Vehicle door and sealing cover attachment method of the same

Abstract

To prevent occurrence of a failure caused by a sealing cover for closing an opening of an inner panel being peeled from a butyl tape in a vehicle door.SOLUTION: A vehicle door D includes an outer panel 1 and an inner panel 2. The inner panel 2 has openings h which penetrate through the inner panel 2 in a thickness direction to allow an internal space formed between the inner panel 2 and the outer panel 1 to communicate with the vehicle inner side. The vehicle door D has a sealing cover 6 which is disposed at the vehicle inner side of the inner panel 2 so as to cover the openings h. The sealing cover 6 is bonded to a vehicle inner surface of the inner panel 2 by an adhesive 7 which is provided continuously at least at front, lower, and rear sides of the openings h with respect to a vehicle front-back direction X. The sealing cover 6 has a shrinkage percentage smaller in the vehicle front-back direction X than that in a vertical direction Y.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a vehicle door and a method for attaching a sealing cover to a vehicle door. [Background technology]

[0002] BACKGROUND ART Doors used as side doors of automobiles (hereinafter referred to as "vehicle doors") include an outer panel and an inner panel, and are configured by joining the inner panel to the inner side of the outer panel.

[0003] The inner panel has one or more openings that penetrate the panel from inside to outside. Electrical components mounted on the door panel, such as a power window regulator, are installed and wired through the openings in the inner panel.

[0004] A sealing cover (also called a hole seal) is attached to the inside of the inner panel, sealing the opening to prevent foreign matter such as water or dust that has entered the interior of the door panel through the sash part of the door panel or the sliding part of the window glass from entering the vehicle interior through the opening in the inner panel. Self-fusing tape made of butyl rubber (hereinafter referred to as "butyl tape") is generally used to attach the sealing cover to the inner panel. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Publication No. 11-151937 Summary of the Invention [Problem to be solved by the invention]

[0006] The butyl tape is placed on the inner panel so as to cover the entire periphery of the opening. While the sealing cover has the property of shrinking due to the effects of heat and the passage of time, the butyl tape does not shrink as much as the sealing cover.

[0007] Therefore, when the sealing cover shrinks, wrinkles form in the sealing cover where the butyl tape does not follow, causing the sealing cover to peel off from the butyl tape and forming a gap between the sealing cover and the butyl tape. If the gap is located below the opening, in other words, along the lower edge of the sealing cover, foreign matter that has entered the interior of the vehicle through the opening in the inner panel, such as water, may reach the gap by running along the inner surface of the inner panel or the back surface of the sealing cover, and depending on the size of the gap, may leak into the vehicle interior.

[0008] In view of the above circumstances, an object of the present invention is to prevent problems caused by a sealing cover that closes an opening in an inner panel in a vehicle door peeling off from a butyl tape. [Means for solving the problem]

[0009] To solve the above-mentioned problems, a vehicle door according to one embodiment of the present invention includes an outer panel and an inner panel joined to the vehicle interior side of the outer panel. A space is formed between the outer panel and the inner panel, and the inner panel has an opening that penetrates the inner panel in its thickness direction and communicates the space with the vehicle interior side. The vehicle door also includes a sealing cover arranged on the vehicle interior side of the inner panel to cover the opening. The sealing cover is attached to the vehicle interior surface of the inner panel with an adhesive that is continuously provided at least in front of, below, and behind the opening in the vehicle front-rear direction. The sealing cover has a smaller shrinkage rate in the vehicle front-rear direction than in the vehicle up-down direction.

