
- the fender liner 1 shown in FIG. 2A includes a first foam layer 11, a mixed layer 12, and a non-woven fabric layer 13 in this order.
- the fender liner 1 shown in FIG. 2A has excellent weather resistance because the nonwoven fabric layer 13 facing the tire 2 does not contain foam.
- the fender liner 1 shown in FIG. 2B includes a first foam layer 11 and a mixed layer 12.
- the fender liner 1 shown in FIG. 2B is excellent in the effect of preventing chipping because the high-strength mixed layer 12 is arranged closer to the tire 2 than the low-strength first foam layer 11.
- the fender liner 1 shown in FIG. 2C includes a first foam layer 11, a mixed layer 12, and a second foam layer 14 in this order.
- the second foam layer 14 is located on the opposite side of the first foam layer 11 with respect to the mixed layer 12.
- the second foam layer 14 is formed of a third foam connected to the second foam of the mixed layer 12. The third foam and the second foam are simultaneously molded with the same resin composition and are continuously molded.
- sound is absorbed by the second foam layer 14 facing the tire 2, so that the sound absorption coefficient can be improved.
- the fender liner 1 includes at least a first foam layer 11 and a mixed layer 12.
- the mixed layer 12 is a composite of the non-woven fabric 6 and the foam. Therefore, the mixed layer 12 has a high density and high strength as compared with the non-woven fabric 6 before the compounding and as compared with the foam before the compounding.
- the first foam layer 11 can be reinforced by the mixed layer 12, and the strength of the fender liner 1 can be improved.
- the fender liner 1 includes, for example, a first foam layer 11 on the side opposite to the tire 2 with the mixed layer 12 as a reference.
- a first foam layer 11 on the side opposite to the tire 2 with the mixed layer 12 as a reference.
- the first foam layer 11 and the mixed layer 12 constituting the fender liner 1 will be described. Since the second nonwoven fabric forming the nonwoven fabric layer 13 is configured in the same manner as the first nonwoven fabric contained in the mixed layer 12, the description of the nonwoven fabric layer 13 will be omitted. Further, since the second foam layer 14 is configured in the same manner as the first foam layer 11, the description thereof will be omitted.
- the thickness of the mixed layer 12 is, for example, 0.15 mm to 5 mm.
- the thickness of the mixed layer 12 is 0.15 mm or more, the strength of the fender liner 1 is sufficiently high.
- the thickness of the mixed layer 12 is 5 mm or less, the thickness of the nonwoven fabric 6 before compounding is thin, and the nonwoven fabric 6 can be easily manufactured.
- the thickness of the mixed layer 12 is preferably 0.7 mm to 4 mm.
- the density of the mixed layer 12 is, for example, 4 to 10 times, preferably 5 to 7 times, the density of the first foam layer 11 from the viewpoint of achieving both strength and sound absorption.
- the density of the mixed layer 12 is a so-called bulk density, and is measured in accordance with JIS K7222: 2005 “Foam Plastics and Rubbers-How to Determine the Apparent Density”.
- the density of the mixed layer 12 is preferably 250 kg / m 3 to 1100 kg / m 3 .
- the nonwoven fabric 6 contained in the mixed layer 12 is an aggregate of polyester (PEs) fibers, polyethylene (PE) fibers, polypropylene (PP) fibers and the like.
- the nonwoven fabric 6 may contain a plurality of types of fibers, for example, polyester fibers and rayon fibers. Specific examples of polyester fibers include polyethylene terephthalate (PET) fibers.
- PET polyethylene terephthalate
- the non-woven fabric 6 can form not only the mixed layer 12 but also the non-woven fabric layer 13.
- the first foam layer 11 Unlike the non-woven fabric 6, the first foam layer 11 has a three-dimensional net-like skeleton.
- the first foam layer 11 has a large number of bubbles inside. Many bubbles are connected to each other, and sound waves propagate inside them. At that time, the air vibrates inside the first foam layer 11. Friction occurs between the three-dimensional network skeleton of the first foam layer 11 and air, and the energy of sound waves is converted into heat energy. As a result, the sound is absorbed. The noise level outside the vehicle and the noise level inside the vehicle can be reduced.
