Sheet, door hole seal and method for manufacturing the same

Abstract

The present invention reduces the generation of abnormal noise caused by vibration of a part of a sheet. The first sheet (100) includes a peripheral portion (20) surrounding a repair hole (P1) of a door inner panel (P) and a middle side portion (10) surrounded by the peripheral portion (20). A plurality of first holes (30) and second holes (40) having a size different from that of the first holes (30) are respectively formed along the boundary between the middle side portion (10) and the peripheral portion (20).

Description

Technical Field

[0001] The present invention relates to a sheet material for constituting a part of a door hole seal material attached to a door inner panel of a vehicle door, a door hole seal material including the sheet material and a sound insulating material, and a method for manufacturing the same. Background Art

[0002] Generally speaking, a vehicle door is mainly composed of: a door outer panel arranged on the vehicle outer side; a door trim; and a door inner panel arranged between the door outer panel and the door trim. In addition, a door hole seal is conventionally installed between the door inner panel and the door trim.

[0003] Furthermore, in recent years, in order to block the sound from outside the vehicle, a foamed body of an elastic body such as EPDM is sometimes used as a door hole seal (see Patent Document 1). Figure 7 The figure shown by reference numeral 702 is a schematic diagram showing the structure of this type of door hole seal. Figure 7 As shown, this type of door hole seal comprises a first sheet 1000 and a second sheet 2000. In addition, the first sheet 1000 is welded to the second sheet 2000 via a welding portion 1200. Figure 7 The figure indicated by reference numeral 701 is a schematic diagram showing the structure of the first sheet material 1000 before attachment to the vehicle door. Before attachment to the vehicle door, the first sheet material 1000 includes a peripheral portion 1020 surrounding the maintenance hole in the door inner panel and a central portion 1010 surrounded by the peripheral portion 1020. An annular perforation line 1040 is formed between the central portion 1010 and the peripheral portion 1020. Furthermore, the second sheet material 2000 is primarily composed of a foamed elastomer such as EPDM.

[0004] The door hole seal is constructed as follows: when or before installation, it is cut on the perforation line 1040, thereby extracting the middle side portion 1010 and leaving the peripheral portion 1020 on the door body. Figure 7 In the figure shown by reference numeral 702, the middle side portion 1010 and the peripheral portion 1020 are disconnected along the perforated line 1040, thereby extracting the middle side portion 1010. Figure 7 In the figure shown by the reference numeral 702, the perforation line 1040 is not visible. In addition, the door hole seal disclosed in Patent Document 2 has the same Figure 7 The door hole seal shown in the figure with reference numeral 702 has the same construction as that of the figure.

[0005] Prior art literature

[0006] Patent Literature

[0007] Patent Document 1: Japanese Patent Gazette "Patent No. 3890568 Specification"

[0008] Patent Document 2: Japanese Patent Gazette "Specification of Patent No. 2636596" Summary of the Invention

[0009] Problems to be Solved by the Invention

[0010] Next, the figure shown by reference numeral 703 and reference numeral 704 is a front view sectional view of the A-A section of the door hole seal of the figure shown by reference numeral 702. As Figure 7 shown, the middle side (lower side with respect to the paper surface) of the welded portion 1200 of the first sheet 1000 is the unwelded portion 600. Therefore, as shown in the figure shown by reference numeral 704 of Figure 7 (description), the unwelded portion 600 (a part of the first sheet 1000) of the door hole seal vibrates due to the vibration of the vehicle and the vibration of the speaker, interfering with the door inner panel P, and thus abnormal noise is likely to be generated. In addition, as described above, the door hole seal disclosed in the Patent Document 2 has the same structure as the door hole seal of the figure shown by reference numeral 702, and thus there is the same problem as the door hole seal of the figure shown by reference numeral 702. Figure 7 (description continues)

[0011] One aspect of the present invention has been completed in view of the above problems, and an object thereof is to provide a sheet, a door hole seal, and a manufacturing method thereof that can reduce the generation of abnormal noise caused by the vibration of a part of the sheet.

