Manufacturing method for overhead ducts for vehicles

Abstract

The present invention provides a method for manufacturing a vehicle ceiling duct that can suppress deformation of the arm portion. [Solution] According to the present disclosure, a method for manufacturing a ceiling duct for a vehicle is provided, comprising a forming step, a cooling step, and a processing step, wherein in the forming step, a parison is formed using a mold to form an intermediate body, the intermediate body includes a main body having length in a first direction, a plurality of arm portions extending in the first direction from the end of the main body, and a support portion connecting the plurality of arm portions, the main body includes a first exhaust port for discharging air, the arm portions include a second exhaust port for discharging air, in the cooling step, the intermediate body is cooled for a predetermined period of time, and in the processing step, the support portion is removed from the intermediate body to form a ceiling duct for a vehicle.

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a ceiling duct for a vehicle.

Background Art

[0002] Patent Document 1 discloses an air conditioner including a plurality of air outlets. This air conditioner includes a duct including a foot outlet and a terminal duct extending toward the rear of the vehicle and including a rear blowout outlet for the driver's seat. In this air conditioner, air sucked through a suction port by the rotation of a fan is blown out from both the foot outlet of the duct and the rear blowout outlet for the driver's seat of the terminal duct.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] When manufacturing the above air conditioner by resin molding, it is conceivable to mold a parison using a mold. However, since the terminal duct is slender and has a shape extending in one direction, when the mold is opened and cooled after molding the parison, the terminal duct may be deformed due to molding shrinkage.

[0005] The present disclosure has been made in view of such circumstances, and provides a method for manufacturing a ceiling duct for a vehicle that can suppress deformation of an arm portion.

Means for Solving the Problems

[0006] According to the present disclosure, the following inventions are provided. [1] A method for manufacturing a ceiling duct for a vehicle, comprising a forming step, a cooling step, and a processing step, wherein in the forming step, a parison is formed using a mold to form an intermediate body, the intermediate body includes a main body having length in a first direction, a plurality of arm portions extending from the end of the main body in the first direction, and a support portion connecting the plurality of arm portions, the main body includes a first exhaust port for discharging air, the arm portions include a second exhaust port for discharging air, in the cooling step, the intermediate body is cooled for a predetermined period of time, and in the processing step, after the cooling step, the support portion is removed from the intermediate body to form a ceiling duct for a vehicle. A method according to [2][1], wherein the main body includes a first air intake and a second air intake, the first air intake and the second air intake introduce air into the main body, the first exhaust port discharges the air introduced from the first air intake, and the second exhaust port discharges the air introduced from the second air intake. A method according to [3][2], wherein the ceiling duct for the vehicle is composed of an upper wall and a lower wall spaced apart from each other, and between the upper wall and the lower wall is formed a first ventilation passage connecting the first air intake and the first exhaust port, and a second ventilation passage connecting the second air intake and the second exhaust port, and the first ventilation passage and the second ventilation passage are fluidly separated from each other. A method according to any one of [4][1] to [3], wherein the second exhaust port is provided at the tip of the arm portion. A method according to any one of [5][1] to [4], wherein the support portion is provided on the side of the second exhaust port that is closer to the center of the arm portion in the first direction. [Effects of the Invention]

[0007] In the method for manufacturing a vehicle ceiling duct according to this disclosure, an intermediate body is formed which includes support parts that connect multiple arm parts, and after the intermediate body has cooled and no more molding shrinkage occurs, the support parts are removed. Since the support parts support the arm parts against molding shrinkage, deformation of the arm parts can be suppressed. [Brief explanation of the drawing]

[0008] [Figure 1] This is a schematic perspective view showing ceiling duct 1. The dashed lines in the figure represent boundaries where the curvature of the surfaces constituting the surface shape changes. The same applies to the other figures. [Figure 2] Figure 1 is a schematic front view of the ceiling duct 1. [Figure 3] This is a cross-sectional view taken along line III-III in Figure 2. [Figure 4] Figure 1 is a schematic rear view of the ceiling duct 1. [Figure 5] Figure 4 is a cross-sectional view along the VV line. [Figure 6] This is a schematic front view showing one step in the manufacturing process of the ceiling duct 1. [Figure 7] This is a schematic enlarged view showing the process after the process shown in Figure 6. [Figure 8] This is a schematic front view showing the process after the process shown in Figure 7. [Figure 9] This is a schematic front view showing the process after the process shown in Figure 8. [Modes for carrying out the invention]

[0009] Embodiments of this disclosure will be described below with reference to the drawings. The various features shown in the embodiments below can be combined with each other. Furthermore, each feature constitutes an independent invention. In addition, any elements in the embodiments below that are not defined in the claims are optional and can be omitted. Any number of zeros (e.g., one or two) may be added to the end of the numerical values ​​disclosed in the following description. For example, one or two zeros may be added after "1.4" to make it "1.40" or "1.400".