- the first foam layer 11 While the nonwoven fabric 6 contains fibers that are two-dimensionally oriented, the first foam layer 11 has a three-dimensionally stretched net-like skeleton. Therefore, the first foam layer 11 can improve the sound absorption coefficient as compared with the nonwoven fabric 6. Further, since the first foam layer 11 has a three-dimensionally stretched net-like skeleton and is continuously connected, shape retention can be improved.
- the first foam layer 11 is, for example, a polyurethane foam.
- the polyurethane foam is a so-called polyurethane foam, which is obtained by foaming and solidifying a resin composition containing a polyisocyanate, a polyol, a catalyst, and a foaming agent.
- the foaming agent contains water.
- the foaming agent may contain chlorine. Details of the resin composition will be described later.
- the first foam layer 11 is a polyurethane foam in the present embodiment, it may be a foam of polyacrylic acid, melamine, rubber, polyolefin, or polyimide. These materials, including polyurethane, are lightweight and have excellent shape retention.
- the thickness of the first foam layer 11 is, for example, 3 mm to 25 mm, preferably 3 mm to 20 mm, from the viewpoint of achieving both lightness and sound absorption.
- the density of the first foam layer 11 is, for example, 20 kg / m 3 to 140 kg / m 3 from the viewpoint of achieving both lightness and sound absorption.
- the density of the first foam layer 11 is a so-called bulk density, and is measured in accordance with JIS K7222: 2005 "Foam plastics and rubber-how to determine the apparent density”.
- the density of the first foam layer 11 is preferably 30 kg / m 3 to 130 kg / m 3 , and more preferably 55 kg / m 3 to 120 kg / m 3 .
- the sound absorption coefficient of the first foam layer 11 is, for example, 0.4 to 1.0.
- the sound absorption coefficient of the first foam layer 11 is measured in accordance with JIS A1405-2: 2007 "Measurement of sound absorption coefficient and impedance by acoustic tube” by cutting out a test piece having a thickness of 10 mm and vertically injecting a sound wave of 1000 Hz. ..
- the sound absorption coefficient of the first foam layer 11 is preferably 0.5 to 1.0.
- a sound absorption coefficient of 1.0 means that no sound is reflected.
- the method for manufacturing the fender liner 1 includes, for example, steps S101 to S107 in FIG.
- the molding dies 5 shown in FIGS. 4 to 6 are used.
- the molding die 5 is a die from the viewpoint of temperature controllability.
- the molding mold 5 may be a sand mold, a wooden mold, or a resin mold.
- step S101 the temperature of the molding die 5 is adjusted.
- the temperature control of the mold 5 is continued in the subsequent steps.
- the temperature control (step S101) may be started before the injection (step S103). Before the injection (step S103), the temperature of the molding die 5 should be stable.
- the temperature of the mold 5 is adjusted to 50 ° C to 70 ° C.
- a flow path through which a temperature control medium such as water flows is formed inside the molding die 5.
- An electric heater or the like may be embedded inside the molding die 5.
- the temperature of the molding die 5 is 50 ° C. or higher, the polymerization reaction and the foaming reaction can proceed. Further, when the temperature of the molding die 5 is 70 ° C. or lower, these reaction rates can be appropriately suppressed, and it is possible to suppress the completion of solidification before the resin spreads over the entire internal space 56 of the molding die 5, which is not possible. The phenomenon of complete filling, the so-called short circuit, can be suppressed.
- the temperature distribution of the molding die 5 may be uniform or non-uniform. In the latter case, the polymerization reaction and the foaming reaction of the resin composition can be adjusted by the temperature difference.
- step S102 as shown in FIG. 4, the lower mold 51 and the upper mold 52 constituting the molding mold 5 are closed. Specifically, by moving the upper mold 52 from the mold opening position (see FIG. 6) to the mold closing position (see FIG. 4), the mold 5 is closed.
- an internal space 56 is formed between the lower mold 51 and the upper mold 52.
- the internal space 56 is a space for molding the fender liner 1.
- the non-woven fabric 6 is installed in the internal space 56 before the mold is closed.
- the thickness of the non-woven fabric 6 is thinner than the thickness of the internal space 56. Therefore, a flow path through which the resin composition passes is formed between the nonwoven fabric 6 and the upper mold 52. The flow path is formed over the entire upper surface of the nonwoven fabric 6.
- the resin composition can be impregnated from the entire upper surface of the nonwoven fabric 6 into the inside of the nonwoven fabric 6.
- the molding die 5 is divided into a lower die 51 and an upper die 52.
