JP5284514B2 - Manufacturing method of duct for automobile - Google Patents

Manufacturing method of duct for automobile Download PDF

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JP5284514B2
JP5284514B2 JP2012112135A JP2012112135A JP5284514B2 JP 5284514 B2 JP5284514 B2 JP 5284514B2 JP 2012112135 A JP2012112135 A JP 2012112135A JP 2012112135 A JP2012112135 A JP 2012112135A JP 5284514 B2 JP5284514 B2 JP 5284514B2
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synthetic resin
resin sheet
porous body
duct
automobile
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JP2012158186A (en
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輝男 白石
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Inoac Corp
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  • Air-Conditioning For Vehicles (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
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Description

この発明は、自動車用ダクトの製造方法に関する。   The present invention relates to a method for manufacturing an automobile duct.

従来、エンジンの吸気ダクトやエアコンのエアダクト等として用いられる自動車用ダクトの製造方法として、次のものが知られている。例えば、熱可塑性バインダーを含む不織布を加熱プレスして断面略凹状の半体に賦形し、前記半体同士をその側部で接合しで自動車用ダクトを製造する方法や、不織布の片面にフィルムを積層して加熱プレス等で断面略凹状の半体に賦形し、次に前記プラスチックフィルムが外側となるようにして前記半体同士をその側部で接合して自動車用ダクトを製造する方法、あるいは、プラスチック製中空筒状体の成形方法として多用されているブロー成形法による自動車用ダクトの製造方法などがある。   Conventionally, the following is known as a manufacturing method of an automobile duct used as an intake duct for an engine, an air duct for an air conditioner, or the like. For example, a non-woven fabric containing a thermoplastic binder is heated and pressed to form a half body with a substantially concave cross section, and the halves are joined to each other at the side to produce a duct for automobiles, or a film on one side of the non-woven fabric Is formed into a half body having a substantially concave cross section with a heating press or the like, and then the half bodies are joined to each other at the side so that the plastic film is on the outside. Alternatively, there is a method of manufacturing a duct for automobiles by a blow molding method that is frequently used as a method of molding a plastic hollow cylindrical body.

しかし、前記熱可塑性バインダーを含む不織布を加熱プレスする自動車用ダクトの製造方法は、不織布を軟化するまで加熱してプレスにより賦形するため、不織布の目付量が少ないと、剛性が不足してプレス時にコーナー部等で破れることがある。また、プレス時に不織布が破れるのを防ぐため、不織布の目付量を増大させると、加熱やプレス時の時間が長くなって成形時間が増大したり、自動車用ダクトの重量が増加したり、製品コストが増大したり、通気性の低下によって自動車用ダクトの吸音性能が低下したりする問題が発生するようになる。   However, the manufacturing method of the automobile duct for heating and pressing the nonwoven fabric containing the thermoplastic binder is heated until the nonwoven fabric is softened and shaped by pressing. Sometimes broken at corners. In order to prevent the nonwoven fabric from being broken during pressing, increasing the basis weight of the nonwoven fabric increases the time required for heating and pressing, increases the molding time, increases the weight of the duct for automobiles, and increases the product cost. Or the sound absorption performance of the automobile duct is lowered due to a decrease in air permeability.

一方、不織布の片面にフィルムを積層して加熱プレスする自動車用ダクトの製造方法は、プラスチックフィルムの積層によって製品コストが増大すると共に、通気性が殆ど無くなるため吸音性能が低下する問題がある。   On the other hand, the manufacturing method of an automobile duct in which a film is laminated on one side of a nonwoven fabric and heated and pressed has a problem that the product cost increases due to the lamination of the plastic film, and the air-absorbing property is almost lost, so that the sound absorbing performance is lowered.

また、ブロー成形法による自動車用ダクトの製造方法は、通気性の無い硬いプラスチックでダクトが構成されるため、吸音性や断熱性が低い問題がある。   Moreover, the manufacturing method of the duct for motor vehicles by a blow molding method has the problem that sound absorption property and heat insulation property are low, since the duct is made of hard plastic having no air permeability.

