Door service hole cover member for automobile

Abstract

To provide a door service hole cover member for automobile which can exhibit all of sound insulation performance, sound absorption performance and waterproof performance with a single component.SOLUTION: A door service hole cover member 100 is formed as a two-layer laminate in which a cushion layer 110 and a board member 120 having sound insulation performance and rigidity are laminated in this order. The cushion layer 110 is formed from a flexible elastic material having sound absorption performance and waterproof performance.SELECTED DRAWING: Figure 7

Description

[Technical field]

[0001] The present invention relates to a door service hole cover member that is applied to an automobile door. [Background technology]

[0002] Conventionally, as an example of this type of service hole member for an automobile door, a vehicle door structure has been proposed as described in the following Patent Document 1. In this vehicle door structure, a service hole cover is attached to a service hole formed in a door inner panel via a seal member so that the cover body covers the service hole from the inside.

[0003] Here, the service hole cover is made of resin, and the seal member is made of a seal material such as butyl rubber, and serves to seal the gap at the boundary between the cover body and the door inner panel. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2019-166950 A Summary of the Invention [Problem to be solved by the invention]

[0005] In the above-mentioned vehicle door structure, the material for the service hole cover is resin, while the material for the seal member is a seal material. For this reason, even if the service hole cover has sound absorption and sound insulation properties and the seal member has waterproof properties, two parts, the service hole cover and a seal member separate from the service hole cover, are required to protect the service hole from the viewpoints of sound absorption, sound insulation and waterproofing. This not only results in an unnecessarily large number of parts, but also requires separate installation work for the service hole cover and the seal member, resulting in a problem of poor workability.

[0006] In order to address the above-mentioned issues, the present invention aims to provide a service hole cover member for an automobile door that has sound insulation performance, sound absorption performance, and waterproof performance all in a single part. [Means for solving the problem]

[0007] In order to solve the above problems, the door service hole cover member for an automobile according to the present invention is applied to an automobile door (D) according to claim 1.

[0008] In the door service hole cover member, a cushion layer (110, 210) that is brought into contact with an inner panel (30) provided on a door body (Da) of a door together with an outer panel (20) so as to cover at least one service hole (31, 32) formed in the inner panel from the side opposite to the outer panel; and a board member (120) laminated on the cushion layer so as to face the inner panel via the cushion layer, The cushion layer is made of a flexible elastic material that has sound absorbing properties as well as waterproof properties. The board member is formed into a board shape using a non-metallic material having sound insulation properties and rigidity.

[0009] According to this configuration, the service hole cover member for an automobile door of the present invention is formed from a cushion layer that is abutted against the inner panel of the door body of the door from the opposite side to the outer panel, and a board member that is laminated on the cushion layer so as to face the inner panel via the cushion layer.

[0010] Here, the cushion layer is made of a flexible elastic material that has waterproof properties in addition to sound absorbing properties, whereas the board member is made of a non-metallic material that has sound insulating properties and rigidity.

[0011] According to this, the cushion layer is made of a soft elastic material, whereas the board member is made of a rigid non-metallic material, which means that the cushion layer is softer than the board member.

[0012] Therefore, when the cushion layer is abutted against the inner panel from the side opposite the outer panel, and the cushion layer is pressed at its multiple outer peripheral regions by multiple corresponding outer peripheral regions of the board member for the multiple outer peripheral regions against multiple corresponding outer peripheral regions of at least one service hole of the inner panel for the multiple corresponding outer peripheral regions, the board member compresses the multiple outer peripheral regions of the cushion layer at its multiple corresponding outer peripheral regions toward the multiple corresponding outer peripheral regions of the at least one service hole of the inner panel.

[0013] Accordingly, the multiple outer peripheral portions of the cushion layer are pressed into intimate contact with the multiple corresponding outer peripheral portions of the at least one service hole, meaning that the cushion layer is pressed into intimate contact with the entire outer peripheral portion of the at least one service hole over its entire outer periphery.

[0014] With this, not only can liquids such as water droplets that penetrate between the outer panel and the inner panel be effectively prevented by the waterproof performance of the cushion layer, but it can also effectively prevent liquids from penetrating to the opposite side of the outer panel from between the outer periphery of the cushion layer and the outer periphery of at least one service hole of the inner panel.

[0015] As described above, the cushion layer has sound absorbing properties, whereas the board member has sound insulating properties. Therefore, noise, such as road noise and wind noise, incident between the outer panel and the inner panel can be effectively absorbed by the cushion layer with its sound absorbing properties. Such sound absorption can be achieved while also effectively blocking road noise and wind noise from between the outer periphery of the cushion layer and the outer periphery of at least one service hole of the inner panel to the opposite side to the outer panel.

[0016] Furthermore, road noise and wind noise from the cushion layer that have been attenuated by the sound absorption as described above can be effectively insulated by the board member due to its sound insulation performance.

[0017] As a result of the above, it is possible to provide a service hole cover member for an automobile door as a single part having all of the sound absorbing properties, sound insulating properties and waterproof properties by using a two-layer laminate consisting of a cushion layer and a board member.

[0018] According to claim 2, the present invention provides a service hole cover member for a door of an automobile according to claim 1, the soft elastic material forming the cushion layer is soft urethane foam, foamed rubber, or foamed elastomer having a volume density within a predetermined volume density range; The predetermined volume density range is set so as to allow the soft urethane foam, the foamed rubber or the foamed elastomer to exhibit waterproof performance.

[0019] With this configuration as well, the same effects as those of the invention described in claim 1 can be achieved.

[0020] According to a third aspect of the present invention, in the automobile door service hole cover member according to the second aspect, The above-mentioned predetermined volume density range is 0.005 g / cm 3 ~0.1g / cm 3 It is characterized in that it is set to.

[0021] This makes it possible to more specifically achieve the effect of the invention as defined in claim 2.

[0022] According to a fourth aspect of the present invention, in the service hole cover member for a door of an automobile according to the first aspect, The non-metallic material from which the board member is made is a synthetic resin material having sound insulation properties and rigidity.

[0023] This makes it possible to achieve the advantageous effects of the invention described in claim 1 more specifically.

[0024] According to a fifth aspect of the present invention, in the automobile door service hole cover member according to the first aspect, The board member is formed to have a board shape by a two-layer laminate including both a non-breathable layer (220) laminated on a cushion layer so as to face the inner panel via the cushion layer, and a hard layer (230) laminated on the non-breathable layer so as to face the cushion layer via the non-breathable layer, The non-breathable layer is formed of a polymer material having sound insulation properties, The hard layer includes a semi-rigid urethane foam layer (230b) and two glass fiber layers (230a, 230c). The semi-rigid urethane foam layer is formed of semi-rigid urethane foam having sound insulation performance and rigidity, Each of the glass fiber layers is formed of a plurality of glass fibers, One of the glass fiber layers is laminated on the non-permeable layer as a one-side glass fiber layer (230a) so as to face the cushion layer via the non-permeable layer, a semi-rigid urethane layer is laminated on the one glass fiber layer so as to face the non-breathable layer via the one glass fiber layer; The other of the two glass fiber layers is characterized in that it is laminated as an other-side glass fiber layer (230c) on the semi-rigid urethane layer so as to face the one-side glass fiber layer via the semi-rigid urethane layer.

[0025] According to this configuration, unlike the invention recited in claim 1, the board member is formed to have a board shape by a two-layer laminate consisting of an air-impermeable layer and a hard layer.

[0026] The air-impermeable layer has sound insulation properties, and the hard layer has a three-layer structure consisting of a glass fiber layer on one side, a semi-rigid urethane layer, and a glass fiber layer on the other side.