- the upper mold 52 is arranged above the lower mold 51.
- the upper mold 52 is further divided into a plurality of split molds 53 to 55.
- the lower mold 51 and the upper mold 52 are also split molds of the molding mold 5.
- the boundary line of these split dies is called the dividing line PL of the forming die 5.
- the lower mold 51 is a fixed mold.
- the lower mold 51 has an upper surface 511 that is convex upward, and has a concave portion 512 on the upper surface 511 thereof.
- the recess 512 is formed at a constant depth from the upper surface 511 of the lower mold 51.
- the nonwoven fabric 6 is installed at the bottom of the recess 512.
- the upper mold 52 is a movable type.
- the upper die 52 has a lower surface 521 that is convex upward.
- the lower surface 521 of the upper mold 52 contacts the upper surface 511 of the lower mold 51.
- a second recess may be formed on the lower surface of the upper mold 52, or the resin composition may be foamed inside the second recess.
- the thickness of the first foam layer 11 can be partially increased.
- the number of the second recesses is one or more.
- the upper mold 52 has an upwardly convex arch shape, and is divided into three split molds 53 to 55 in the circumferential direction thereof.
- the split molds 53 and 55 at both ends are connected to the lower mold 51 by different hinges H1 and H2.
- the split mold 53 at one end rotates about the hinge H1 and rotates between the mold closed position (see FIG. 4) and the mold open position (see FIG. 6).
- the split mold 55 at the other end rotates about the hinge H2 and rotates between the mold closed position (see FIG. 4) and the mold open position (see FIG. 6).
- the intermediate split mold 54 is connected to one of the two split molds 53 and 55 at both ends (for example, the split mold 53) by a hinge H3.
- the split mold 54 in the middle rotates about the hinge H3, and rotates between the mold closed position (see FIG. 4) and the mold open position (see FIG. 6) with respect to the split mold 53 at one end.
- the upper mold 52 is divided into three split molds 53 to 55, but it may be divided into two split molds or four or more split molds.
- the number of divisions of the upper die 52 is not particularly limited.
- the upper mold 52 is divided into a plurality of split molds 53 to 55.
- a plurality of split molds 53 to 55 can be moved individually, and the movable range of the upper mold 52 can be reduced as compared with the case where the entire upper mold 52 is moved at once.
- step S103 the resin composition is injected from the injection port 57 into the internal space 56 of the molding die 5 closed in step S102.
- the internal space 56 has an upwardly convex arch shape, and the injection port 57 is arranged directly above the uppermost portion thereof.
- the resin composition enters the internal space 56 from the injection port 57, it is bifurcated and flows down the flow path between the upper mold 52 and the nonwoven fabric 6 by gravity.
- a stopper 58 is inserted into the injection port 57 as shown in FIG. 5, and the stopper 58 closes the injection port 57.
- step S104 the non-woven fabric 6 is impregnated with the resin composition in the internal space 56 of the molding die 5, and the resin composition is foamed.
- the resin composition is impregnated into the inside of the nonwoven fabric 6 from the entire upper surface of the nonwoven fabric 6. Impregnation and foaming may proceed at the same time.
- the dividing line PL of this embodiment is not arranged on the surface 1b of the fender liner 1 facing the tire 2. Therefore, no burr B is generated on the surface 1b of the fender liner 1 facing the tire 2. Therefore, it is possible to prevent the burr B from interfering with the tire 2.
- the burr B is formed on the surface 1a of the fender liner 1 opposite to the tire 2.
- step S105 the foamed resin composition is solidified.
- Solidification involves hardening.
- a fender liner 1 including the first foam layer 11, the mixed layer 12, and the nonwoven fabric layer 13 in this order can be obtained.
- the fender liner 1 shown in FIGS. 2 (B) and 2 (C) can be adjusted by adjusting the injection amount of the resin composition, the thickness of the nonwoven fabric 6 before compounding, the setting of the nonwoven fabric 6 before compounding, and the like. It is also possible to obtain.
- a fender liner 1 having a laminated structure opposite to that of the fender liner 1 shown in FIG. 6 can be obtained. Even when the molding die 5 is installed upside down, the injection port 57 is provided above the internal space 56.
- the fender liner 1 is molded to have the same shape and dimensions as the internal space 56 of the molding die 5. Therefore, the fender liner 1 having the same shape and the same dimensions can be mass-produced.