[0012] Means for Solving the Problems

[0013] In order to solve the above problems, a sheet according to one aspect of the present invention is a sheet for forming a part of a door hole seal for mounting on a door inner panel of a vehicle door, and includes a peripheral portion surrounding a repair hole of the door inner panel and a middle portion surrounded by the peripheral portion. Along the boundary between the middle portion and the peripheral portion, a plurality of first holes and second holes having a size different from that of the first holes are respectively formed.

[0014] In order to solve the above problems, a door hole seal according to one aspect of the present invention is a door hole seal for mounting on a door inner panel of a vehicle door, and includes: a sheet formed with an opening surrounding a repair hole formed in the door inner panel; and a sound insulation material welded to the sheet for blocking the repair hole from the vehicle interior side. The inner peripheral wall of the opening formed in the sheet has a plurality of concave and convex shapes in a top view.

[0015] In order to solve the above problems, a manufacturing method of a door hole seal according to one aspect of the present invention is a manufacturing method of a door hole seal installed on an inner door panel of a vehicle door, including the following steps: a hole forming step of forming a plurality of first holes and second holes having a size different from that of the first holes in a sheet material that forms a part of the door hole seal, thereby forming a peripheral portion surrounding a repair hole of the inner door panel and a middle portion surrounded by the peripheral portion in the sheet material; a welding step of welding a sound insulation material in the sheet material in which the plurality of first holes and the second holes are respectively formed, so as to cover the middle portion from the vehicle interior side through the sound insulation material; and a drawing step of drawing out the middle portion from the sheet material to which the sound insulation material is welded.

[0016] Advantages of the Invention

[0017] According to one aspect of the present invention, the generation of abnormal noise caused by the vibration of a part of the sheet material can be reduced. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 FIG. is a view showing the inner structure of the front door on which the door hole seal of Embodiment 1 of the present invention is installed.

[0019] Figure 2 FIG. is a plan view of a sheet material constituting the door hole seal of Embodiment 1 of the present invention.

[0020] Figure 3 FIG. is a plan view of the door hole seal of Embodiment 1 of the present invention.

[0021] Figure 4 FIG. is a partial enlarged view of a part of a partially enlarged peripheral portion of the sheet material.

[0022] Figure 5 In FIG., the figure indicated by reference numeral 501 is Figure 3 a front view sectional view of the B-B section shown in FIG., and the figure indicated by reference numeral 502 is Figure 3 a front view sectional view of the C-C section shown in FIG.

[0023] Figure 6 FIG. is a plan view of a sheet material constituting the door hole seal of Embodiment 2 of the present invention.

[0024] Figure 7 In FIG., the figure indicated by reference numeral 701 is a schematic view showing the structure of a sheet material constituting a conventional door hole seal, the figure indicated by reference numeral 702 is a schematic view showing the structure of a conventional door hole seal, and the figures indicated by reference numerals 703 and 704 are front view sectional views of the A-A section of the figure indicated by reference numeral 702. DETAILED DESCRIPTION OF THE INVENTION

[0025] 〔Embodiment 1〕

[0026] Hereinafter, an embodiment of the present invention will be described in detail using Figures 1 to 5 .

[0027] <Installation example of door hole sealant>

[0028] First, with reference to Figure 1 , the structure on the inner side of the front door (vehicle door) D where the door hole sealant 300 of an embodiment of the present invention is installed will be described. In addition, in the example of Figure 1 , facing the paper surface, the right side corresponds to the front side, and the left side corresponds to the rear side.

[0029] As Figure 1 shows, the front door D that is switchably provided in the opening for the front door of the vehicle (not shown) includes an outer door panel (not shown) and an inner door panel P. A repair hole P1 for installing, repairing the glass or the regulator is formed in the inner door panel P.