[0027] In the hard layer, the semi-rigid urethane layer has sound insulation performance and rigidity. Also, the glass fiber layers on one side and the other side have rigidity due to their respective multiple glass fibers. This means that in the hard layer, the glass fiber layers on one side and the other side play a role in reinforcing the rigidity of the semi-rigid urethane foam layer with their respective rigidities. This can further increase the rigidity of the hard layer.

[0028] Thus, while the cushion layer is made of a flexible elastic material, the hard layer of the board component is made of a three-layer laminate structure in which the rigidity of the semi-rigid urethane layer is further increased by the rigidity of both the one-side glass fiber layer and the other-side glass fiber layer, as described above.

[0029] Therefore, when the cushion layer is abutted against the inner panel from the side opposite the outer panel, when the cushion layer is pressed at its multiple outer peripheral regions with multiple corresponding outer peripheral regions of the hard layer for the multiple outer peripheral regions, via multiple corresponding outer peripheral regions of the non-breathable layer for the multiple corresponding outer peripheral regions, against the multiple corresponding outer peripheral regions of at least one service hole of the inner panel for the multiple corresponding outer peripheral regions, with multiple pressing tools, the hard layer compresses the multiple outer peripheral regions of the cushion layer toward the multiple corresponding outer peripheral regions of at least one service hole of the inner panel at its multiple corresponding outer peripheral regions, via the multiple corresponding outer peripheral regions of the non-breathable layer for the multiple corresponding outer peripheral portions.

[0030] The compression causes the cushion layer to be pressed at its circumferential portions into intimate contact with the corresponding circumferential portions of the at least one service hole, meaning that the cushion layer is pressed over its entire periphery into intimate contact with the entire periphery of the at least one service hole.

[0031] Accordingly, liquids such as water droplets that penetrate between the outer panel and the inner panel can be effectively waterproofed by the waterproofing performance of the cushion layer, as described above, while preventing the penetration of liquids from between the outer periphery of the cushion layer and the outer periphery of at least one service hole to the opposite side of the outer panel.

[0032] In addition, the cushion layer has sound absorbing properties. In contrast, in the board member, the non-breathable layer has sound insulation properties, and the glass fiber layers on one side and the other side of the hard layer serve to further enhance the sound insulation properties of the semi-rigid urethane layer with their respective sound insulation properties. This means that the board member can exhibit even better sound insulation properties due to the synergistic effect of the sound insulation properties of the non-breathable layer and the hard layer.

[0033] Therefore, noise, such as road noise and wind noise, incident between the outer panel and the inner panel is effectively absorbed by the cushion layer due to its sound absorbing performance. Furthermore, the road noise and wind noise from the cushion layer thus attenuated by sound absorption can be effectively insulated by the synergistic sound insulating performance of the non-breathable layer and the hard layer described above.

[0034] As a result of the above, it is possible to provide a service hole cover member for automobile doors as a single component having all of the sound absorption performance, sound insulation performance and waterproof performance, with a three-layer laminated structure consisting of a cushion layer, a non-breathable layer of a board member and a hard layer.

[0035] According to a sixth aspect of the present invention, in the service hole cover member for a door of an automobile according to the first aspect, the outer periphery laminated portion (100a) and at least one protruding laminated portion (100b, 100c) formed on the inner periphery side of the outer periphery laminated portion so as to correspond to the at least one service hole of the inner panel, The at least one protruding laminated portion is formed so as to protrude from the outer peripheral laminated portion so as to be press-fitted into the at least one service hole from the side of the inner panel opposite the outer panel.

[0036] According to this, at least one protruding laminated portion protrudes from the outer peripheral laminated portion and is press-fitted into at least one service hole, which can more effectively prevent water droplets from entering through the inner panel from the outer panel side to the opposite side of the inner panel from the outer panel side.

[0037] According to a seventh aspect of the present invention, in the automobile door service hole cover member according to the fifth aspect, the outer periphery laminated portion (200a) and at least one protruding laminated portion (200b, 200c) formed on the inner periphery side of the outer periphery laminated portion so as to correspond to the at least one service hole of the inner panel, The at least one protruding laminate portion is formed so as to protrude from the outer peripheral laminate portion so as to be press-fittable into at least one service hole from the side of the inner panel opposite the outer panel.

[0038] With this configuration, the at least one protruding laminated portion protrudes from the outer peripheral laminated portion and is press-fitted into the at least one service hole, and accordingly, even if the board member is a laminate of a non-breathable layer and a hard layer, the intrusion of water droplets and the ingress of noise from the outer panel side to the opposite side of the inner panel through the inner panel can be more effectively prevented.

[0039] According to an eighth aspect of the present invention, in the automobile door service hole cover member according to the fifth aspect, The sheet has a nonwoven fabric skin layer (240) laminated on the other glass fiber layer so as to face the semi-rigid urethane layer via the other glass fiber layer, The lamination of the other glass fiber layer to the semi-rigid urethane layer is characterized by being performed by impregnating the other glass fiber layer with liquid isocyanate and curing it.

[0040] According to this configuration, the nonwoven fabric skin layer is laminated on the other glass fiber layer, so that, as described above, even if liquid isocyanate seeps out from the other glass fiber layer to the side opposite the semi-rigid urethane layer during the process of impregnating the other glass fiber layer with liquid isocyanate when laminating the other glass fiber layer on the semi-rigid urethane layer, the seeped isocyanate can be satisfactorily absorbed by the nonwoven fabric of the skin layer.

[0041] As a result, the effect of the invention as recited in claim 5 can be achieved while maintaining a good appearance of the door service hole cover member as viewed from the skin layer side.

[0042] The reference symbols in parentheses for each of the above means indicate the corresponding relationship with the specific means described in the embodiments described later. [Brief description of the drawings]

[0043] [Figure 1] 1 is a schematic partial cutaway view of an automobile to which a first embodiment of a service hole cover member for an automobile door according to the present invention is applied. [Diagram 2] 2 is a schematic cross-sectional view of the door body taken along line 2-2 in FIG. 1. [Diagram 3] 3 is a front view of an inner panel to which the door service hole cover member of FIG. 2 is attached. FIG. [Figure 4] 3 is a surface view showing the inner panel of FIG. 2 as viewed from the outer panel side. [Diagram 5] FIG. 3 is an enlarged perspective view showing the pressing tool of FIG. 2. [Figure 6] 3 is a back view showing the door service hole cover member of FIG. 2 as viewed from the soft layer side. FIG. [Figure 7] 7 is a cross-sectional view of the door service hole cover member taken along line 7-7 in FIG. 6. [Figure 8] 3 is a front view showing the inner panel to which the door service hole cover member of FIG. 2 is attached, as viewed from the outer panel side. FIG. [Figure 9] 4 is a graph showing the transfer function characteristics of the door service hole cover member in the first embodiment and a conventional service hole cover in relation to noise frequency. [Figure 10] FIG. 4 is a cross-sectional view showing a second embodiment of a service hole cover member for an automobile door according to the present invention. [Figure 11] FIG. 4 is a cross-sectional view showing a third embodiment of a service hole cover member for an automobile door according to the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0044] Hereinafter, each embodiment of the present invention will be described with reference to the drawings. (First embodiment) 1 shows a first embodiment of a service hole cover member for an automobile door (hereinafter also referred to as a service hole cover member) according to the present invention, which is applied to a left front door D of an automobile. In this embodiment, the service hole cover member is hereinafter indicated by the reference numeral 100. In addition, the left front door D is hereinafter also simply referred to as the door D.

[0045] The door D is hinged to a left front pillar (not shown) of a left front door frame F of the vehicle to open and close a passenger compartment 10 of the vehicle (see FIG. 1). As shown in FIG. 1 or 2, the door D includes an outer panel 20, an inner panel 30, and a door trim 40, which are assembled to a lower frame portion of the left front door frame F and form a door body Da of the door D together with the left front door frame F. The outer panel 20 and the inner panel 30 are each made of, for example, an aluminum alloy plate material.