[0010] A method for attaching a sealing cover to a vehicle door according to another embodiment of the present invention includes a conveying step of conveying a uniaxially stretched film in its stretching direction, a cutting step of cutting a sealing cover from the uniaxially stretched film during conveyance, and a pasting step of pasting the cut-out sealing cover to an inner panel of the vehicle door with an adhesive so as to close an opening of the inner panel from the vehicle interior side. In the cutting step, the sealing cover is cut out in an orientation in which its width direction is perpendicular to the conveying direction of the film or within a range of 45° forward or backward from the direction perpendicular to the conveying direction, and in the pasting step, the width direction of the sealing cover is aligned with the longitudinal direction of the vehicle and pasted with adhesive continuously provided at least in front of, below, and behind the opening in the longitudinal direction of the vehicle. [Effects of the Invention]

[0011] According to the present invention, the sealing cover has a smaller shrinkage rate in the longitudinal direction of the vehicle than in the vertical direction. Therefore, when the sealing cover shrinks due to heat or the passage of time, the shrinkage in the longitudinal direction of the vehicle can be kept smaller than that in the vertical direction. This makes it possible to prevent peeling caused by the difference in shrinkage rate between the adhesive provided below the opening and the sealing cover attached by this adhesive. Therefore, it is possible to prevent foreign matter that passes through the opening in the inner panel from moving between the inner panel and the sealing cover and entering the vehicle interior through a gap created by peeling of the sealing cover, thereby preventing problems caused by peeling of the sealing cover from the butyl tape. [Brief explanation of the drawings]

[0012] [Figure 1] 1 is a view showing a vehicle door according to an embodiment of the present invention as viewed from inside the vehicle; [Figure 2] 4A to 4C are diagrams schematically showing a manufacturing process of the sealing cover provided on the vehicle door. [Figure 3]4 is a diagram showing a schematic diagram of a cutting process of the sealing cover from a raw sheet (film material). FIG. [Figure 4] 10A and 10B are explanatory diagrams showing a modified example of the cutting step. [Figure 5] 1 is an explanatory diagram showing the principle of peeling of the sealing cover. FIG. [Figure 6] 10A to 10C are diagrams illustrating examples of patterns in which adhesive is applied. [Figure 7] 10A and 10B are diagrams schematically showing other examples of patterns in which adhesive is applied. [Figure 8] 10A and 10B are explanatory diagrams showing the effect of providing discontinuous portions in the adhesive. [Figure 9] FIG. 10 is a diagram schematically showing a slit provided in the sealing cover. DETAILED DESCRIPTION OF THE INVENTION

[0013] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to the drawings.

[0014] FIG. 1 shows a vehicle door D according to one embodiment of the present invention as viewed from inside the vehicle. In FIG. 1, a left-right arrow X indicates the front-rear direction of the vehicle, and an up-down arrow Y indicates the up-down direction of the vehicle. In the state shown in FIG. 1, the front-rear direction X of the vehicle coincides with the width direction Dw of the vehicle door D, and the up-down direction Y coincides with the height direction Dh of the vehicle door D. In FIG. 1, the left side is the front of the vehicle, and the right side is the rear of the vehicle. A direction perpendicular to both the arrow X and the arrow Y corresponds to the left-right direction of the vehicle.

[0015] A vehicle door D according to this embodiment (hereinafter simply referred to as "vehicle door") constitutes a side door of an automobile such as a passenger car. FIG. 1 shows the door with the door trim removed. In this embodiment, a case where the vehicle door D is applied to a front side door disposed on the side of the front seats will be described. However, the vehicle door D is not limited to this, and can also be applied to a rear side door disposed on the side of the rear seats.

[0016] The vehicle door D has, as its main elements, an outer panel 1, an inner panel 2, and a door trim 3. FIG. 1 schematically shows the door trim 3 using a two-dot chain line. The outer panel 1 and the inner panel 2 are both made of sheet metal, and the inner panel 2 is joined to the interior side of the outer panel 1 to form a main body of the vehicle door D (hereinafter sometimes referred to as the "panel main body"). The panel main body has a closed cross-sectional structure, and a space (hereinafter sometimes referred to as the "internal space of the panel main body") is formed between the outer panel 1 and the inner panel 2. In this embodiment, the vehicle door D is a so-called sash-integrated door in which a door sash portion 4 is integrally formed with the panel main body. The door sash portion 4 has a quadrilateral frame shape as a whole and forms a window opening that guides a retractable glass 5 so that it can slide up and down. The door trim 3 is attached to the interior side of the inner panel 2 to form the interior of the vehicle compartment.