[0030] In the inner door panel P, the door hole sealant 300 is installed by an adhesive such as butyl sealant (not shown). The door hole sealant 300 blocks the repair hole P1 formed in the inner door panel P from the inner side of the vehicle, thereby preventing rainwater or the like that has entered between the door glass (not shown) and the outer door panel from further entering the vehicle through the repair hole P1.

[0031] In addition, the installation of the above-mentioned door hole sealant 300 is only an example. For example, the door hole sealant 300 can also be installed on the rear door (not shown). In this way, there is no limitation on the type of the vehicle door on which the door hole sealant of an embodiment of the present invention is installed. In addition, for the vehicle that is the installation object of the door hole sealant of an embodiment of the present invention, it can also be a hardtop vehicle or a convertible vehicle, etc., and there is no limitation on the type.

[0032] <Structure of the first sheet>

[0033] Next, based on Figures 2 to 5 , the structure of the first sheet (sheet) 100 and the door hole sealant 300 of an embodiment of the present invention will be described. The first sheet 100 is a sheet that forms a part of the door hole sealant 300 installed on the inner door panel P of the front door D. The first sheet 100 of the present embodiment is made of a transparent resin material.

[0034] As Figure 2As shown, the first sheet 100 includes a peripheral portion 20 and a middle portion 10 surrounded by the peripheral portion 20. The peripheral portion 20 is the portion surrounding the repair hole P1 formed in the inner door panel P. In addition, in the first sheet 100, a plurality of first holes 30 and second holes 40 having a size different from that of the first holes 30 are respectively formed along the boundary between the middle portion 10 and the peripheral portion 20. In addition, the first holes 30 are holes larger than the second holes 40.

[0035] Here, the first hole 30 is a hole for extracting the middle portion 10 from the first sheet 100, and in the present embodiment, it is a substantially rectangular hole. In addition, the shape of the first hole 30 is not limited to a substantially rectangular shape, and it may be a hole of various shapes. On the other hand, the second hole 40 is a hole for disconnecting the middle portion 10 from the peripheral portion 20. For example, a plurality of small holes are arranged along the boundary between the middle portion 10 and the peripheral portion 20. In the present embodiment, a plurality of second holes 40 are present between adjacent first holes 30, but the configuration is not limited to this. For example, as long as at least one smaller second hole 40 is present between adjacent first holes 30.

[0036] According to the above-described configuration, when disconnecting the middle portion 10 from the peripheral portion 20 and extracting the middle portion 10 from the first sheet 100, the vicinity of the first hole 30 is a range where there is no unwelded portion 60 of the first sheet 100 (refer to the figure shown by reference numeral 502 in Figure 5 ). Therefore, the range occupied by the unwelded portion 60 of the entire first sheet 100 becomes smaller, and thus the generation of abnormal noise caused by the vibration of a part (unwelded portion 60) of the first sheet 100 can be reduced.

[0037] In addition, preferably, as shown in Figure 2 , the first holes 30 and the second holes 40 are alternately arranged along the boundary between the middle portion 10 and the peripheral portion 20. Thus, compared with the case where the first holes 30 and the second holes 40 are not alternately arranged, it is easier to extract the middle portion 10 from the first sheet 100. In other words, preferably, as shown in Figure 2 , one or more second holes 40 are arranged along the boundary between the middle portion 10 and the peripheral portion 20 between a specific first hole 30 among the plurality of first holes 30 and the first hole 30 adjacent to the first hole 30. Thus, compared with the case where the second holes 40 are not arranged between adjacent first holes 30, it is easier to extract the middle portion 10 from the first sheet 100.

[0038] <Structure of door hole seal>

[0039] Next, based on Figure 3 , an embodiment of the door hole seal 300 of the present invention will be described. As described above, the door hole seal 300 is installed on the inner door panel P of the front door D. In addition, as shown inFigure 3 As shown, the door hole seal 300 includes a first sheet 100 and a second sheet (sound insulation material) 200 (refer to Figure 5 ).