- the shape and dimensions of the fender liner 1 are determined by the shape and dimensions of the internal space 56 of the molding die 5, a fine structure can be imparted, and post-processing such as cutting or pressing is not required.
- the number of steps can be reduced and the manufacturing cost of the fender liner 1 can be reduced. ..
- step S106 as shown in FIG. 6, the lower mold 51 and the upper mold 52 are opened. Specifically, by moving the upper mold 52 from the mold closing position (see FIG. 4) to the mold opening position (see FIG. 6), the mold 5 is opened.
- the fender liner 1 is taken out from the molding die 5 after the die is opened.
- the fender liner 1 may include a tapered surface 1c that is tapered toward the tire 2 side (inward in the radial direction of the tire 2).
- the tapered surface 1c makes it easy to remove the fender liner 1 from the lower mold 51 and suppresses damage during mold release.
- the tapered surface 1c is unnecessary. In this case, the mold is released while deforming the fender liner 1.
- the method for manufacturing the fender liner 1 may include steps other than steps S101 to S107 in FIG.
- the method for manufacturing the fender liner 1 may include a step of removing the fender liner 1 from the molding die 5 and then forming a water-repellent layer on the surface 1b of the fender liner 1 facing the tire 2.
- the water-repellent layer makes the water droplets scattered by the tire 2 slippery. Therefore, it is possible to suppress the remaining of water droplets and the formation of the ice film. If the ice film is not stretched, there will be no damage due to the peeling of the ice film.
- the water-repellent layer is formed of, for example, a fluorine-based, silicone-based, or a hydrocarbon-based coating agent having a low polarity such as polyethylene or polypropylene.
- the water repellent layer may have breathability. Compared to the case where the water-repellent layer does not have breathability, sound waves such as running noise of the tire 2 are more likely to enter the inside of the fender liner 1. Therefore, the reflection of sound waves can be suppressed.
- the breathable water repellent layer is formed, for example, by a spray coating method.
- the foam forms the first foam layer 11 and is included in the mixed layer 12.
- the foam may form not only the first foam layer 11 but also the second foam layer 14.
- the resin composition comprises a polyisocyanate, a polyol, a catalyst, and a foaming agent.
- the resin composition may further contain additives.
- the resin composition is usually prepared by mixing a system liquid containing a raw material other than polyisocyanate with polyisocyanate.
- polyisocyanate examples include toluene diisocyanate (TDI), diphenylmethane diisocyanate (MDI), polymethylene polyphenyl isocyanate (commonly known as crude MDI), xylylene diisocyanate (XDI), isophorone diisocyanate (IPDI) and hexamethylene diisocyanate (HMDI).
- TDI toluene diisocyanate
- MDI diphenylmethane diisocyanate
- MDI polymethylene polyphenyl isocyanate
- XDI xylylene diisocyanate
- IPDI isophorone diisocyanate
- HMDI hexamethylene diisocyanate
- the TDI may be any of 2,4-TDI and 2,
- polyol examples include polyoxyalkylene polyols and polyester polyols.
- Water can be used as the foaming agent, but the foaming agent is not limited to this.
- an inert compound having a low boiling point is preferable.
- examples of such an inert compound include an inert gas and a saturated hydrocarbon having a boiling point of 70 ° C. or lower and a carbon number of 8 or less, in which a hydrogen atom bonded to a carbon atom may be replaced with a halogen atom.
- the halogen atom is, for example, a chlorine atom or a fluorine atom.
- saturated hydrocarbons examples include butane, pentane, cyclopentane, hexane, dichloromethane (methylene chloride), trichloroethane and various freon compounds, but are not limited thereto. Further, one type of foaming agent may be used alone, or two or more types may be used in combination.
- the catalyst is at least one selected from the group consisting of amine-based catalysts and tin-based catalysts.
- One type of catalyst may be used alone, or two or more types may be used in combination.
- Examples of the amine-based catalyst include triethylenediamine, bis (2-dimethylaminoethyl) ether, N, N, N', N'-tetramethylhexamethylenediamine, N, N-dimethylaminoethoxyethoxyethanol, N, N.
- tin catalyst examples include tin 2-ethylhexanoate, di-n-butyl tin oxide, di-n-butyl tin dilaurate, di-n-butyl tin diacetate, di-n-octyl tin oxide, and di-n-octyl.