[0017] The inner panel 2 has a plurality of openings h (two in this embodiment) that penetrate the panel from the inside to the outside and connect the interior space of the panel body to the vehicle interior. These openings h are called service holes and are used for installing and wiring electrical components, such as a power window regulator, that are attached to the panel body. There is no limit to the number of service holes h, and they are not limited to two, and may be one, or three or more. The shape of the service holes h shown in FIG. 1 is shown simply for convenience and does not represent the actual shape.

[0018] A sealing cover 6 is attached to the surface of the inner panel 2 facing the interior of the vehicle, i.e., the inner surface 21 of the inner panel 2. The sealing cover 6 is provided to seal the service hole h from the interior of the vehicle and prevent foreign matter such as water or dust that has entered the internal space of the panel body from the door sash portion 4 or the like from entering the vehicle interior through the service hole h. The sealing cover 6 can be formed from a synthetic resin film material such as PE-LLD (low-density polyethylene), and is arranged to cover the entire service hole h. When multiple service holes h are provided, the sealing cover 6 may cover each individual service hole h or may cover multiple service holes h collectively. In the example shown in FIG. 1 , two service holes h arranged side by side in the fore-and-aft direction X are collectively covered by a single sealing cover 6.

[0019] The sealing cover 6 is attached to the inner surface 21 of the inner panel 2 using an adhesive 7. An example of the adhesive 7 that can be used to attach the sealing cover 6 is a self-fusing tape, and in this embodiment, a butyl tape, which is a type of self-fusing tape, is used.

[0020] The butyl tape 7 is continuously provided on the inner surface 21 of the inner panel 2 on at least three sides in front of, below, and behind the service hole h in the longitudinal direction X of the vehicle. This arrangement allows the sealing cover 6 to retain foreign matter, such as water, that has entered between the inner panel 2 and the sealing cover 6 through the service hole h. In this embodiment, the butyl tape 7 is arranged so as to surround the entire periphery of the service hole h, front to back and top to bottom.

[0021] Here, when multiple service holes h (h1, h2) are formed side by side in the fore-and-aft direction X of the vehicle, the butyl tape 7 is provided at least in front of, below, and behind each of the multiple service holes h. Specifically, when multiple service holes h are collectively covered with a single sealing cover 6, the butyl tape 7 is provided forward of the front edge of the forwardmost service hole h1 and rear of the rearmost service hole h2, and is also provided continuously below the multiple service holes h1, h2 so as to bridge between the front and rear butyl tapes 7. On the other hand, when multiple service holes h (h1, h2) are each covered with an individual sealing cover 6, the butyl tape 7 is provided continuously in front of, below, and behind each of the multiple service holes h.

[0022] The sealing cover 6 has anisotropy with respect to shrinkage rate, and has a smaller shrinkage rate in the longitudinal direction X of the vehicle than in the vertical direction Y. Setting such a shrinkage rate can be realized, for example, by using a uniaxially stretched film as the material of the sealing cover 6 and aligning the stretching direction of the sealing cover 6 with a direction perpendicular to the longitudinal direction X of the vehicle, that is, with the vertical direction Y of the vehicle. However, this is not limited to this, and it is also possible to form the sealing cover 6 from a film material having anisotropy with respect to shrinkage rate and align the direction with the smallest shrinkage rate with the longitudinal direction X of the vehicle.

[0023] 2 and 3 show schematic diagrams of the manufacturing process of the sealing cover 6 to be provided on the vehicle door D. Fig. 2 shows the process of producing a roll (hereinafter simply referred to as "roll") R of raw material M from which the sealing cover 6 is cut out, and Fig. 3 shows the process of cutting out the sealing cover 6 from the raw material M unwound from the roll R.