[0046] The outer panel 20 is attached to the lower frame portion of the door frame F from its outer side (the vehicle exterior side). The inner panel 30 is attached to the lower frame portion from its inner side (the vehicle interior side) so as to face the outer panel 20. The door trim 40, as a decorative interior part, is attached to the lower frame portion from the opposite side to the outer panel 20 so as to cover the inner panel 30.

[0047] 1, the door D has a window formed by a window glass W and an upper frame portion Fa of a left front door frame F, and the window glass W is disposed within the upper frame portion Fa so as to be movable up and down. The window glass W is lowered by a lowering operation of a lifting mechanism (not shown) and is accommodated within the outer panel 20 and the inner panel 30 through the gap between the respective upper ends thereof to open the window, or is raised along the upper frame portion Fa by a rising operation of the lifting mechanism to close the window.

[0048] Next, the configuration of the service hole cover member 100 according to the present invention will be described in relation to the configuration of the inner panel 30.

[0049] As shown in any one of Figs. 1 to 4, the inner panel 30 has upper and lower service holes 31, 32, which are both formed as holes for work at a distance from each other in the middle of the inner panel 30. The area between the upper and lower service holes 31, 32 of the inner panel 30 is called an inter-hole panel area 33 (hole common outer peripheral area 33). The area indicated by the dashed line R in Fig. 3 indicates the area where the service hole cover member 100 is attached to the inner panel 30.

[0050] The service hole cover member 100 is attached to the inner panel 30 in an assembly area (area indicated by dashed line R) from the door trim 40 side by a plurality of pressing tools 50 (see FIG. 5) as described below.

[0051] The service hole cover member 100 is formed to have a shape as shown in Figures 6 and 7. The service hole cover member 100 is formed of a soft layer 110 and a board member 120 as shown in either Figure 6 or Figure 7 so as to exhibit good sound absorption performance, sound insulation performance, and waterproof performance. The service hole cover member 100 formed in this manner is assembled so that the soft layer 110 abuts against the inner panel 30 as shown in Figure 8. In the first embodiment, the soft layer 110 is also referred to as the cushion layer 110 hereinafter.

[0052] The cushion layer 110 and the board member 120 that form the service hole cover member 100 are laminated in this order to form a two-layer laminate. In this embodiment, since the two-layer laminate is the service hole cover member 100, the two-layer laminate will also be indicated by the reference numeral 100, like the service hole cover member 100.

[0053] The service hole cover member 100, in other words, the two-layer laminate 100, is formed by an outer peripheral laminate portion 100a, upper and lower both protruding laminate portions 100b and 100c, and an area between the laminate portions 100d, as shown in either Figure 6 or Figure 7.

[0054] Here, in the two-layer laminate 100, the peripheral laminated portion 100a is formed as a peripheral portion with respect to the upper and lower protruding laminated portions 100b and 100c and the inter-laminated portion portion 100d.

[0055] The upper and lower protruding laminated portions 100b and 100c are formed to protrude from the outer peripheral laminated portion 100a and the inter-laminated portion region 100d of the two-layer laminate 100 toward the inner panel 30, in a shape that allows them to be pressed into the upper and lower service holes 31, 32 of the inner panel 30, as shown in any one of Figures 2, 6 to 8.

[0056] The inter-laminar portion portion 100d is interposed between the upper and lower protruding laminate portions 100b and 100c in the two-layer laminate 100, and serves to separate the upper and lower protruding laminate portions 100b and 100c from each other.

[0057] In the two-layer laminate 100 thus formed, i.e., the service hole cover member 100, the upper and lower protruding laminated portions 100b and 100c are press-fitted into the upper and lower service holes 31, 32 of the inner panel 30 from the door trim 40 side, and the outer periphery laminated portion 100a and the inter-laminated portion area 100d abut against the assembly area (area indicated by dashed line R) of the inner panel 30. The service hole cover member 100 is pressed against the inner panel 30 at its outer periphery laminated portion 100a via a plurality of through holes 101 (see FIG. 6) by fastening a plurality of pressing tools 50 to a plurality of female screw holes 34 (see FIG. 2) of the inner panel 30 as described below.

[0058] In this first embodiment, the multiple through holes 101 are formed in a penetrating manner in the vicinity of both the upper and lower protruding laminated portions 100b and 100c of the outer periphery laminated portion 100a of the service hole cover member 100. In other words, the multiple through holes 101 are formed in the outer periphery laminated portion 100a at positions corresponding to the positions adjacent to the upper and lower service holes 31, 32 of the inner panel 30.

[0059] Meanwhile, the plurality of female screw holes 34 are formed in corresponding positions to the through holes 101 of the outer periphery laminated portion 100a in the assembly region (region indicated by dashed line R) of the inner panel 30. In other words, the plurality of female screw holes 34 are formed in positions adjacent to the service holes 31, 32 on both the upper and lower sides of the inner panel 30.

[0060] The reason for forming the multiple through holes 101 and multiple female screw holes 34 at these positions will be described below. The closer the pressing positions of the service hole cover member 100 (two-layer laminate 100) against the inner panel 30 by the pressing tools 50 are to the upper and lower service holes 31, 32 (for example, the inner peripheries of the upper and lower service holes 31, 32), the closer the service hole cover member 100 is to the inner panel 30.

[0061] 5, each of the pressing tools 50 is formed as a male screw member having a head 51 and a male screw portion 52 extending coaxially from the head 51. Each of the pressing tools 50 has an annular flange portion 53, and the flange portion 53 is formed coaxially with the head 51 and the male screw portion 53 for each pressing tool 50. Thus, each of the pressing tools 50 is fastened by the male screw portion 52 to each female screw hole portion 34 of the inner panel 30 via each through hole portion 101 of the service hole cover member 100, so that the flange portion 53 presses the outer periphery of each through hole portion 101.

[0062] Below, we will explain in detail the configuration of each of the cushion layer 110 and the board member 120. The cushion layer 110 is formed in layers of soft urethane foam, which is a material that exhibits good sound absorbing performance and also has appropriate soft elasticity (a type of soft elastic material).

[0063] As shown in FIG. 6 or FIG. 7, the cushion layer 110 is formed to have an outer periphery 111, upper and lower protruding portions 112, 113, and a portion 114 between the protruding portions.

[0064] Here, the outer peripheral portion 111 corresponds to the corresponding portion of the outer peripheral laminate portion 100a of the two-layer laminate 100 relative to the outer peripheral portion 111, the upper and lower side protruding portions 112, 113 correspond to the corresponding portions of the upper and lower side protruding laminate portions 100b, 100c of the two-layer laminate 100 relative to the upper and lower side protruding portions 112, 113, and the inter-protruding portion portion 114 corresponds to the corresponding portion of the inter-lamination portion portion 100d of the two-layer laminate 100 relative to the inter-protruding portion portion 114.

[0065] As a result, in the cushion layer 110, upper and lower protruding parts 112, 113 are formed so as to protrude from the outer periphery 111 and the area 114 between the protruding parts (see FIG. 7).

[0066] As described above, the soft urethane foam, which is the material forming the cushion layer 110, is a type of flexible elastic material that can exhibit good sound absorbing performance. Therefore, in order to allow the soft urethane foam to also exhibit good soundproofing performance, in the first embodiment, the soft urethane foam is set to have a volume density within a predetermined volume density range (for example, 0.007 g / cm 3 ) In other words, the soft urethane foam has a volume density within the above-mentioned predetermined volume density range, and thus can exhibit good waterproof performance. In other words, such a soft urethane foam is a type of flexible elastic material that can exhibit good sound absorbing and waterproof performance.