特開平１１−３４３９３８号公報JP-A-11-343938 特開２００２−３０２８５８号公報JP 2002-302858 A 特開平９−２６４４８７号公報JP-A-9-264487 特開昭６３−５３０２９号公報JP 63-53029 A

この発明は前記の点に鑑みなされたものであって、不織布や合成樹脂発泡体等の多孔質体を用いる自動車用ダクトの製造方法において、多孔質体の目付量や厚みを増大させることなくダクトの剛性を高めて製造時の破れを防ぎ、軽量で、通気量のコントロールが可能な自動車用ダクトを得ることができるようにすることを目的とする。   The present invention has been made in view of the above points, and in a method for manufacturing a duct for an automobile using a porous body such as a nonwoven fabric or a synthetic resin foam, the duct without increasing the basis weight or thickness of the porous body. An object of the present invention is to provide a duct for automobiles that can increase the rigidity of the sheet to prevent tearing during production, is lightweight, and can control the air flow rate.

請求項１の発明は、多数の貫通孔を有する合成樹脂シートと多孔質体を加熱し、前記合成樹脂シートと前記多孔質体を重ねて凹型と凸型でプレスすることにより一体化および賦形して断面略凹状のダクト半体を形成し、前記ダクト半体同士を凹面が内側となるように側部で接合して管状にする自動車用ダクトの製造方法であって、前記合成樹脂シートを前記多孔質体よりも融点の低いものとし、前記多孔質体上に前記合成樹脂シートを載置して前記加熱を行い、前記合成樹脂シートと前記多孔質体の加熱温度を、前記合成樹脂シートの融点以上であって前記多孔質体の融点より低くすることを特徴とする。   The invention of claim 1 integrates and shapes by heating a synthetic resin sheet having a large number of through-holes and a porous body, and pressing the synthetic resin sheet and the porous body in a concave shape and a convex shape. Forming a duct half body having a substantially concave cross-section, and joining the duct half bodies at the side portions so that the concave surfaces are on the inside to form a tubular shape, wherein the synthetic resin sheet is The melting point is lower than that of the porous body, the synthetic resin sheet is placed on the porous body, the heating is performed, and the heating temperature of the synthetic resin sheet and the porous body is set to the synthetic resin sheet. The melting point of the porous body is lower than the melting point of the porous body.

請求項１の発明によれば、多数の貫通孔を有する合成樹脂シートと多孔質体を加熱し、合成樹脂シートと多孔質体を重ねて凹型と凸型でプレスすることにより一体化および賦形して断面略凹状のダクト半体を形成し、ダクト半体同士を凹面が内側となるように側部で接合して管状にするため、プレスにより合成樹脂シートと多孔質体を一体化および賦形する際には、多孔質体のみの場合と比べて合成樹脂シートの存在によって剛性が高くなることから、多孔質体の厚みを増大させたり、多孔質体として不織布を用いる場合に不織布の目付量を過度に増大させたりしなくても、コーナー部等で破れるのを防ぐことができ、自動車用ダクトを品質が良好で軽量なものにすることができる。さらに、請求項１の発明によれば、製造された自動車用ダクトは、合成樹脂シートが多数の貫通孔を有するため、合成樹脂シートの貫通孔部分で多孔質体を介して通気性を確保することができ、その通気性によって吸音性を良好なものとすることができる。しかも、貫通孔のサイズや数によって自動車用ダクトの通気性をコントロールすることが可能である。   According to the first aspect of the present invention, the synthetic resin sheet having a large number of through-holes and the porous body are heated, and the synthetic resin sheet and the porous body are stacked and pressed in a concave shape and a convex shape, thereby integrating and shaping. In order to form duct halves having a substantially concave cross section and to join the duct halves at the sides with the concave surfaces on the inside to form a tube, the synthetic resin sheet and the porous body are integrated and applied by pressing. When forming, since the rigidity is increased by the presence of the synthetic resin sheet compared to the case of only the porous body, the thickness of the porous body is increased, or when the nonwoven fabric is used as the porous body, the weight of the nonwoven fabric is increased. Even if the amount is not increased excessively, it can be prevented from being broken at the corners and the like, and the automobile duct can be made of good quality and light weight. Furthermore, according to the invention of claim 1, since the synthetic resin sheet has a large number of through holes in the manufactured automobile duct, air permeability is ensured through the porous body at the through hole portion of the synthetic resin sheet. And the sound absorption can be improved by the air permeability. In addition, the air permeability of the automobile duct can be controlled by the size and number of the through holes.