[0040] The first sheet 100 is a sheet formed with an opening 50 that surrounds a repair hole P1 formed in the door inner panel P. On the other hand, the second sheet 200 is a sheet welded to the first sheet 100 and used to block the repair hole P1 from the vehicle interior.

[0041] As the material of the second sheet 200, elastomers such as ethylene-propylene-diene terpolymer rubber (EPDM) and other rubbers are listed. In addition, for example, it can also be resins such as polyethylene (PE), polypropylene (PP), polyvinyl alcohol (PVA), and ABS (acrylonitrile-butadiene-styrene), and thermoplastic elastomers (TPE). Moreover, these rubbers, resins, or thermoplastic elastomers can be foams, fibers, or composites thereof, or composites with other materials.

[0042] In addition, as Figure 3 shown, the inner peripheral wall of the opening 50 forming the first sheet 100 has a plurality of concave and convex shapes in a top view. The vicinity of the concave part of the concave and convex shape is a range where there is no unwelded part 60 of the first sheet 100 (refer to Figure 5 ). Therefore, the range occupied by the unwelded part 60 of the entire first sheet 100 becomes smaller, and the generation of abnormal noise caused by the vibration of a part (unwelded part 60) of the first sheet 100 can be reduced.

[0043] Next, Figure 4 is a partial enlarged view of a part of the partial enlarged peripheral edge part 20 of the first sheet 100. As Figure 4 shown, a plurality of first holes 30 are formed along the welded part 120, and a plurality of second holes 40 slightly smaller than the first holes 30 are formed between the adjacent first holes 30. In addition, in Figure 4 the example shown, a part of the first hole 30 penetrates into the welded part 120 side, and a part of the welded part 120 becomes a cavity part.

[0044] In the first sheet 100 having the above-described structure, the middle part 10 and the peripheral part 20 are disconnected along the plurality of second holes 40, and the middle part 10 is extracted from the first sheet 100. In this case, the inner peripheral wall of the opening 50 forming the first sheet 100 has a plurality of concave and convex shapes in a top view (refer to Figure 3 ). Therefore, in the first sheet 100, there are parts such as the cross-sectional view indicated by reference numeral 501 as shown in Figure 5 and parts such as the cross-sectional view indicated by reference numeral 502. In addition, as Figure 5As shown, the first sheet 100 and the second sheet 200 are welded via the welding portion 120.

[0045] Next, Figure 5 The figure indicated by the reference numeral 501 in Figure 3 is a front view sectional view of the B - B section shown in Figure 3 . On the other hand, the figure indicated by the reference numeral 502 is a front view sectional view of the C - C section shown in Figure 5 . In the case of the section of the figure indicated by the reference numeral 501 in

[0046] <Method for manufacturing a door hole seal>

[0047] The door hole seal 300 described above can be manufactured, for example, by a manufacturing method including the following steps (1) to (3).

[0048] (1) As Figure 2 shown, a step of forming a plurality of first holes 30 and second holes 40 in the first sheet 100 respectively, thereby forming a middle portion 10 and a peripheral portion 20 in the first sheet 100 (hole forming step).

[0049] (2) As Figure 5 shown, a step of welding the second sheet 200 to the first sheet 100 in which a plurality of first holes 30 and second holes 40 are respectively formed, so as to cover the middle portion 10 from the vehicle inner side with the second sheet 200 (welding step).

[0050] (3) As Figure 3 shown, a step of extracting the middle portion 10 from the first sheet 100 to which the second sheet 200 is welded, and forming an opening 50 (extracting step).

[0051] 〔Embodiment 2〕

[0052] In other embodiments of the present invention, hereinafter, Figure 6 will be used for explanation. In addition, for convenience of explanation, components having the same functions as those described in the above embodiments are denoted by the same reference numerals, and their explanations will not be repeated.