[0067] Here, the predetermined volume density range is, for example, 0.005 g / cm3 ~0.1g / cm 3 If the volume density of the soft urethane foam is outside the lower limit of the predetermined volume density range, the soft urethane foam will lack waterproof performance. If the volume density of the soft urethane foam is greater than the upper limit of the predetermined volume density range, the soft urethane foam will lack flexibility and elasticity.

[0068] The board member 120 is formed into a board shape using foamed polypropylene or polypropylene, which is a type of foamed synthetic resin material having appropriate rigidity and appropriate sound insulation performance.

[0069] As shown in FIG. 7, the board member 120 is formed to have an outer periphery 121, upper and lower protruding portions 122, 123, and a portion 124 between the protruding portions.

[0070] Here, the outer peripheral portion 121 corresponds to the corresponding portion of the outer peripheral laminate portion 100a of the two-layer laminate 100 relative to the outer peripheral portion 121, the upper and lower side protruding portions 122, 123 correspond to the corresponding portions of the upper and lower side protruding laminate portions 100b, 100c of the two-layer laminate 100 relative to the upper and lower side protruding portions 122, 123, and the inter-protruding portion portion 124 corresponds to the corresponding portion of the inter-lamination portion portion 100d of the two-layer laminate 100 relative to the inter-protruding portion portion 124.

[0071] As a result, in the board member 120, upper and lower protruding portions 122, 123 are formed so as to protrude from the outer periphery 121 and the area 124 between the protruding portions (see FIG. 7).

[0072] In the first embodiment configured as described above, the service hole cover member 100 is attached to the inner panel 30 as follows.

[0073] In this assembly, the service hole cover member 100 is opposed to the inner panel 30 from the door trim 40 side.

[0074] In this state, the upper protruding laminated portion 110b and the lower protruding laminated portion 110c of the service hole cover member 100 are press-fitted into the upper service hole 31 and the lower service hole 32 of the inner panel 30. Therefore, noise, gas (e.g., air), and liquid (e.g., water) do not pass between the outer periphery of the upper protruding laminated portion 110b and the inner periphery of the upper service hole 31, and between the outer periphery of the lower protruding laminated portion 110c and the inner periphery of the lower service hole 32.

[0075] With the upper and lower protruding laminated portions 110b, 110c pressed into the upper and lower service holes 31, 32 as described above, the multiple pressing tools 50 are successively fastened with their male thread portions 53 to the corresponding female thread portions 34 of the inner panel 30 through the corresponding through hole portions 101 of the service hole cover member 100. As a result, the outer periphery of each corresponding through hole portion 101 of the service hole cover member 100 is pressed by each corresponding pressing portion 50 with its flange portion 53 against the outer periphery of each corresponding female thread hole portion 34 of the inner panel 30.

[0076] Here, the cushion layer 110 of the service hole cover member 100 has appropriate flexibility and appropriate elasticity. Also, polypropylene, which is the material forming the board member 110 of the service hole cover member 100, has appropriate rigidity.

[0077] For this reason, the service hole cover member 100, i.e., the board portion of the outer peripheral laminate portion 100a of the two-layer laminate 100 that corresponds to the board member 110, is less likely to deform than the cushion layer portion of the outer peripheral laminate portion 100a of the two-layer laminate 100 that corresponds to the cushion layer 110.

[0078] Therefore, when pressing is performed as described above, the corresponding board parts are pressed against the outer periphery of each corresponding female screw hole 34 of the inner panel 30 at the parts corresponding to the flanges 53 of the pressing tools 50, compressing the parts of the corresponding cushion layer parts that correspond to the outer periphery of each corresponding female screw hole 34 of the inner panel 30. This means that the cushion layer 110 is airtightly and liquidtightly adhered to the outer periphery of each corresponding female screw hole 34 at the parts of the corresponding cushion layer parts that correspond to the outer periphery of each corresponding female screw hole 34 of the inner panel 30.

[0079] Therefore, noise, gas, and liquid do not pass through both the female screw holes 34 of the inner panel 30 and the corresponding through holes 101 of the outer periphery laminated portion 100a. The larger the outer diameter of the flange 53 of each pressing tool 50, the wider the above-mentioned contact range. Moreover, since the corresponding board portion is difficult to deform as described above, as a result of the above-mentioned pressing, each laminated portion located between the flanges 53 of the multiple pressing tools 50 on both sides of the outer periphery laminated portion 100a can be well contacted with the corresponding portion of the inner panel 30 for each laminated portion.

[0080] As described above, the automobile is put into a traveling state with the service hole cover member 100 attached to the inner panel 30 of the door body Da of the door D. In this state, for example, if the automobile is traveling in the rain, liquid (e.g., water droplets) may penetrate between the outer panel 20 and the inner panel 30 through the hinge hole 21 (support hole for the hinge part h of the door handle) of the outer panel 20 of the door body Da and / or the gap between the upper ends of the outer panel 20 and the inner panel 30 (see arrow AR1 in FIG. 2).

[0081] In addition, road noise generated from the road surface on which the vehicle is traveling through the front wheels of the vehicle and / or wind noise generated due to the vehicle's traveling may be incident on the inner panel 30 through the outer panel 20 (see arrow AR2 in FIG. 2). Furthermore, noise may be incident between the outer panel 20 and the inner panel 30 through the hinge hole of the outer panel 20.

[0082] In contrast to this, in the first embodiment, the cushion layer 110 can exhibit both excellent sound absorbing performance and waterproof performance as described above.

[0083] As described above, the upper protruding laminated portion 110b is firmly pressed into the upper service hole 31 in an airtight and liquid-tight manner, and the lower protruding laminated portion 110c is firmly pressed into the lower service hole 32 in an airtight and liquid-tight manner.

[0084] As described above, due to the flexibility of the cushion layer 110 and the rigidity of the board member 120, the cushion layer 110 adheres airtight and liquidtight to the outer circumferential portions of the female screw holes 34 of the inner panel 30 at the portions corresponding to the flanges 53 of the multiple pressing tools 50. Furthermore, due to the flexibility of the cushion layer 110 and the rigidity of the board member 120, the cushion layer portions of the cushion layer 110 between the adjacent pressing tools 50 also adhere well to the corresponding portions of the inner panel 30 for the respective cushion layer portions.

[0085] Therefore, even if water droplets penetrate between the outer panel 20 and the inner panel 30, the cushion layer 110, by its waterproofing performance, can effectively prevent the water droplets from penetrating into the area between the inner panel 30 and the door trim 40. As a result, the inside of the vehicle compartment 20 can be effectively waterproofed.

[0086] In addition, the cushion layer 110 exhibits appropriate sound absorbing performance. Therefore, even if road noise or wind noise is incident on the inner panel 30 through the outer panel 20, the road noise or wind noise can be satisfactorily absorbed by the cushion layer 110 due to its sound absorbing performance.

[0087] Furthermore, even if the road noise and wind noise that have been absorbed and attenuated in this manner enter the board member 120 from the cushion layer 110, the road noise and wind noise can be effectively blocked by the board member 120 due to its sound-insulating performance.

[0088] As a result, the interior of the vehicle compartment 20 can be well soundproofed by the service hole cover member 100, due to the sound absorbing performance of the cushion layer 110 and the sound insulating performance of the board member 120.

[0089] As described above, the service hole cover member 100 can be provided as a single-piece service hole cover member for an automobile door that can exhibit good sound absorbing and sound insulating performance as well as good waterproof performance.

[0090] Incidentally, the acoustic performance of the service hole cover member 100 was measured in terms of the relationship between the transfer function (FRP) and the noise frequency. For this measurement, the service hole cover described at the beginning of this specification (hereinafter referred to as the conventional service hole cover) was prepared as a comparison subject to the service hole cover member 100.