また、請求項１の発明によれば、合成樹脂シートを多孔質体よりも融点の低いものとし、多孔質体上に合成樹脂シートを載置して加熱を行い、合成樹脂シートと多孔質体の加熱温度を、合成樹脂シートの融点以上であって多孔質体の融点より低くするため、多孔質体の溶融変形を生じるのを防ぐことができ、多孔質体の溶融変形による通気性及び吸音性の低下を防止することができる。さらに、加熱により融点よりも高い温度になっている合成樹脂シートは、加熱により融点よりも低い温度になっている多孔質体上に載置されているため、合成樹脂シートを多孔質体が下から支えて合成樹脂シートが自重で変形するのを防止することができ、凹型５７と凸型５９の間に合成樹脂シートと前記多孔質体を正しく配置することができる。   According to the invention of claim 1, the synthetic resin sheet has a lower melting point than the porous body, the synthetic resin sheet is placed on the porous body and heated, and the synthetic resin sheet and the porous body are heated. Since the heating temperature is higher than the melting point of the synthetic resin sheet and lower than the melting point of the porous body, the porous body can be prevented from being melted and deformed. The fall of property can be prevented. Furthermore, since the synthetic resin sheet having a temperature higher than the melting point by heating is placed on the porous body having a temperature lower than the melting point by heating, the synthetic resin sheet is placed below the synthetic resin sheet. Therefore, the synthetic resin sheet can be prevented from being deformed by its own weight, and the synthetic resin sheet and the porous body can be correctly disposed between the concave mold 57 and the convex mold 59.

本発明の製造方法により製造された一実施形態に係る自動車用ダクトを示す斜視図である。It is a perspective view which shows the duct for motor vehicles based on one Embodiment manufactured with the manufacturing method of this invention. 図１の自動車用ダクトの一部を示す斜視図である。It is a perspective view which shows a part of duct for motor vehicles of FIG. 図２の３−３断面図である。FIG. 3 is a cross-sectional view taken along the line 3-3 in FIG. 2. 合成樹脂シートと多孔質体の斜視図である。It is a perspective view of a synthetic resin sheet and a porous body. 製造装置の概略図である。It is the schematic of a manufacturing apparatus. プレス時を示す断面図である。It is sectional drawing which shows the time of a press. ダクト半体同士の接合時を示す断面図である。It is sectional drawing which shows the time of joining of duct halves.

以下この発明の実施形態を詳細に説明する。図１は本発明の製造方法により製造された一実施形態に係る自動車用ダクトを示す斜視図、図２は図１の自動車用ダクトの一部を示す斜視図、図３は図２の３−３断面図、図４は合成樹脂シートと多孔質体の斜視図、図５は製造装置の概略図、図６はプレス時を示す断面図、図７はダクト半体同士の接合時を示す断面図である。   Hereinafter, embodiments of the present invention will be described in detail. FIG. 1 is a perspective view showing an automobile duct according to an embodiment manufactured by the manufacturing method of the present invention, FIG. 2 is a perspective view showing a part of the automobile duct of FIG. 1, and FIG. 3 is a cross-sectional view, FIG. 4 is a perspective view of a synthetic resin sheet and a porous body, FIG. 5 is a schematic view of a manufacturing apparatus, FIG. 6 is a cross-sectional view showing the time of pressing, and FIG. FIG.

図１から図３に示す自動車用ダクト１０は、本発明の製造方法により製造されたものであって、断面略凹状の半体１１同士が凹面１１ａを内側となるようにして側部のフランジ部１２で接合された管状体からなり、前記管状体の内側が空気流通路１７（図３に示す）とされている。前記フランジ部１２の接合は融着等で行われている。なお、前記自動車用ダクト１０は、自動車用ダクト１０が装着される自動車に応じて適宜の断面形状及び屈曲形状とされる。   The automobile duct 10 shown in FIG. 1 to FIG. 3 is manufactured by the manufacturing method of the present invention. 12, and the inside of the tubular body is an air flow passage 17 (shown in FIG. 3). The flange 12 is joined by fusion or the like. The automobile duct 10 has an appropriate cross-sectional shape and bent shape depending on the automobile to which the automobile duct 10 is mounted.