[0024] The manufacturing process of the sealing cover 6 mainly includes a first step of forming a roll R of raw material (i.e., film material) M, a second step of unwinding the film material M from the roll R, and a third step of cutting out the sealing cover 6 from the unwinding film material M. In this embodiment, the first and second steps are performed chronologically, and the second and third steps are performed substantially simultaneously.

[0025] As shown in FIG. 2, in the first step, synthetic resin pellets such as low-density polyethylene are melted and the molten synthetic resin is extruded by an extruder E. The extruded synthetic resin is cooled and solidified while being stretched by cooling rollers C. Here, the synthetic resin cools while its molecular chains are oriented in the extrusion direction D1 by the extruder E (cooling factor). The synthetic resin is then conveyed while applying tension in the extrusion direction or its extension direction D1 (conveyance factor), and is wound up by a winder W. In this way, the film material M is wound up by the winder W in a state in which its molecular chains are stretched due to the cooling and conveyance factors, and it comes to have anisotropy in terms of shrinkage rate.

[0026] As shown in FIG. 3, in the second step, the roll R of the raw web M is transferred from the winder W to the unwinder, and the film material M is unwound from the unwinder. Then, in the third step after unwinding, a sealing cover 6 is cut out from the film material M. The sealing cover 6 is cut out so that its width direction Dw, i.e., the direction aligned with the longitudinal direction X of the vehicle, is perpendicular to the unwinding direction of the film material M or the subsequent conveying direction D2. The unwinding direction of the film material M from the roll R and the conveying direction D2 of the film material M during cutting coincide with the extrusion direction of the molten resin in the first step and the conveying direction D1 of the raw web M after extrusion, and thus coincide with the orientation direction of the molecular chains. In this embodiment, the dimension of the width direction Dw of the sealing cover 6 is longer than the dimension of the height direction Dh.

[0027] Thereafter, the cut-out sealing cover 6 is attached to the inner panel 2 of the vehicle door D with butyl tape 7 so as to cover the service hole h from the inside of the vehicle. As described above, when attaching the sealing cover 6, the sealing cover 6 is positioned so that its width direction Dw is aligned with the front-rear direction X of the vehicle and its height direction Dh is aligned with the up-down direction Y of the vehicle.

[0028] In this embodiment, when the sealing cover 6 is cut out from the original film material M, the width direction Dw of the sealing cover 6 is set to be aligned with a direction perpendicular to the unwinding or conveying direction D2 of the film material M. The orientation of the sealing cover 6 when cut out is not limited to this, and it is sufficient if the width direction Dw of the sealing cover falls within a range of 45° before and after the direction perpendicular to the unwinding or conveying direction D2 of the film material M.

[0029] FIG. 4 shows an example of the third step and its modifications. FIG. 4(a) shows a case where the sealing cover 6 is oriented such that the width direction Dw is perpendicular to the unwinding or conveying direction D2 of the film material M when cut out from the film material M. FIGS. 4(b) and 4(c) show cases where the sealing cover 6 is oriented such that the width direction Dw is inclined forward or backward relative to the direction perpendicular to the unwinding or conveying direction D2 of the film material M. As shown in FIG. 4(b), the sealing cover 6 may be cut out with its width direction Dw inclined forward of the unwinding direction D2 at an angle θ relative to the direction perpendicular to the unwinding or conveying direction D2 of the film material M. Alternatively, as shown in FIG. 4(c), the sealing cover 6 may be cut out with its width direction Dw inclined backward of the unwinding direction D2 at an angle θ. Here, the angle θ is an angle between 0° and 45°.

[0030] The vehicle door D according to this embodiment has the above-described configuration. The effects obtained by this embodiment will be described below.

[0031] In this embodiment, the sealing cover 6 that covers the service hole h is attached to the inner surface 21 of the inner panel 2 with adhesive 7 that is continuously provided at least in front of, below, and behind the service hole h in the fore-and-aft direction X of the vehicle. This makes it possible to prevent foreign matter such as water or dust that has passed through the service hole h from adhering to the door trim 3 or from further passing through the door trim 3 and entering the vehicle interior.