[0091] The acoustic performance of the service hole cover member 100 and the conventional service hole cover were measured, resulting in graphs 1 and 2 shown in Figure 9. Graph 1 shows the acoustic performance of the service hole cover member 100. Meanwhile, graph 2 shows the acoustic performance of the conventional service hole cover.

[0092] Comparing graph 1 with graph 2, it can be seen that the acoustic performance of the service hole cover member 100 is almost the same as that of a conventional service hole cover. In other words, it can be seen that the acoustic performance of the service hole cover member 100 against road noise and wind noise, for example, the sound absorption and blocking performance, is almost the same as that of a conventional service hole cover.

[0093] However, the service hole cover member 100 is formed to integrally include the cushion layer 110 having waterproof performance together with the board member 120. Therefore, the service hole cover member 100 is formed as a two-layer laminate as a single component consisting of the cushion layer 110 and the board member 120. Furthermore, in the two-layer laminate, the cushion layer 110 exhibits sound absorbing performance and waterproof performance, while the board member 120 exhibits sound insulating performance. In other words, the service hole cover member 100 is formed as a single component that can exhibit all of sound absorbing performance, sound insulating performance, and waterproof performance.

[0094] In contrast, conventional service hole covers only have sound absorption and sound insulation properties by themselves, and require a separate sealing material with waterproof properties. This means that sound absorption, sound insulation and waterproof properties cannot be achieved without the two parts consisting of the conventional service hole cover and the sealing material.

[0095] In other words, the service hole cover member 100, unlike conventional service hole covers, has the characteristic of being a single component that can exhibit all of the sound absorbing performance, sound insulating performance, and waterproofing performance.

[0096] Second embodiment 10 shows a second embodiment of the service hole cover member for an automobile door according to the present invention. In the second embodiment, a service hole cover member 200 is adopted instead of the service hole cover member 100 in the first embodiment.

[0097] The service hole cover member 200 is formed of a two-layer laminate consisting of a cushion layer 210 corresponding to the cushion layer 110 in the first embodiment, and a film layer 220 and a hard layer 230 corresponding to the board member 120 in the first embodiment. In this second embodiment, the service hole cover member 200 is abutted against the inner panel 30 at the cushion layer 210 in place of the cushion layer 110 in the first embodiment, similarly to the cushion layer 110. Note that a three-layer laminate consisting of the film layer 220 and hard layer 230 of the two-layer laminate and the cushion layer 210 is the service hole cover member 200, and therefore the three-layer laminate is also indicated by the reference symbol 200, similarly to the service hole cover member 200.

[0098] The cushion layer 210 corresponds to the cushion layer 110 described in the first embodiment, and the cushion layer 210 is formed from the same material as the cushion layer 110 and has the same shape as the cushion layer 110. The soft urethane foam that is the material for forming the cushion layer 210 is formed to have the same volume density as the soft urethane foam that is the material for forming the cushion layer 110. The volume densities are each within the predetermined volume density ranges described in the first embodiment.

[0099] The film layer 220 is formed as a non-breathable layer capable of exhibiting good sound insulation performance, and the film layer 220 is laminated on its back surface along the soft layer 110 from its front surface side with an adhesive. The material forming the film layer 220 may be a type of polymer material, such as a film made of nylon. The basis weight of the film is within a predetermined basis weight range (for example, 400 g / m 2 ) and the thickness of the film is set to a value within a predetermined thickness range (for example, 50 μm).

[0100] The specified weight range is 10 g / m 2 ~500g / m 2The lower limit of the specified weight range is set to 10 g / m 2 The reason for this is that it is difficult to manufacture the film below this lower limit. Also, the upper limit of the specified weight range is 500 g / m 2 This is because if the thickness is higher than the upper limit, the film, that is, the film layer 220, becomes too heavy.

[0101] The predetermined thickness range of the film is set to 10 μm to 500 μm. The reason why the lower limit of the predetermined thickness range is set to 10 μm is because the film is too thin below this lower limit and difficult to manufacture. The reason why the upper limit of the predetermined thickness range is set to 500 μm is because the film becomes too heavy if it is thicker than this upper limit.

[0102] The hard layer 230 is formed of one side glass fiber layer 230a, a semi-rigid urethane foam layer 230b, and the other side glass fiber layer 230c so as to exhibit good sound insulation performance together with the film layer 220 and have appropriate rigidity.

[0103] The one-side glass fiber layer 230a is laminated to the film layer 220 by bonding with an adhesive so as to face the cushion layer 210 with the film layer 220 interposed therebetween.

[0104] The semi-rigid urethane foam layer 230b is laminated on the one-side glass fiber layer 230a so as to face the film layer 220 via the one-side glass fiber layer 230a. The other-side glass fiber layer 230c is laminated on the semi-rigid urethane foam layer 230b so as to face the one-side glass fiber layer 230a via the semi-rigid urethane foam layer 230b.

[0105] In the hard layer 230, the lamination of the semi-rigid urethane foam layer 230b and the one-side glass fiber layer 230a and the lamination of the semi-rigid urethane foam layer 230b and the other-side glass fiber layer 230c are performed, for example, by impregnation with liquid isocyanate and subsequent curing. The isocyanate is impregnated so as to extend over the one-side and other-side glass fiber layers 230a, 230c and the semi-rigid urethane layer 230b.

[0106] In this embodiment, the volume density of the semi-rigid urethane foam, which is the material for forming the semi-rigid urethane foam layer 230b, is within a predetermined volume density range (for example, 0.03 g / cm 3 In this embodiment, the predetermined volume density range is a range required for the semi-rigid urethane foam layer 230b to exhibit appropriate rigidity and good sound insulation performance, and is set to, for example, 0.015 g / cm 3 ~0.1g / cm 3 is set to.

[0107] The lower limit of the specified volume density range is 0.015 g / cm 3 The reason for this is that if the volume density is less than the lower limit, the semi-rigid urethane foam layer 230b will lack the necessary rigidity and sound insulation performance. 3 This is because if the thickness is greater than the upper limit, the semi-rigid urethane foam layer 230b becomes too heavy.

[0108] In addition, the glass fiber layers 230a, 230c on one side and the other side are each made of a plurality of glass fibers, and the glass fiber layers 230a, 230c on one side and the other side play a role in further improving the rigidity and sound insulation performance of the semi-rigid urethane foam layer 230b upon impregnation and curing of the above-mentioned isocyanate.

[0109] Since the hard layer 230 has good sound insulation performance, the hard layer 230, in combination with the sound insulation performance of the film layer 220, can play a role in maintaining the sound insulation performance of the service hole cover member 200 even better. This allows the hard layer 230 to exhibit good sound insulation performance.

[0110] Meanwhile, the service hole cover member 200 is attached to the inner panel 30 by pressing the outer periphery of the service hole cover member 200 against the inner panel 30 with a plurality of pressing tools 50. If it is assumed that the service hole cover member 200 is formed only of the cushion layer 210, the cushion layer 210 will not come into uniform contact with the inner panel 30 when pressed by the plurality of pressing tools 50 as described above, and a gap will be created between the cushion layer 210 and the inner panel 30. This makes it impossible to prevent noise and moisture from entering the inside of the inner panel 30 from the outer panel 20 side.

[0111] Furthermore, even if the hard layer 230 is laminated on the cushion layer 210, assuming that the hard layer 230 has the same flexibility as the cushion layer 210, the hard layer 230 will not uniformly abut the cushion layer 210 against the inner panel 30 due to the above-mentioned pressing force, and a gap will still be generated between the cushion layer 210 and the inner panel 30.