前記半体１１は、多数の貫通孔２２を有する合成樹脂シート２１の片面に多孔質体３１が積層一体化された積層体４１から形成されている。図４に前記多数の貫通孔２２を有する合成樹脂シート２１を示す。前記多数の貫通孔２２を有する合成樹脂シート２１は、合成樹脂シートに多数の貫通孔２２が所定間隔で形成されたものであって、合成樹脂製網状体（あるいはネット）とも称される。前記合成樹脂シート２１と前記多孔質体３１は、加熱されてプレスされることによって一体化および賦形されている。   The half body 11 is formed of a laminated body 41 in which a porous body 31 is laminated and integrated on one surface of a synthetic resin sheet 21 having a large number of through holes 22. FIG. 4 shows a synthetic resin sheet 21 having the numerous through holes 22. The synthetic resin sheet 21 having a large number of through holes 22 is a synthetic resin sheet in which a large number of through holes 22 are formed at predetermined intervals, and is also referred to as a synthetic resin net (or net). The synthetic resin sheet 21 and the porous body 31 are integrated and shaped by being heated and pressed.

前記貫通孔２２は、合成樹脂シートの製造時に形成されたものであっても、あるいは合成樹脂シートの製造後にパンチング加工等によって形成されたものでもよい。前記貫通孔２２の形状、大きさおよび数は、適宜とされるが、例として一辺３〜１０ｍｍ程度の正方形からなり、貫通孔の中心間隔が５〜１０ｍｍ程度の場合を挙げる。   The through hole 22 may be formed at the time of manufacturing the synthetic resin sheet, or may be formed by punching or the like after manufacturing the synthetic resin sheet. The shape, size, and number of the through-holes 22 are appropriately determined. As an example, a case where the through-holes 22 are formed of a square having a side of about 3 to 10 mm and the center interval between the through-holes is about 5 to 10 mm is given.

前記合成樹脂シート２１の厚みは、前記半体１１を成形する際の成形性や、自動車用ダクト１０における剛性等を考慮して決定されるが、例として、１〜４ｍｍ程度の厚みを挙げる。   The thickness of the synthetic resin sheet 21 is determined in consideration of moldability when the half body 11 is molded, rigidity in the automobile duct 10, and the like. As an example, the thickness is about 1 to 4 mm.

前記合成樹脂シート２１の材質は、ポリエチレン、ポリプロピレン等の熱可塑性合成樹脂とされ、融点が前記多孔質体３１の融点よりも低いものが好ましい。前記合成樹脂シート２１の融点を前記多孔質体３１の融点よりも低くすれば、加熱してプレスにより前記半体１１を成形する際に、加熱温度を前記合成樹脂シート２１の融点以上で前記多孔質体３１の融点より低い温度とすれば、プレス時に前記多孔質体３１が溶融変形して多孔質性が損なわれ、それにより多孔質体の通気性や吸音性、すなわちダクトの通気性や吸音性が低下するのを防止することができる。また、前記合成樹脂シート２１の合成樹脂は、多孔質体３１内に入り込んで多孔質体３１の骨格や繊維にからまり、それにより前記合成樹脂シート２１と多孔質体３１の積層一体化が強固となっている。   The synthetic resin sheet 21 is made of a thermoplastic synthetic resin such as polyethylene or polypropylene, and preferably has a melting point lower than that of the porous body 31. If the melting point of the synthetic resin sheet 21 is lower than the melting point of the porous body 31, when the half body 11 is molded by heating and pressing, the heating temperature is equal to or higher than the melting point of the synthetic resin sheet 21. If the temperature is lower than the melting point of the material 31, the porous material 31 is melted and deformed at the time of pressing to impair the porous property, whereby the air permeability and sound absorbing property of the porous material, that is, the air permeability and sound absorbing property of the duct. It is possible to prevent the performance from deteriorating. Further, the synthetic resin of the synthetic resin sheet 21 enters the porous body 31 and becomes entangled with the skeleton and fibers of the porous body 31, whereby the synthetic integration of the synthetic resin sheet 21 and the porous body 31 is strong. It has become.