[0032] Here, the sealing cover 6 has shrinkage properties and shrinks due to the effects of heat and the passage of time, whereas the butyl tape 7 used as the adhesive for the sealing cover 6 does not have the same shrinkage properties as the sealing cover 6. Therefore, when the sealing cover 6 shrinks, wrinkles occur in the sealing cover 6 in places where the butyl tape 7 does not follow, and the sealing cover 6 peels off from the butyl tape 7, forming a gap between the sealing cover 6 and the butyl tape 7.

[0033] Figure 5 shows the principle by which the sealing cover 6 peels off due to the difference in shrinkage between the sealing cover 6 and the butyl tape 7. Figure 5(a) shows the state of the sealing cover 6 before shrinkage occurs, and Figure 5(b) shows the state of the sealing cover 6 after shrinkage occurs.

[0034] As shown in FIG. 5( a ), before shrinkage, the sealing cover 6 is not wrinkled and is in close contact with the butyl tape 7 .

[0035] 5(b), while the sealing cover 6 shrinks, the butyl tape 7 does not shrink as much as the sealing cover 6, and in the areas where the butyl tape 7 does not follow the shrinkage of the sealing cover 6, a difference in perimeter occurs between the sealing cover 6 and the butyl tape 7, causing wrinkles or waves 6w in the sealing cover 6. When this difference in perimeter becomes significant, the wrinkles 6w expand, causing the sealing cover 6 to peel off from the butyl tape 7, and forming a gap between the sealing cover 6 and the butyl tape 7.

[0036] If the gap occurs below the service hole h, in other words, along the lower edge of the sealing cover 6, foreign matter, such as water, entering the interior of the vehicle through the service hole h can reach the gap by traveling along the inner surface 21 of the inner panel 2 or the back surface of the sealing cover 6, and depending on the size of the gap, may leak into the vehicle interior. In FIG. 1, arrows A1 to A3 indicate the path of water movement. Arrow A1 indicates the movement of water entering the internal space of the panel body through the gap in the door sash portion 4, arrow A2 indicates the movement of water entering the interior of the vehicle through the service hole h, and arrow A3 indicates the movement of water passing through the gap between the sealing cover 6 and the butyl tape 7.

[0037] In contrast to this, in the present embodiment, the sealing cover 6 has a smaller shrinkage rate in the longitudinal direction X of the vehicle than in the vertical direction Y, so that when shrinkage occurs in the sealing cover 6 due to the influence of heat or the passage of time, the shrinkage occurring in the longitudinal direction X of the vehicle can be kept relatively small, specifically, it can be kept smaller than the shrinkage occurring in the vertical direction Y of the vehicle.

[0038] This makes it possible to prevent peeling caused by differences in shrinkage rates between the butyl tape 7 provided below the service hole h and the portion of the sealing cover 6 attached by this butyl tape 7. In this embodiment, a drainage outlet 22 that penetrates the inner panel 2 in its thickness direction is provided below the service hole h, specifically directly above the portion of the service hole h where the butyl tape 7 is provided, and water that has entered the vehicle interior through the service hole h (arrow A2) is discharged to the outside of the vehicle through this drainage outlet 22 (arrow A4).

[0039] Therefore, according to this embodiment, it is possible to prevent foreign matter that has passed through the opening in the inner panel 2 (i.e., the service hole h) from moving between the inner panel 2 and the sealing cover 6 and entering the vehicle interior through a gap created by peeling off of the sealing cover 6, thereby preventing the occurrence of defects caused by peeling off of the sealing cover 6 from the butyl tape 7.

[0040] In this embodiment, the dimension of the sealing cover 6 is set to be longer in the front-rear direction X than in the up-down direction Y of the vehicle.