[0112] In contrast, if the hard layer 230 has an appropriate rigidity, the cushion layer 210 can be brought into uniform contact with the inner panel 30 by the above-mentioned pressing force due to the rigidity of the hard layer 230, and therefore the above-mentioned gap does not occur. Therefore, it was decided that the hard layer 230 should have an appropriate rigidity.

[0113] The service hole cover member 200, in other words the three-layer laminate 200, is formed of an outer peripheral laminate portion 100a of the two-layer laminate which is the service hole cover member 100 described in the first embodiment above, an outer peripheral laminate portion 200a which corresponds to the upper and lower both protruding laminate portions 100b and 100c and the inter-laminar portion area 100d, upper and lower both protruding laminate portions 200b and 200c and the inter-laminar portion area 200d (see Figure 10).

[0114] Here, in the three-layer laminate 200, the outer periphery laminated portion 200a is formed as an outer periphery side portion of the upper and lower protruding laminated portions 200b and 200c and the inter-laminated portion portion 200d.

[0115] The upper and lower protruding laminated portions 200b and 200c, instead of the upper and lower protruding laminated portions 100b and 100c described in the first embodiment above, are formed to protrude from the outer peripheral laminated portion 200a and the inter-laminated portion region 200d of the three-layer laminate 200 toward the inner panel 30, in a shape that can be pressed into the upper and lower service holes 31, 32 of the inner panel 30 to correspond to the upper and lower service holes 31, 32 of the inner panel 30.

[0116] The inter-laminar portion portion 200d is interposed between the upper and lower protruding laminate portions 200b and 200c in the three-layer laminate 200, and serves to separate the upper and lower protruding laminate portions 200b and 200c from each other.

[0117] In the three-layer laminate 200 formed in this manner, i.e., the service hole cover member 200, the upper and lower protruding laminate portions 200b and 200c are pressed into the upper and lower service holes 31, 32 of the inner panel 30 from the door trim 40 side, so that the outer peripheral laminate portion 200a and the area between the laminate portions 200d abut against the assembly area of ​​the inner panel 30 (the area indicated by dashed line R).

[0118] When the three-layer laminate 200 is pressed against the inner panel 30 by the multiple pressing tools 50 of the first embodiment, each of the multiple pressing tools 50 is fastened by the male thread portion 52 to the corresponding female thread hole portion 34 of the inner panel 30 via the corresponding through hole portion 201 of the multiple through hole portions 201 (only a single through hole portion 201 is shown in FIG. 10) of the peripheral laminate portion 200a, and the flange portion 53 presses the outer periphery of the through hole portion 201 of the peripheral laminate portion 200a against the outer periphery of the corresponding female thread hole portion 34 of the inner panel 30. The multiple through holes 201 are formed in a penetrating manner in the peripheral laminate portion 200a of the three-layer laminate 200 at positions corresponding to the multiple through holes 101 of the two-layer laminate 100 described in the first embodiment.

[0119] In the second embodiment configured as above, the service hole cover member 200 is attached to the inner panel 30 as follows.

[0120] The service hole cover member 200 is placed with its cushion layer 210 facing the inner panel 30 from the door trim 40 side. At this time, the service hole cover member 200 is held so that its upper protruding laminated portion 200b and lower protruding laminated portion 200c face the upper service hole 31 and lower service hole 32 of the inner panel 30. Accordingly, each through hole portion 201 of the service hole cover member 200 faces each female screw hole portion 34 of the inner panel 30.

[0121] In this state, the upper protruding laminated portion 200 b and the lower protruding laminated portion 200 c of the service hole cover member 200 are inserted into the upper service hole 31 and the lower service hole 32 of the inner panel 30 .

[0122] Here, upper protruding laminated portion 200b is formed with its outer circumferential shape so that it can be press-fitted into upper service hole 31, and lower protruding laminated portion 200c is formed with its outer circumferential shape so that it can be press-fitted into lower service hole 32. Therefore, upper protruding laminated portion 200b is securely inserted into upper service hole 31 in an airtight and liquid-tight manner, and lower protruding laminated portion 200c is securely inserted into lower service hole 32 in an airtight and liquid-tight manner.

[0123] Therefore, noise, gas (e.g., air) or liquid (e.g., water) do not pass between the outer periphery of the upper protruding stack portion 210b and the inner periphery of the upper service hole 31, and between the outer periphery of the lower protruding stack portion 210c and the inner periphery of the lower service hole 32.

[0124] Furthermore, when the upper and lower protruding laminated portions 200b, 200c are inserted into the upper and lower service holes 31, 32 as described above, the through-holes 201 of the service hole cover 200 coaxially contact the corresponding female threaded holes 34 of the inner panel 30. In this state, the multiple pressing tools 50 are sequentially fastened, with their male threaded portions 53, to the corresponding female threaded portions 34 of the inner panel 30 through the corresponding through-holes 201 of the service hole cover member 200.

[0125] Here, the cushion layer 210 of the service hole cover member 200 is formed of the soft urethane layer as described above. The soft urethane that forms the soft urethane layer has flexibility and elasticity.

[0126] As described above, the hard layer 230 of the service hole cover 200 is formed of a three-layer laminate structure consisting of the one-side glass fiber layer 230a, the semi-rigid urethane layer 230b, and the other-side glass fiber layer 230c. In this three-layer laminate structure, the semi-rigid urethane forming the semi-rigid urethane layer 230b has rigidity. The two-side glass fiber layers 230a and 230c are each formed by intertwining a plurality of glass fibers, and the plurality of glass fibers have rigidity. Moreover, the rigidity of the two-side glass fiber layers 230a and 230c is further strengthened by the above-mentioned impregnation and curing of isocyanate.

[0127] Accordingly, in the hard layer 230, the semi-rigid urethane layer 230b can exert good rigidity in combination with the two glass fiber layers 230a, 230c. This means that the hard layer 230 is less likely to deform, unlike the cushion layer 210. In other words, the service hole cover member 200, i.e., the hard layer portion of the outer peripheral laminated portion 200a of the three-layer laminate 200 corresponding to the hard layer 230, is less likely to deform, unlike the cushion layer portion of the outer peripheral laminated portion 200a of the three-layer laminate 200 corresponding to the cushion layer 210.

[0128] Therefore, when fastening is performed as described above, the corresponding hard layer portion is pressed by each of the flange portions 53 of the multiple pressing tools 50 so as to compress the corresponding cushion layer portion through the corresponding film layer portion relative to the film layer 220 of the outer circumferential laminate portion 200a.

[0129] This means that the corresponding laminated portions (the outer peripheral portions of the through holes 201) of the outer periphery laminated portion 200a corresponding to the flanges 53 are airtightly and liquidtightly attached to the outer peripheral portions of the female screw holes 34 of the inner panel 30. Therefore, noise, gas, and liquid do not pass through both the female screw holes 34 of the inner panel 30 and the corresponding through holes 201 of the outer periphery laminated portion 200a.

[0130] In addition, the larger the outer diameter of the flange 53 of each pressing tool 50 is, the wider the range of adhesion between the corresponding laminated portion (the outer peripheral portion of each through hole 201) and the outer peripheral portion of each female screw hole 34. Moreover, since the corresponding hard layer portion is difficult to deform as described above, as a result of the fastening as described above, each laminated portion located between the flanges 53 of the multiple pressing tools 50 among the outer peripheral laminated portion 200a can be well adhered to each corresponding portion of the inner panel 30 for each laminated portion.

[0131] As described above, the three-layer laminate 200 can be well adhered to the mounting area of ​​the inner panel 30 under compression of the cushion layer 210. This means that noise, gas, and liquid cannot enter the vehicle interior 10 through the inner panel 30 and the service hole cover member 200 from between the outer panel 20 and the inner panel 30.