前記多孔質体３１は、不織布や連通気泡構造の合成樹脂発泡体等からなる。前記連通気泡構造の合成樹脂発泡体の一例としてポリウレタン発泡体を挙げる。前記多孔質体３１の厚みは、材質によって異なるが、例として１〜５ｍｍ程度を挙げる。また、前記多孔質体３１は、図３に示すように、前記合成樹脂シート２１の貫通孔２２の位置で貫通孔２２内に入り込んで他の位置よりも厚みが大になっている。この構成によって、ダクト内の音が前記貫通孔２２の位置で多孔質体３１を通って外部へ漏れるのを抑えることができると共に、吸音性を高めることができる。また、前記多孔質体３１が前記合成樹脂シート２１の貫通孔２２の位置で貫通孔２２内に入り込んでいることにより、前記多孔質体３１と合成樹脂シート２１の一体性が高く、自動車用ダクト１０の管壁の剛性を高くすることができる。   The porous body 31 is made of a non-woven fabric or a synthetic resin foam having an open cell structure. An example of the synthetic resin foam having the open cell structure is a polyurethane foam. Although the thickness of the porous body 31 varies depending on the material, about 1 to 5 mm is given as an example. Further, as shown in FIG. 3, the porous body 31 enters the through hole 22 at the position of the through hole 22 of the synthetic resin sheet 21 and is thicker than other positions. With this configuration, the sound in the duct can be prevented from leaking to the outside through the porous body 31 at the position of the through hole 22, and the sound absorption can be enhanced. Further, since the porous body 31 enters the through hole 22 at the position of the through hole 22 of the synthetic resin sheet 21, the integrity of the porous body 31 and the synthetic resin sheet 21 is high, and the duct for automobiles. The rigidity of the ten tube walls can be increased.

さらに、前記多孔質体３１は、前記合成樹脂シート２１の貫通孔２２の位置で非圧縮あるいは他の位置よりも圧縮程度が低くされ、これにより、前記合成樹脂シート２１の貫通孔２２の位置では他の位置よりも前記多孔質体３１の密度が粗に（不織布にあっては繊維間が粗く、一方、発泡体にあっては密度が低く）なっている。そのため、前記多孔質体３１の厚みが前記合成樹脂シート２１の貫通孔２２の位置で大になっていても、吸音性を良好にするのに必要となる通気性が不足するのを防ぐことができる。   Furthermore, the porous body 31 is uncompressed at the position of the through hole 22 of the synthetic resin sheet 21 or is compressed to a lower degree than the other positions, whereby the position of the through hole 22 of the synthetic resin sheet 21 is reduced. The density of the porous body 31 is coarser than the other positions (in the case of a nonwoven fabric, the spacing between fibers is coarse, whereas in the case of a foam, the density is low). Therefore, even if the thickness of the porous body 31 is large at the position of the through hole 22 of the synthetic resin sheet 21, it is possible to prevent a shortage of air permeability necessary to improve sound absorption. it can.

前記自動車用ダクト１０において、前記合成樹脂シート２１はダクトの内側、前記多孔質体３１はダクトの外側とされるのが好ましい。この構成により、前記合成樹脂シート２１の貫通孔２２部分でのみ多孔質体３１がダクト内に露出していることになり、ダクト内を空気が通過する際に多孔質体３１表面の凹凸と接触することによる空気の通過抵抗増大を抑えることができ、ダクト内の空気の流れを良好にすることができる。   In the automobile duct 10, it is preferable that the synthetic resin sheet 21 is inside the duct and the porous body 31 is outside the duct. With this configuration, the porous body 31 is exposed in the duct only at the through-hole 22 portion of the synthetic resin sheet 21, and contact with the irregularities on the surface of the porous body 31 when air passes through the duct. It is possible to suppress an increase in the air passage resistance due to this, and to improve the flow of air in the duct.

前記自動車用ダクト１０の製造方法について説明する。前記自動車用ダクト１０の製造方法は、加熱工程、プレス工程および半体接合工程とよりなる。   A method for manufacturing the automobile duct 10 will be described. The manufacturing method of the automobile duct 10 includes a heating process, a pressing process, and a half body bonding process.