[0053] The first sheet 100a is a sheet that forms part of the door hole seal 300 for the door inner panel P installed on the front door D. As Figure 6 shown, the first sheet 100a includes a peripheral portion 20a and a middle side portion 10a surrounded by the peripheral portion 20a. The peripheral portion 20a is the portion that surrounds the service hole P1 formed in the door inner panel P. In the first sheet 100a of the present embodiment, it is different from the first sheet 100 of Embodiment 1 in that the shape of the middle side portion 10a is substantially Y-shaped.

[0054] In addition, a plurality of first holes 30a and second holes 40a having a size different from that of the first holes 30a are respectively formed along the boundary between the middle side portion 10a and the peripheral portion 20a. Here, the first holes 30a are holes for extracting the middle side portion 10a from the first sheet 100a. On the other hand, the second holes 40a are holes for disconnecting the middle side portion 10a from the peripheral portion 20a. For example, a plurality of small holes are arranged along the boundary between the middle side portion 10 and the peripheral portion 20. In addition, in the present embodiment, the first holes 30a are slightly larger than the first holes 30 of the first sheet 100 of Embodiment 1.

[0055] The first sheet 100a of the present embodiment is different from the first sheet 100 of Embodiment 1 in that the number of the first holes 30a is less than three, and the first holes 30a are slightly larger than the second holes 40a. Therefore, each first hole 30a occupies a large area of the first sheet 100a. By adopting such a structure, the number of the second holes 40a when disconnecting the middle side portion 10a from the peripheral portion 20a via the second holes 40a can be reduced, so that the middle side portion 10a can be easily extracted from the first sheet 100a.

[0056] 〔Summary〕

[0057] The sheet (the first sheets 100, 100a) of Solution 1 of the present invention is a sheet that forms part of the door hole seal (300) for the door inner panel (P) installed on the vehicle door (front door D), and includes a peripheral portion (20) that surrounds the service hole (P1) of the door inner panel and a middle side portion (10) surrounded by the peripheral portion. A plurality of first holes (30) and second holes (40) having a size different from that of the first holes are respectively formed along the boundary between the middle side portion and the peripheral portion.

[0058] According to the above configuration, when disconnecting the middle side portion from the peripheral portion and extracting the middle side portion from the sheet, the range where there is no unwelded portion of the sheet is near the first hole or the second hole. Therefore, the range occupied by the unwelded portion of the entire sheet becomes smaller, so that the generation of abnormal noise caused by the vibration of a part (unwelded portion) of the sheet can be reduced.

[0059] The sheet materials (first sheet materials 100, 100a) of the second aspect of the present invention may also be such that, in the first aspect, the first hole (30) is a hole for extracting the middle side portion (10) from the sheet material, and the second hole (40) is a hole for disconnecting the middle side portion from the peripheral portion. According to this configuration, when disconnecting the middle side portion from the peripheral portion and extracting the middle side portion from the sheet material, the vicinity of the first hole is a range where there is no unwelded portion of the sheet material. Therefore, the range occupied by the unwelded portion of the entire sheet material becomes smaller, and thus the generation of abnormal noise caused by the vibration of a part (unwelded portion) of the sheet material can be reduced.

[0060] The sheet materials (first sheet materials 100, 100a) of the third aspect of the present invention are preferably such that, in the first or second aspect, the first hole (30) is larger than the second hole (40). According to this configuration, when disconnecting the middle side portion from the peripheral portion and extracting the middle side portion from the sheet material, the vicinity of the first hole is a range where there is no unwelded portion of the sheet material. Therefore, the range occupied by the unwelded portion of the entire sheet material becomes smaller, and thus the generation of abnormal noise caused by the vibration of a part (unwelded portion) of the sheet material can be reduced.

[0061] The sheet material of the fourth aspect of the present invention is preferably such that, between a specific first hole and an adjacent first hole among the plurality of first holes (30), one or more second holes (40) are arranged along the boundary between the middle side portion (10) and the peripheral portion (20). According to this configuration, compared with the case where the second holes are not arranged between adjacent first holes, it is easier to extract the middle side portion from the sheet material.