[0132] In this manner, the automobile is put into a running state with the service hole cover member 200 attached to the inner panel 30 of the door body Da of the door D. In this state, as in the above-described first embodiment, liquid (e.g., water droplets) may penetrate between the outer panel 20 and the inner panel 30 through the hinge hole portion 21 of the outer panel 20 of the door body Da and / or the gap between the upper ends of the outer panel 20 and the inner panel 30.

[0133] Similarly to the first embodiment, road noise and / or wind noise may be incident on the inner panel 30 through the outer panel 20. Furthermore, road noise and / or wind noise may be incident between the outer panel 20 and the inner panel 30 through the hinge hole of the outer panel 20.

[0134] In contrast to this, in the second embodiment, the cushion layer 210 can exhibit both excellent sound absorbing performance and waterproof performance, similar to the cushion layer 110 described in the first embodiment.

[0135] As described above, the upper protruding laminated portion 210b is firmly inserted into the upper service hole 31 in an airtight and liquid-tight manner, and the lower protruding laminated portion 210c is firmly inserted into the lower service hole 32 in an airtight and liquid-tight manner.

[0136] As described above, due to the flexibility of the cushion layer 210 and the rigidity of the hard layer 230, the laminated portions of the outer periphery laminated portion 200a of the three-layer laminate 200 (service hole cover member 200) corresponding to the flanges 53 are airtightly and liquidtightly adhered to the outer periphery of each female screw hole portion 34 of the inner panel 30. Furthermore, due to the flexibility of the cushion layer 210 and the rigidity of the hard layer 230, the laminated portions between the two pressing tools 50 of the outer periphery laminated portion 200a of the three-layer laminate 200 are also well adhered to the corresponding portions of the inner panel 30 for each of the laminated portions.

[0137] Therefore, even if water droplets penetrate between the outer panel 20 and the inner panel 30 as described above, the waterproof performance of the cushion layer 210 can effectively prevent the water droplets from penetrating into the area between the inner panel 30 and the door trim 40. As a result, the inside of the vehicle compartment 20 can be effectively waterproofed.

[0138] Furthermore, even if road noise or wind noise is incident between the outer panel 20 and the inner panel 30 as described above, the road noise or wind noise can be effectively absorbed by the soft layer 210 due to its sound absorbing performance.

[0139] Even if the road noise or wind noise thus absorbed and attenuated enters the film layer 220 from the soft layer 210, the road noise or wind noise can be satisfactorily blocked by the sound insulating performance of the film layer 220. Furthermore, even if the road noise or wind noise thus absorbed and attenuated enters the hard layer 230 from the film layer 220, the road noise or wind noise can be blocked even more satisfactorily by the sound insulating performance of the three-layer laminated structure of the hard layer 230 described above.

[0140] As a result, the interior of the vehicle compartment 20 can be well soundproofed by the service hole cover member 200 due to the sound absorbing performance of the cushion layer 210 and the sound insulating performance of the film layer 220 and the hard layer 230.

[0141] Based on the above, the service hole cover member 200, like the service hole cover member 100 described in the first embodiment above, can be provided as a single-piece service hole cover member for an automobile door that is capable of exhibiting good sound absorption performance, good sound insulation performance, and also good waterproof performance. Third embodiment 11 shows a third embodiment of the door service hole cover member of an automobile according to the present invention. The door service hole cover member of the third embodiment has a structure in which a skin layer 240 is added to the service hole cover member 200 described in the second embodiment.

[0142] The skin layer 240 is formed of a nonwoven fabric layer made of nonwoven fabric, and is laminated on the hard layer 230 described in the second embodiment so as to face the film layer 220 via the hard layer 230. The reason for adopting the skin layer 240 in the third embodiment is as follows.

[0143] In the hard layer 230, as described in the second embodiment, the glass fiber layer 230c on the other side is adhered to the semi-rigid urethane layer 230b by impregnation with liquid isocyanate between the hard layer 230 and the semi-rigid urethane layer 230b and curing the liquid isocyanate.

[0144] However, if, during the bonding process, the liquid isocyanate impregnated between the semi-rigid urethane layer 230b and the other-side glass fiber layer 230c seeps out from the other-side glass fiber layer 230c to the opposite side from the semi-rigid urethane layer 230b (the surface side of the other-side glass fiber layer 230c), this will impair the appearance of the surface of the other-side glass fiber layer 230c of the service hole cover member 100.

[0145] Therefore, the skin layer 240 is laminated on the surface side of the other-side glass fiber layer 230c. This allows the skin layer 240 to absorb the seepage of isocyanate from the surface of the other-side glass fiber layer 230c with its nonwoven fabric, thereby maintaining a good appearance of the service hole cover member 200. This is the basis for adopting the skin layer 240.

[0146] The skin layer 240 has a thickness within a predetermined thickness range (e.g., 50 μm) and a volume density within a predetermined volume density range (e.g., 100 g / cm 3 The nonwoven fabric is made of synthetic resin fibers such as polyethylene terephthalate (PET) and nylon.

[0147] In the third embodiment, the above-mentioned predetermined thickness range of the nonwoven fabric layer which is the material forming the skin layer 240 is set to, for example, 0.1 mm to 1 mm. The reason why the lower limit of the predetermined thickness range is set to 0.1 mm is that it is difficult to manufacture the nonwoven fabric layer below this lower limit. The reason why the upper limit of the predetermined thickness range is set to 1 mm is that if the nonwoven fabric layer is thicker than this upper limit, the light weight of the service hole cover member 200 is hindered.

[0148] The predetermined volume density range of the nonwoven fabric layer is, for example, 10 g / cm 3 ~300g / cm 3 The lower limit of the specified volume density range is set to 10 g / cm 3 The reason why the upper limit of the volume density range is set to 300 g / cm is that it is difficult to manufacture the nonwoven fabric layer below the lower limit. 3 The reason for this is that if the nonwoven fabric layer has a volume density greater than this upper limit, it will hinder the lightweight nature of the service hole cover member 200. The other configurations of the second embodiment are similar to those of the first embodiment.

[0149] In the third embodiment thus configured, the skin layer 240 made of a nonwoven fabric layer is laminated on the surface side of the other-side glass fiber layer 230c. As a result, as described above, when the other-side glass fiber layer 230c and the semi-rigid urethane layer 230b are bonded by impregnation and curing with liquid isocyanate, even if the liquid isocyanate seeps out to the surface side of the other-side glass fiber layer 230c during the impregnation process, the seeped out isocyanate can be well absorbed by the nonwoven fabric of the skin layer 240.

[0150] This allows the skin layer 240 to maintain a good appearance when the service hole cover member 200 is viewed from the other-side glass fiber layer 230c side. The other effects of the third embodiment are similar to those of the second embodiment.

[0151] It should be noted that the present invention is not limited to the above-described embodiments, and various modifications may be made as follows. (1) In carrying out the present invention, the material forming cushion layer 110 or 210 is not limited to the soft foamed urethane described in the above embodiment, but may be, for example, foamed rubber or foamed elastomer that, like the soft foamed urethane, can exhibit waterproof performance in addition to sound absorbing performance, or in general, any flexible elastic material that has waterproof performance and sound absorbing performance may be used. (2) In carrying out the present invention, the material for forming the film layer 220 is not limited to the nylon described in the above embodiment, but may be, for example, a polymeric material having sound insulation properties, such as polypropylene (PP), polyethylene (PE), or polyethylene terephthalate (PET). (3) In carrying out the present invention, the film layer 220 described in the above embodiment may be a sheet made of a sound-insulating material. In addition, since the film layer 220 has a non-breathable property, the film layer 220 may be replaced with a non-breathable layer made of a non-breathable material. (4) In implementing the present invention, the number of service holes in the inner panel 30 to which the service hole cover member 100 or 200 is assembled may differ from that in the above embodiments and may, for example, be one or three, and generally may be at least one or more. (5) In carrying out the present invention, the positions and number of the through holes in the service hole cover member described in the above embodiment may be changed as necessary. In this case, the positions of the through holes in the service hole cover member may be positions corresponding to the portions of the inner panel that are as close as possible to the service holes.