前記自動車用ダクト１０の製造に用いる製造装置の一例を図５に示す。図５に示す製造装置５１は、前記半体１１を連続的に製造するためのものであって、前記多数の貫通孔２２を有する合成樹脂シート２１と前記多孔質体３１を一方向へ供給する供給手段５３と、前記合成樹脂シート２１と前記多孔質体３１の供給途中に設けた加熱手段５５と、前記加熱手段５５よりも前記合成樹脂シート２１と前記多孔質体３１の進行方向前方に設けた凹型５７と凸型５９とよりなる。なお、前記供給手段５３は、図示の例では駆動モータ（図示せず）で一方向へ回転するようにされた駆動ローラで構成され、前記駆動ローラ上に載置された前記合成樹脂シート２１と前記多孔質体３１を駆動ローラの回転方向へ供給する。   An example of a manufacturing apparatus used for manufacturing the automobile duct 10 is shown in FIG. A manufacturing apparatus 51 shown in FIG. 5 is for continuously manufacturing the half body 11 and supplies the synthetic resin sheet 21 having the numerous through holes 22 and the porous body 31 in one direction. A supply means 53; a heating means 55 provided in the middle of supplying the synthetic resin sheet 21 and the porous body 31; and a forward direction of the synthetic resin sheet 21 and the porous body 31 relative to the heating means 55. It consists of a concave mold 57 and a convex mold 59. In the illustrated example, the supply means 53 is configured by a drive roller that is rotated in one direction by a drive motor (not shown), and the synthetic resin sheet 21 placed on the drive roller. The porous body 31 is supplied in the rotation direction of the drive roller.

前記多数の貫通孔２２を有する合成樹脂シート２１と前記多孔質体３１は、前記合成樹脂シート２１が前記多孔質体３１よりも融点の低いものとされ、融点の高い前記多孔質体３１上に融点の高い前記合成樹脂シート２１が載置されて一方向へ供給される。   The synthetic resin sheet 21 having the numerous through-holes 22 and the porous body 31 are such that the synthetic resin sheet 21 has a lower melting point than the porous body 31, and is on the porous body 31 having a higher melting point. The synthetic resin sheet 21 having a high melting point is placed and supplied in one direction.

前記加熱手段５５の位置では加熱工程が行われる。前記加熱工程では、少なくとも前記合成樹脂シート２１を加熱する。前記加熱手段５５は、電気ヒーター等、適宜の加熱装置で構成され、図示のように前記合成樹脂シート２１と前記多孔質体３１を挟むように上下に配置して、前記合成樹脂シート２１と前記多孔質体３１の両方を加熱する他、前記合成樹脂シート２１側のみを加熱するように片側（上側）のみに配置してもよい。前記加熱手段５５による加熱温度は、前記合成樹脂シート２１の融点以上で前記多孔質体３１の融点より低く設定され、前記多孔質体３１が溶融変形しないようにされる。前記加熱された合成樹脂シート２１と前記多孔質体３１は、前記凹型５７と凸型５９の位置に供給される。
その供給時、前記加熱により融点よりも高い温度になっている前記合成樹脂シート２１は、前記加熱により融点よりも低い温度になっている前記多孔質体３１上に載置されているため、前記合成樹脂シート２１を多孔質体３１が下から支えて合成樹脂シート２１が自重で変形するのを防止することができ、前記凹型５７と凸型５９の間に前記合成樹脂シート２１と前記多孔質体３１を正しく配置することができる。 A heating step is performed at the position of the heating means 55. In the heating step, at least the synthetic resin sheet 21 is heated. The heating means 55 is composed of an appropriate heating device such as an electric heater, and is arranged vertically so as to sandwich the synthetic resin sheet 21 and the porous body 31 as shown in the figure, and the synthetic resin sheet 21 and the In addition to heating both of the porous bodies 31, they may be arranged only on one side (upper side) so as to heat only the synthetic resin sheet 21 side. The heating temperature by the heating means 55 is set to be higher than the melting point of the synthetic resin sheet 21 and lower than the melting point of the porous body 31 so that the porous body 31 is not melted and deformed. The heated synthetic resin sheet 21 and the porous body 31 are supplied to the positions of the concave mold 57 and the convex mold 59.
At the time of supply, the synthetic resin sheet 21 having a temperature higher than the melting point due to the heating is placed on the porous body 31 having a temperature lower than the melting point due to the heating. The synthetic resin sheet 21 can be supported by the porous body 31 from below and the synthetic resin sheet 21 can be prevented from being deformed by its own weight, and the synthetic resin sheet 21 and the porous sheet are interposed between the concave mold 57 and the convex mold 59. The body 31 can be arranged correctly.