[0041] Here, when cutting out a sealing cover 6 that is longer in the longitudinal direction X of the vehicle than in the vertical direction Y, in other words, a sealing cover 6 whose dimension in the width direction Dw is longer than its dimension in the height direction Dh, in a typical manufacturing process, the width direction Dw of the sealing cover 6 is aligned with the conveying direction D2 of the film material M. This is because by aligning the height direction Dh of the sealing cover 6 with a direction perpendicular to the conveying direction D2, the equipment involved in the manufacturing of the sealing cover 6 or the space occupied by the sealing cover 6 during conveyance can be made compact in the direction perpendicular to the conveying direction D2, i.e., in the depth direction.

[0042] In this embodiment, the dimension of the sealing cover 6 is set to be longer in the width direction Dw than in the height direction Dh, and the sealing cover 6 is cut out from the film material M in a direction in which the width direction Dw of the sealing cover 6 is perpendicular to the conveying direction D2 of the film material M. As a result, although the space occupied by the sealing cover 6 during conveyance extends in the depth direction, it is possible to avoid or suppress a situation in which peeling of the sealing cover 6 occurs below the service hole h, that is, at the lower edge of the sealing cover 6, due to a difference in shrinkage rate with the butyl tape 7, and it becomes possible for the sealing cover 6 to effectively seal in foreign matter that has entered the vehicle interior through the service hole h.

[0043] Furthermore, in this embodiment, the sealing cover 6 is formed from a uniaxially stretched film, and the orientation of the sealing cover 6 when it is attached to the inner surface 21 of the inner panel 2 is set so that the stretching direction of the film material M, which is the original roll, is the vertical direction Y of the vehicle. This clarifies the difference in shrinkage rate of the sealing cover 6 between the front-rear direction X and the vertical direction Y of the vehicle when the sealing cover 6 is attached to the inner surface 21 of the inner panel 2, and makes it possible to more reliably suppress peeling of the sealing cover 6 that occurs below the service hole h.

[0044] In the above description, the butyl tape 7 is arranged to surround the entire periphery of the service hole h. However, the arrangement of the butyl tape 7 is not limited to this, and the butyl tape 7 may be removed at any other location as long as it surrounds the service hole h from the front, bottom, and rear.

[0045] 6(a) shows an example of a pattern for applying butyl tape 7, and FIG. 6(b) shows an example of a pattern for applying butyl tape 7 in the present embodiment. As shown in FIG. 6(b), by disposing butyl tape 7 in front of, below, and behind service hole h, and eliminating or removing it above service hole h, it is possible to ensure the watertightness of butyl tape 7, prevent foreign matter from entering the vehicle interior, and reduce the amount of butyl tape 7 used.

[0046] Furthermore, the butyl tape 7 can be provided not only continuously between both ends, but also in a partially discontinuous manner.

[0047] 7A and 7B are diagrams schematically illustrating another example of a pattern for applying butyl tape 7. FIG. 7A illustrates an application pattern in which an interruption or slit 71 is provided in the butyl tape 7 above the service hole h, and FIG. 7B illustrates a pattern in which an interruption or slit 72 (72a, 72b) is provided in the butyl tape 7 in front of or behind the service hole h. The interruption 72 in the butyl tape 7 may be provided only in front of or behind the service hole h, or, as shown in FIG. 7B, it may be provided both in front of and behind the service hole h. By providing the interruptions 71 and 72 in the butyl tape 7 in this way, shrinkage that occurs in the sealing cover 6 can be absorbed by these interruptions 71 and 72, making it possible to prevent the sealing cover 6 from peeling off.

[0048] Specifically, as shown in Figure 7(a), by providing an interrupted portion 71 in the butyl tape 7 above the service hole h, it is possible to prevent the sealing cover 6 from peeling off above the service hole h, and as shown in Figure 7(b), by providing an interrupted portion 72 (72a, 72b) in the butyl tape 7 in front of or behind the service hole h, it is possible to prevent the sealing cover 6 from peeling off in front of or behind the service hole h.