[0062] The door hole seal (300) of the fifth aspect of the present invention is a door hole seal installed on the door inner panel (P) of a vehicle door (front door D), and includes: a sheet material (first sheet material 100) formed with an opening (50) surrounding a service hole (P1) formed in the door inner panel; and a sound insulation material (second sheet material 200) welded to the sheet material for blocking the service hole from the vehicle interior side, and the inner peripheral wall of the opening forming the sheet material has a plurality of concavo-convex shapes in a top view.

[0063] According to this configuration, the inner peripheral wall of the opening forming the sheet material has a plurality of concavo-convex shapes in a top view. In addition, the vicinity of the concave portion of the concavo-convex shape is a range where there is no unwelded portion of the sheet material. Therefore, the range occupied by the unwelded portion of the entire sheet material becomes smaller, and thus the generation of abnormal noise caused by the vibration of a part (unwelded portion) of the sheet material can be reduced.

[0064] The manufacturing method of the door hole seal (300) of Solution 6 of the present invention is a manufacturing method of a door hole seal installed on the inner door panel (P) of a vehicle door (front door D), and includes the following steps: a hole forming step, in which a plurality of first holes (30) and second holes (40) having a size different from that of the first holes are respectively formed in a sheet (first sheet 100) for forming a part of the door hole seal, and a peripheral portion (20) surrounding a repair hole (P1) of the inner door panel and a middle side portion (10) surrounded by the peripheral portion are formed in the sheet; a welding step, in which a sound insulation material (second sheet 200) is welded in the sheet in which the plurality of first holes and the second holes are respectively formed, so that the middle side portion is covered from the vehicle inner side by the sound insulation material; and an extraction step, in which the middle side portion is extracted from the sheet to which the sound insulation material is welded. According to the method, the same effect as that of Solution 1 is achieved.

[0065] 〔Supplementary Notes〕

[0066] The present invention is not limited to the above-described embodiments, and various modifications can be made within the scope shown in the claims. Embodiments obtained by appropriately combining technical means separately disclosed in different embodiments are also included in the technical scope of the present invention. Moreover, by combining the technical means separately disclosed in each embodiment, new technical features can be formed.

[0067] Explanation of Reference Numerals

[0068] 10 Middle side portion

[0069] 10a Middle side portion

[0070] 20 Peripheral portion

[0071] 20a Peripheral portion

[0072] 30 First hole

[0073] 30a First hole

[0074] 40 Second hole

[0075] 40a Second hole

[0076] 50 Opening

[0077] 100 First sheet (sheet)

[0078] 100a First sheet (sheet)

[0079] 120 Welding portion

[0080] 200 Second sheet (sound insulation material)

[0081] 300 Door hole seal

[0082] D Front door (car door)

[0083] P Inner door panel

[0084] P1 Service hole

Claims

1. A door hole seal installed on an inner door panel of a vehicle door, comprising: a sheet material formed with an opening surrounding a service hole formed in the inner door panel; and a sound insulation material welded to the sheet material for blocking the service hole from the vehicle interior side, the inner peripheral wall forming the opening of the sheet material has a plurality of concave and convex shapes in a plan view, in the sheet material, in the vicinity of each of the plurality of concave portions of the concave and convex shapes, there is a range where there is no unwelded portion between the sheet material and the sound insulation material.

2. A method for manufacturing the door hole seal according to claim 1, comprising: a hole forming step of forming a peripheral portion surrounding a service hole of the inner door panel and a middle portion surrounded by the peripheral portion in the sheet material by forming a plurality of first holes and second holes having different sizes from the first holes in the sheet material that forms a part of the door hole seal; a welding step of welding a sound insulation material in the sheet material in which the plurality of first holes and the second holes are respectively formed so as to cover the middle portion from the vehicle interior side by the sound insulation material; and a drawing step of drawing out the middle portion from the sheet material to which the sound insulation material is welded.

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