前記プレス工程では、コールドプレスが行われる。すなわち、図６に示すように、前記加熱工程で加熱された前記合成樹脂シート２１と前記多孔質体３１を重ねて前記凹型５７と前記凸型５９でプレスし、一体化及び賦形を行う。前記凹型５７は前記合成樹脂シート２１と前記多孔質体３１の下方に位置し、一方、前記凸型５９は上方に位置し、前記合成樹脂シート２１が前記凸型５９側へ向けて配置されると共に前記多孔質体３１が前記凹型５７側へ向けて配置され、前記凹型５７と前記凸型５９を接近させることにより、前記合成樹脂シート２１と前記多孔質体３１のプレスが行われる。前記凹型５７により、前記自動車用ダクト１０の外面側が形成され、前記凸型５９により自動車用ダクト１０の内面側が形成される。   In the pressing step, cold pressing is performed. That is, as shown in FIG. 6, the synthetic resin sheet 21 heated in the heating step and the porous body 31 are stacked and pressed with the concave mold 57 and the convex mold 59 to perform integration and shaping. The concave mold 57 is positioned below the synthetic resin sheet 21 and the porous body 31, while the convex mold 59 is positioned above, and the synthetic resin sheet 21 is disposed toward the convex mold 59. At the same time, the porous body 31 is arranged toward the concave mold 57 side, and the concave mold 57 and the convex mold 59 are brought close to each other, whereby the synthetic resin sheet 21 and the porous body 31 are pressed. The concave mold 57 forms the outer surface side of the automobile duct 10, and the convex mold 59 forms the inner surface side of the automobile duct 10.

前記プレスによって、前記合成樹脂シート２１における前記貫通孔２２以外の骨格部分２４（図４等に示す）では、前記多孔質体３１を前記骨格部分２４に圧接して圧縮する一方、前記貫通孔２２の部分では前記多孔質体３１を前記貫通孔２２内へ入り込ませて前記骨格部分２４に圧接している前記多孔質体３１の部分よりも圧縮程度を低く、あるいは非圧縮とする。これにより、前記合成樹脂シート２１における前記貫通孔２２以外の骨格部分２４では、前記合成樹脂シートの合成樹脂が前記多孔質体３１内に入り込んで前記多孔質体３１にからまり、前記合成樹脂シート２１と前記多孔質体３１の一体化が強固なものとなる。一方、前記合成樹脂シート２１における前記貫通孔２２の部分では、前記多孔質体３１が前記貫通孔２２以外の骨格部分２４よりも密度が粗になると共に厚みが大になる。   In the skeleton portion 24 (shown in FIG. 4 and the like) other than the through hole 22 in the synthetic resin sheet 21 by the pressing, the porous body 31 is pressed against the skeleton portion 24 and compressed, while the through hole 22 is compressed. In this part, the degree of compression is made lower or uncompressed than the part of the porous body 31 in which the porous body 31 enters the through-hole 22 and is in pressure contact with the skeleton portion 24. Thereby, in the skeleton part 24 other than the through hole 22 in the synthetic resin sheet 21, the synthetic resin of the synthetic resin sheet enters the porous body 31 and becomes entangled with the porous body 31. The integration of 21 and the porous body 31 becomes strong. On the other hand, in the portion of the through-hole 22 in the synthetic resin sheet 21, the porous body 31 becomes denser and thicker than the skeleton portion 24 other than the through-hole 22.

前記プレス工程後、前記凹型５７および凸型５９で賦形された部分の周囲を切断して断面略凹状の前記ダクト半体１１を得る。次いで、半体接合工程を行う。半体接合工程では、図７に示すように、前記ダクト半体１１同士を凹面１１ａが内側となって互いに対向するようにして側部のフランジ部１２で接合一体化し、図１に示す自動車用ダクト１０を得る。前記接合一体化は、二つのダクト半体１１におけるフランジ部１２を重ねて熱板７１でプレスする等してフランジ部１２を融着する方法等によって行われる。   After the pressing step, the periphery of the portion formed by the concave mold 57 and the convex mold 59 is cut to obtain the duct half body 11 having a substantially concave cross section. Next, a half body joining step is performed. In the half-body joining step, as shown in FIG. 7, the duct halves 11 are joined and integrated at the flange portion 12 on the side so that the concave surfaces 11a face each other, and are shown in FIG. A duct 10 is obtained. The joint integration is performed by a method of fusing the flange portions 12 by overlapping the flange portions 12 in the two duct halves 11 and pressing them with the hot plate 71.