[0049] Here, since the sealing cover 6 has a relatively large shrinkage rate in the vertical direction Y of the vehicle, by providing an interrupted portion 72 (72a, 72b) in the butyl tape 7 in front of or behind the service hole h, the shrinkage of the sealing cover 6 in areas where shrinkage is relatively likely to occur can be effectively absorbed by the interrupted portions 72 (72a, 72b) of the butyl tape 7, thereby helping to prevent peeling.

[0050] 8 is an explanatory diagram showing the effect of providing interrupted portions 71, 72 in the butyl tape 7, and is a schematic cross-sectional view showing the state of the sealing cover 6 and the butyl tape 7 after shrinkage of the sealing cover 6. Fig. 8(a) shows the case where the butyl tape 7 is provided with no interrupted portions and is provided continuously between both ends, and Fig. 8(b) shows the case where an interrupted portion 7i is formed in the butyl tape 7 and is provided discontinuously in part.

[0051] As shown in Figure 8(a), when the butyl tape 7 does not have any interruptions, the difference in shrinkage rate between the sealing cover 6 and the butyl tape 7 causes a circumferential shift between them to be concentrated, resulting in relatively large wrinkles 6wa in the sealing cover 6. In contrast, as shown in Figure 8(b), when the butyl tape 7 has interruptions 7i, the circumferential shift between the sealing cover 6 and the butyl tape 7 is dispersed to the front and rear of the interruptions 7i, and the wrinkles 6wb in the sealing cover 6 are kept relatively small. As a result, by providing the interruptions 7i in the butyl tape 7, it is possible to prevent wrinkles from occurring in the sealing cover 6 that could cause peeling, and to maintain the sealing cover 6 bonded to the butyl tape 7.

[0052] 7(b), in the interrupted portion 72 provided in front of or behind the service hole h, the butyl tapes 7 are arranged so as to overlap each other in the front-to-rear direction X of the vehicle with a gap therebetween. Furthermore, the inner butyl tape 7a closer to the service hole h extends upward from the interrupted portion 72a, and the outer butyl tape 7b farther from the service hole h extends downward from the interrupted portion 72b. This prevents foreign matter that has passed through the service hole h, such as water, from crossing the butyl tapes 7a, 7b of the interrupted portions 72a, 72b in a forward or rearward direction, and also makes it possible to guide foreign matter that moves or drips from above into the space enclosed by the sealing cover 6 and toward the drain outlet 22 provided near the lower edge of the sealing cover 6.

[0053] FIG. 9 shows a schematic diagram of an embodiment in which a slit 6s is provided in the sealing cover 6. In FIG.

[0054] In the sealing cover 6, a slit 6s is formed in the portion that joins to the butyl tape 7 in a direction that crosses the butyl tape 7, in other words, in a direction perpendicular to the extending direction of the butyl tape 7. This makes it possible to suppress wrinkles that occur in the sealing cover 6 due to the difference in shrinkage rate between the sealing cover 6 and the butyl tape 7, and to suppress peeling of the sealing cover 6 from the butyl tape 7.

[0055] Here, by forming a slit 6s in the sealing cover 6 at a location where the extension direction of the film material M that forms the sealing cover 6 coincides with the extension direction of the butyl tape 7, in the example shown in Figure 9, at a location in front of or behind the service hole h, it is possible to effectively suppress the occurrence of wrinkles in the sealing cover 6 and prevent the sealing cover 6 from peeling off.

[0056] In the above description, a uniaxially stretched film is used as the film material M of the sealing cover 6. However, this is not limiting, and any appropriate film material having anisotropy in terms of shrinkage rate can be used. The sealing cover 6 is cut out from such a film material, and is positioned so that the direction with the smallest shrinkage rate is aligned with the longitudinal direction X of the vehicle, and is bonded with an appropriate adhesive 7 such as butyl tape 7. As a result, as described above, it is possible to suppress shrinkage that occurs in the sealing cover 6 below the service hole h and prevent the sealing cover 6 from peeling off.