[0152] For example, in the case of the inner panel 30 in the first embodiment having upper and lower service holes 31, 32, the through holes 101 may be formed at predetermined intervals (e.g., equal intervals) at positions corresponding to the outer peripheries of the upper and lower service holes 31, 32 (outer peripheries as close as possible to the inner peripheries of the upper and lower service holes 31, 32) excluding the common outer periphery 33. Also, the through holes 101 may be formed at predetermined intervals (e.g., equal intervals) at positions corresponding to the outer peripheries of the upper and lower service holes 31, 32, including the common outer periphery 33, of the service hole cover member.

[0153] In addition, the number of through holes in the service hole cover member may be a number that, in conjunction with the formation positions of the through holes in the service hole cover member, enables the service hole cover member to be uniformly adhered to the outer periphery of the service hole at the corresponding locations relative to the outer periphery of the service hole.

[0154] The positions and number of the through holes 34 in the inner panel 30 may be made to correspond to the positions and number of the through holes 101 in the service hole cover member 100. The above also applies to the service hole cover member 200. (6) In implementing the present invention, the board member 120 in the first embodiment is not limited to a board layer made of foamed polypropylene, but may be a board layer made of various synthetic resin materials or other non-metallic materials having sound insulation properties and rigidity. (7) In carrying out the present invention, the service hole cover member 100 in the first embodiment may be formed on a flat plate without forming the upper and lower protruding laminated portions 100b, 100c on both sides.

[0155] In this case, by ensuring a tight fit between the outer peripheries of the upper and lower service holes 31, 32 and the corresponding parts of the cushion layer 110 for these outer peripheries by applying pressure with multiple pressing devices 50, the intrusion of liquid and noise into the dream member 40 from between the outer peripheries of the upper and lower service holes 31, 32 and the corresponding parts of the cushion layer 110 for these outer peripheries can be effectively prevented. (8) In carrying out the present invention, the service hole cover member 200 in the second embodiment may be formed on a flat plate without forming the upper and lower protruding laminated portions 200b, 200c.

[0156] In this case, by ensuring a tight fit between the outer peripheries of the upper and lower service holes 31, 32 and the corresponding parts of the cushion layer 210 for these outer peripheries by applying pressure with multiple pressing devices 50, the intrusion of liquid and noise into the dream member 40 from between the outer peripheries of the upper and lower service holes 31, 32 and the corresponding parts of the cushion layer 210 for these outer peripheries can be effectively prevented. (9) In implementing the present invention, the service hole cover member 100 or 200 is not limited to the left front door D described in the above embodiment, but may also be attached to the inner panel of the right front door, the left rear door or the right rear door from the opposite side of the outer panel so as to cover the service hole. (10) In carrying out the present invention, the female threaded holes 34 of the inner panel 30 may be formed as through holes, unlike the above embodiment, and the male threaded portion 52 of the pressing tool 50 may be formed as a press-in portion that can be press-fitted into the through holes instead of the female threaded holes 34, unlike the above embodiment. This can ensure the same effects as the pressing tool 50 of the above embodiment. (11) Furthermore, in implementing the present invention, the assembly of the service hole cover member to the inner panel 30 is not limited to the assembly using the pressing tool 50 described in the above embodiment, but may be any assembly configuration that can assemble the service hole cover member to the inner panel 30 in a liquid-tight and airtight manner. (12) In carrying out the present invention, the number of protruding laminated portions of the service hole cover member may be one, unlike the above embodiment, and generally may be at least one or more. [Explanation of symbols]

[0157] D...door, Da...door body, 20...outer panel, 30...inner panel, 31, 32...service hole, 34...female thread hole portion, 50...pressure tool, 100a, 200a...peripheral laminated portion, 100b, 100c, 200b, 200c...Protruding laminated part, 101, 201... through hole portion, 110, 210... soft layer (cushion layer), 120...board member, 220...film layer, 230...hard layer, 230a... one side glass fiber layer, 230b... semi-rigid urethane foam layer, 230c...other side glass fiber layer, 240...skin layer.

Claims

1. A service hole cover member applied to an automobile door, a cushion layer that is abutted against the inner panel from the opposite side to the outer panel along the inner panel so as to cover at least one service hole formed in an inner panel provided on a door body of the door together with an outer panel and positioned opposite the outer panel; a board member laminated on the cushion layer so as to face the inner panel via the cushion layer, The cushion layer is made of a soft elastic material having sound absorbing properties and waterproof properties, The board member is a service hole cover member for an automobile door, which is formed into a board shape using a non-metallic material having sound insulation properties and rigidity.

2. the soft elastic material forming the cushion layer is soft urethane foam, foamed rubber, or foamed elastomer having a volume density within a predetermined volume density range, 2. The service hole cover member for an automobile door according to claim 1, wherein the predetermined volume density range is set so as to provide the soft foamed urethane, the foamed rubber or the foamed elastomer with waterproof performance.

3. The predetermined volume density range is 0.005 g / cm 3 ~0.1 g / cm 3 3. The automobile door service hole cover member according to claim 2, wherein said cover member is set to:

4. 2. The vehicle door service hole cover member according to claim 1, wherein the non-metallic material from which the board member is made is a synthetic resin material having sound insulation properties and rigidity.

5. the board member is formed to have a board shape by a two-layer laminate including both a non-breathable layer laminated on the cushion layer so as to face the inner panel with the cushion layer interposed therebetween, and a hard layer laminated on the non-breathable layer so as to face the cushion layer with the non-breathable layer interposed therebetween; The non-breathable layer is formed of a polymer material having sound insulation properties, The hard layer includes a semi-rigid urethane foam layer and two glass fiber layers, The semi-rigid urethane foam layer is formed of semi-rigid urethane foam having sound insulation performance and rigidity, Each of the glass fiber layers is formed of a plurality of glass fibers, one of the glass fiber layers is laminated on the non-permeable layer as a one-side glass fiber layer so as to face the cushion layer via the non-permeable layer; the semi-rigid urethane layer is laminated on the one glass fiber layer so as to face the non-breathable layer via the one glass fiber layer, 2. The service hole cover member for an automobile door as claimed in claim 1, wherein the other of the two glass fiber layers is laminated as an other-side glass fiber layer on the semi-rigid urethane layer so as to face the one-side glass fiber layer via the semi-rigid urethane layer.

6. an outer periphery laminated portion; and at least one protruding laminated portion formed on an inner periphery side of the outer periphery laminated portion so as to correspond to the at least one service hole of the inner panel, A service hole cover member for an automobile door as described in claim 1, characterized in that the at least one protruding laminate portion is formed so as to protrude from the outer peripheral laminate portion so as to be press-fitted into the at least one service hole from the opposite side of the inner panel to the outer panel.

7. an outer periphery laminated portion; and at least one protruding laminated portion formed on an inner periphery side of the outer periphery laminated portion so as to correspond to the at least one service hole of the inner panel, A service hole cover member for an automobile door as described in claim 5, characterized in that the at least one protruding laminate portion is formed so as to protrude from the outer peripheral laminate portion so as to be press-fitted into the at least one service hole from the opposite side of the inner panel to the outer panel.

8. a nonwoven fabric skin layer laminated on the other glass fiber layer so as to face the semi-rigid urethane layer via the other glass fiber layer, 6. The automobile door service hole cover member according to claim 5, wherein the lamination of the other side glass fiber layer to the semi-rigid urethane layer is performed by impregnating the other side glass fiber layer with liquid isocyanate and curing it.

Images