なお、前記自動車用ダクトの製造は、図５のような連続製造装置を用いて連続して行うる方法に限定されず、所定寸法に裁断した合成樹脂シートおよび多孔質体を用いて、一個単位あるいは所定個数単位で製造する方法であってもよい。   The production of the automobile duct is not limited to a method of continuously performing using a continuous production apparatus as shown in FIG. 5, but using a synthetic resin sheet and a porous body cut to a predetermined size, one unit. Or the method of manufacturing by a predetermined number unit may be used.

以下、一実施例を具体的に示す。５ｍｍ×５ｍｍからなる正方形の貫通孔が７ｍｍ間隔（孔中心間隔）で形成された厚み２ｍｍのポリエチレン樹脂製合成樹脂シート（融点１３５℃）と、多孔質体として目付量５０ｇ／ｍ２、厚み１ｍｍの不織布（ＰＰ繊維、融点１６０℃）を用い、前記加熱温度を１４０℃とし、前記凹型を下側に位置させる一方、前記凸型を上側に位置させて、前記多孔質体上に前記合成樹脂シートを重ねて前記凹型と前記凸型でプレスして一体化及び賦形を行った。そして、賦形された部分の周囲を切断して断面略凹状のダクト半体を得た。次いで、前記ダクト半体同士を側部のフランジ部で重ねて、１８０℃の熱板でフランジ部をプレスして融着し、７５ｍｍ×８０ｍｍの四角形断面からなる長さ６００ｍｍの直管状自動車用ダクトを製造した。得られた自動車用ダクトは、コーナー部で破れが無く、軽量なものであった。 An example will be specifically described below. A 2 mm thick polyethylene resin synthetic resin sheet (melting point 135 ° C.) in which square through holes of 5 mm × 5 mm are formed at intervals of 7 mm (hole center interval), a basis weight of 50 g / m 2 as a porous body, and a thickness of 1 mm Non-woven fabric (PP fiber, melting point 160 ° C.), the heating temperature is 140 ° C., the concave mold is positioned on the lower side, and the convex mold is positioned on the upper side, and the synthetic resin is placed on the porous body. The sheets were stacked and pressed with the concave mold and the convex mold to perform integration and shaping. And the circumference | surroundings of the shaped part were cut | disconnected and the duct half body of cross-sectional substantially concave shape was obtained. Next, the duct halves are overlapped with each other on the side flange portion, and the flange portion is pressed and fused with a hot plate at 180 ° C., and a straight tubular automobile duct having a square cross section of 75 mm × 80 mm and having a length of 600 mm. Manufactured. The obtained automobile duct was lightweight without tearing at the corners.

１０ 自動車用ダクト
１１ ダクト半体
１２ フランジ部
２１ 合成樹脂シート
２２ 貫通孔
３１ 多孔質体
５５ 加熱手段
５７ 凹型
５９ 凸型 DESCRIPTION OF SYMBOLS 10 Automotive duct 11 Duct half body 12 Flange part 21 Synthetic resin sheet 22 Through-hole 31 Porous body 55 Heating means 57 Concave type 59 Convex type

Claims (1)

多数の貫通孔を有する合成樹脂シートと多孔質体を加熱し、
前記合成樹脂シートと前記多孔質体を重ねて凹型と凸型でプレスすることにより一体化および賦形して断面略凹状のダクト半体を形成し、
前記ダクト半体同士を凹面が内側となるように側部で接合して管状にする自動車用ダクトの製造方法であって、
前記合成樹脂シートを前記多孔質体よりも融点の低いものとし、
前記多孔質体上に前記合成樹脂シートを載置して前記加熱を行い、
前記合成樹脂シートと前記多孔質体の加熱温度を、前記合成樹脂シートの融点以上であって前記多孔質体の融点より低くすることを特徴とする自動車用ダクトの製造方法。 Heat the synthetic resin sheet having a large number of through holes and the porous body,
The synthetic resin sheet and the porous body are stacked and pressed with a concave mold and a convex mold to form a duct half having a substantially concave cross section by integrating and shaping,
A method for manufacturing a duct for an automobile, in which the duct halves are tubularly joined to each other so that the concave surfaces are inside,
The synthetic resin sheet has a lower melting point than the porous body,
Place the synthetic resin sheet on the porous body and perform the heating,
A method for manufacturing a duct for an automobile, wherein a heating temperature of the synthetic resin sheet and the porous body is equal to or higher than a melting point of the synthetic resin sheet and lower than a melting point of the porous body.
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