- tin dilaurate monobutyl tin trichloride, di-n-butyl tin dialkyl mercaptan and di-n-octyl tin dialkyl mercaptan.
- a defoaming agent may be contained.
- the defoaming agent include, but are not limited to, a silicone-based defoaming agent or a fluorine-containing compound-based defoaming agent.
- One type of defoaming agent may be used alone, or two or more types may be used in combination.
- a cross-linking agent may be contained as an additive.
- a compound having two or more active hydrogen-containing groups selected from a hydroxyl group, a primary amino group and a secondary amino group can be selected.
- the cross-linking agent include ethylene glycol, propylene glycol, 1,4-butanediol, neopentyl glycol, 1,6-hexanediol, diethylene glycol, triethylene glycol, dipropylene glycol, glycerin, trimethylolpropane, pentaerythritol and diglycerin.
- cross-linking agent the above-mentioned polyoxyalkylene polyol having a molecular weight / number of hydroxyl groups of less than 500 can also be used.
- One type of cross-linking agent may be used alone, or two or more types may be used in combination.
- Additives other than the above include emulsifiers, antioxidants, antiaging agents such as UV absorbers, fillers such as calcium carbonate or barium sulfate, plasticizers, colorants, flame retardants, antifungal agents, foam breakers and the like. Examples thereof include, but are not limited to, various known additives and auxiliaries, and additives conventionally used for polyurethane foam can be used.
- Examples 1 to 13 are examples.
- the same resin composition was used as the material of the foam.
- 109.3 parts by mass of the system liquid and 39.3 parts by mass of polyisocyanate (mixture of TDI and MDI, manufactured by Tosoh Corporation, trade name: Coronate 1021) are placed in a container and mixed with a high-speed mixer. , Prepared at room temperature.
- system liquid 60 parts by mass of a polyoxyalkylene polyol (manufactured by AGC, trade name: EXCENOL820), 40 parts by mass of another polyoxyalkylene polyol (manufactured by AGC, trade name: EXCENOL923), and water as a foaming agent.
- a polyoxyalkylene polyol manufactured by AGC, trade name: EXCENOL820
- another polyoxyalkylene polyol manufactured by AGC, trade name: EXCENOL923
- the above resin composition was injected, foamed, and solidified without installing the non-woven fabric in the internal space of the molding die in advance, and a test piece composed of only the foam was prepared.
- the evaluation results of the test piece are shown in Table 1.
- the tensile strength and tensile stress of the test piece were measured by pulling the test piece in the longitudinal direction orthogonal to the thickness direction with the precision universal testing machine Autograph AG-X plus manufactured by Shimadzu Corporation.
- the density of the test piece was the so-called bulk density, and was measured in accordance with JIS K7222: 2005 "Foam Plastics and Rubber-How to Obtain the Apparent Density".
- JIS K7222 2005 "Foam Plastics and Rubber-How to Obtain the Apparent Density”.
- the tensile strength, tensile stress, and density of the test piece were measured in the same manner.
- Example 1 to 13 in a state where the nonwoven fabrics shown in Tables 2 to 3 are previously installed in the internal space of the molding die, the above resin composition is injected, impregnated, foamed, and solidified, and a test consisting of a laminated body is performed. Pieces were made. The evaluation results of the test pieces are shown in Tables 2 to 3 and FIGS. 7 to 9.
- PEs + means that the nonwoven fabric contains polyester fibers and rayon fibers.
- the "strength improvement rate A” indicates the tensile strength of the laminated body after the composite as a percentage with respect to the tensile strength of the nonwoven fabric before the composite.
- the "strength improvement rate B” indicates the tensile strength of the laminated body after the compounding as a percentage with respect to the tensile strength of the foam before the compounding.
- the non-woven fabric was impregnated with the resin composition and composited. Therefore, as is clear from Tables 2 to 3 and FIGS. 8 to 9, the tensile strength of the laminated body after the compounding is the tensile strength of the foam before the compounding, and the tensile strength of the non-woven fabric before the compounding. I was able to improve.
- the fender liner 1 may contain a mesh instead of the non-woven fabric 6.
- the mixed layer 12 includes a mesh and foam foamed inside the mesh. That is, the mixed layer 12 is a composite of the mesh and the foam.