[0057] Furthermore, in the above explanation, after the roll R of the uniaxially stretched film M is produced, the sealing cover 6 is cut out from the raw material unwound from the roll R, i.e., the film material M having stretchability in one direction. However, it is not limited to this, and a non-stretched film having no anisotropy in terms of shrinkage rate may be used as the material, and by performing a stretching and heating process on this, stretchability and anisotropy may be imparted to the sealing cover 6, and the sealing cover 6 may be cut out.

[0058] Furthermore, it is also possible to cut out the sealing cover 6 directly from the film material M during transportation after extrusion, without forming the roll R of the raw material M. [Explanation of symbols]

[0059] D...vehicle door (front side door), 1...outer panel, 2...inner panel, 3...door trim, 4...door sash portion, 5...window glass (liftable glass), 6...sealing cover, 6s...slit, 6w...wrinkle, 7...adhesive (butyl tape), 71, 72...intermittent portion, h, h1, h2...service hole (opening), E...extruder, C...cooling roller, W...winder, M...raw material, film material, D1...extrusion direction, conveying direction, D2...feeding direction, conveying direction.

Claims

1. The outer panel and an inner panel joined to the outer panel on the vehicle interior side, A space is formed between the outer panel and the inner panel, The inner panel has an opening that penetrates the inner panel in a thickness direction and communicates the space with an interior side of the vehicle, a sealing cover disposed on the vehicle interior side of the inner panel so as to cover the opening; The sealing cover is the adhesive is attached to the vehicle interior surface of the inner panel by a continuous adhesive at least in front of, below, and behind the opening in the front-to-rear direction of the vehicle; A vehicle door having a smaller shrinkage rate in a front-to-rear direction of the vehicle than in a top-to-bottom direction of the vehicle.

2. The vehicle door according to claim 1 , wherein the sealing cover has a dimension in the front-rear direction that is longer than a dimension in the up-down direction.

3. 2. The vehicle door according to claim 1, wherein the sealing cover is formed of a uniaxially stretched film, and the stretching direction of the film is set to the vertical direction.

4. The vehicle door according to claim 1 , wherein the sealing cover has anisotropy with respect to the shrinkage rate, and the direction in which the shrinkage rate is smallest is set to the front-rear direction.

5. The vehicle door according to claim 1 , wherein the adhesive has an interrupted portion in a portion provided in front of or behind the opening.

6. 6. The vehicle door according to claim 5, wherein in the interrupted portion, the adhesives are arranged side by side with a gap in the front-to-rear direction and overlapping in the front-to-rear direction, and the adhesive on an inner side closer to the opening continues upward from the interrupted portion, and the adhesive on an outer side farther from the opening continues downward from the interrupted portion.

7. The vehicle door according to claim 1 , wherein the sealing cover has a slit formed across the adhesive in a portion provided in front of or behind the opening.

8. The vehicle door according to claim 1 , wherein the adhesive is a self-fusing tape.

9. a conveying step of conveying the uniaxially stretched film in its stretching direction; a cutting step of cutting out a sealing cover from the uniaxially stretched film during conveyance; and a bonding step of bonding the cut-out sealing cover to an inner panel of a vehicle door with an adhesive so as to close an opening of the inner panel from the inside of the vehicle, In the cutting step, the sealing cover is cut out in a direction in which its width direction is perpendicular to the conveying direction of the film or within a range of 45° before and after the conveying direction with respect to the direction perpendicular to the conveying direction, In the attaching process, the width direction of the sealing cover is aligned with the fore-and-aft direction of the vehicle, and the sealing cover is attached using adhesive that is continuously provided at least in front of, below, and behind the opening in the fore-and-aft direction of the vehicle.

10. The method for attaching a sealing cover to a vehicle door according to claim 9, wherein in the cutting out step, the sealing cover is cut out so that it is longer in a width direction than in a height direction.

Images