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Abstract
Description
2 タイヤ
11 第1発泡層
12 混合層
Claims (12)
- 車両のタイヤの外周に沿って湾曲状に配置されるフェンダーライナーであって、
第1発泡体で形成される第1発泡層と、
第1不織布と、前記第1不織布の内部で発泡した第2発泡体とを含む混合層と、を備え、
前記第1発泡層を形成する前記第1発泡体は、前記混合層に含まれる前記第2発泡体につながる、フェンダーライナー。 - 前記混合層を基準として前記第1発泡層とは反対側に、前記混合層の前記第1不織布につながる第2不織布で形成される不織布層を備える、請求項1に記載のフェンダーライナー。
- 前記混合層を基準として前記第1発泡層とは反対側に、前記混合層の前記第2発泡体につながる第3発泡体で形成される第2発泡層を備える、請求項1に記載のフェンダーライナー。
- 前記混合層の厚みが、0.15mm~5mmである、請求項1~3のいずれか1項に記載のフェンダーライナー。
- 前記混合層の密度が、前記第1発泡層の密度の4倍~10倍である、請求項1~4のいずれか1項に記載のフェンダーライナー。
- 前記第1発泡層を形成する前記第1発泡体は、ポリウレタン、ポリアクリル、メラミン、ゴム、ポリオレフィン、又はポリイミドを含む、請求項1~5のいずれか1項に記載のフェンダーライナー。
- 前記混合層に含まれる前記第1不織布は、ポリエステル繊維、ポリエチレン繊維、又はポリプロピレン繊維を含む、請求項1~6のいずれか1項に記載のフェンダーライナー。
- 請求項1~7のいずれか1項に記載のフェンダーライナーを製造する、フェンダーライナーの製造方法であって、
成形型の内部空間の一部に不織布を設置した状態で、前記内部空間に樹脂組成物を注入することと、
前記成形型の前記内部空間で、前記樹脂組成物を前記不織布に含浸させ、前記樹脂組成物を発泡させることと、
前記成形型の前記内部空間で発泡させた前記樹脂組成物を固化し、前記第1発泡層と前記混合層を成形することと、を含む、フェンダーライナーの製造方法。 - タイヤと、請求項1~7のいずれか1項に記載のフェンダーライナーと、を備えた、車両。
- 前記第1発泡層は、前記混合層を基準として前記タイヤとは反対側に配置される、請求項9に記載の車両。
- 前記フェンダーライナーの前記タイヤとの対向面に、撥水層を含む、請求項9または10に記載の車両。
- 前記撥水層は、通気性を有する、請求項11に記載の車両。
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EP21891657.5A EP4245498A1 (en) | 2020-11-11 | 2021-10-27 | Fender liner and manufacturing method thereof, and vehicle |
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JP2002275749A (ja) * | 2001-03-21 | 2002-09-25 | Unitika Ltd | 積層不織布および不織布補強ウレタンフォーム |
JP2009298339A (ja) * | 2008-06-16 | 2009-12-24 | Hirotani:Kk | 自動車用路面側吸音フロアーアンダーカバー |
JP2015017339A (ja) | 2013-07-11 | 2015-01-29 | 直也 佐藤 | 耐着氷・防音緩衝材及びその製造方法並びにそれを用いた車両用外装材 |
JP2018171820A (ja) * | 2017-03-31 | 2018-11-08 | マツダ株式会社 | 機能性積層体およびその製造方法 |
JP2020188140A (ja) | 2019-05-15 | 2020-11-19 | 国立大学法人九州工業大学 | 希土類コバルト永久磁石及びその製造方法、並びにデバイス |
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JP2002275749A (ja) * | 2001-03-21 | 2002-09-25 | Unitika Ltd | 積層不織布および不織布補強ウレタンフォーム |
JP2009298339A (ja) * | 2008-06-16 | 2009-12-24 | Hirotani:Kk | 自動車用路面側吸音フロアーアンダーカバー |
JP2015017339A (ja) | 2013-07-11 | 2015-01-29 | 直也 佐藤 | 耐着氷・防音緩衝材及びその製造方法並びにそれを用いた車両用外装材 |
JP2018171820A (ja) * | 2017-03-31 | 2018-11-08 | マツダ株式会社 | 機能性積層体およびその製造方法 |
JP2020188140A (ja) | 2019-05-15 | 2020-11-19 | 国立大学法人九州工業大学 | 希土類コバルト永久磁石及びその製造方法、並びにデバイス |
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