[0010] [1. Configuration of Ceiling Duct 1] An embodiment of the ceiling duct 1 (a ceiling duct for a vehicle) of the present disclosure will be described with reference to Figures 1 to 5. The ceiling duct 1 is installed in vehicles such as tractors and excavators. The ceiling duct 1 is located, for example, in the ceiling portion of the cabin. The ceiling duct 1 introduces air supplied from a supply source (not shown) into the cabin.

[0011] As shown in Figure 1, the ceiling duct 1 has length in one direction and width in another direction that intersects (e.g., perpendicularly) that direction. In the following description, one direction may be referred to as the first direction D1, and the other direction as the second direction D2. The direction that intersects (e.g., perpendicularly) both the first and other directions may be referred to as the third direction D3. For example, the first direction D1 coincides with the longitudinal direction of the vehicle, the second direction D2 coincides with the width direction of the vehicle, and the third direction D3 coincides with the height direction of the vehicle. The terms "inside" and "outside" may also be used based on the viewpoint in the drawing.

[0012] The length of the first direction D1 of the ceiling duct 1 is, for example, 50 cm to 150 cm, preferably, for example, 70 cm to 120 cm. Specifically, the length of the first direction D1 of the ceiling duct 1 is, for example, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 105, 110, 115, 120, 125, 130, 135, 140, 145, or 150 cm, and may be within the range of any two of the values ​​exemplified here. In this embodiment, the length of the first direction D1 of the ceiling duct 1 is 143 cm.

[0013] The length of the second direction D2 of the ceiling duct 1 is, for example, 80 cm to 220 cm, preferably, for example, 120 cm to 180 cm. Specifically, the length of the second direction D2 of the ceiling duct 1 is, for example, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220 cm, and may be within the range of any two of the values ​​exemplified here. In this embodiment, the length of the second direction D2 of the ceiling duct 1 is 92 cm.

[0014] As shown in FIG. 2, the ceiling duct 1 includes a main body portion 2 and a plurality of arm portions 3.

[0015] The main body portion 2 is a portion that forms the main body of the ceiling duct 1. The main body portion 2 has a length in the first direction D1. The main body portion 2 is, for example, substantially rectangular in plan view. The main body portion 2 includes an air supply port 2a (first air supply port), an air supply port 2b (second air supply port), and an exhaust port 2c (first exhaust port). In the present embodiment, the main body portion 2 includes a plurality (for example, four) of exhaust ports 2c.

[0016] The air supply ports 2a and 2b introduce air into the main body portion 2. The air supply ports 2a and 2b introduce, for example, the air supplied from the above supply source into the main body portion 2. The air supply ports 2a and 2b are, for example, rectangular in plan view. However, the shape of the air supply ports 2a and 2b is not particularly limited. The air supply port 2a is provided at an end of the main body portion 2 in the first direction D1 and at an end in the second direction D2. The air supply port 2b is located outside the air supply port 2a in the main body portion 2. The air supply port 2b is separated from the air supply port 2a in the first direction D1 and the second direction D2.

[0017] The exhaust port 2c discharges the air introduced from the air supply port 2a. The exhaust port 2c is, for example, rectangular. However, the shape of the exhaust port 2c is not particularly limited. The plurality of exhaust ports 2c are provided at an end of the main body portion 2 opposite to the air supply ports 2a and 2b. Two of the four exhaust ports 2c are provided on one end side of the center of the main body portion 2 in the second direction D2, and the remaining two exhaust ports 2c are provided on the other end side of the center of the main body portion 2 in the second direction D2.

[0018] Since the main body portion 2 includes a plurality of exhaust ports 2c, the number of exhaust ports 2c increases as compared with the case where the main body portion 2 includes only one exhaust port 2c. For this reason, it is possible to blow air over a wider range.

[0019] The arm portion 3 is the part that extends from the end of the main body portion 2 in the first direction D1. The arm portion 3 extends from the end of the main body portion 2 opposite to the air intake ports 2a and 2b. Multiple arm portions 3 are spaced apart from each other in the second direction D2. In this embodiment, each of the multiple arm portions 3 extends from both ends of the main body portion 2 in the second direction D2.

[0020] The arm portion 3 is a rod-shaped hollow body. The length of the arm portion 3 (length in the first direction D1) is, for example, 30 cm to 150 cm, preferably, for example, 50 cm to 100 cm. Specifically, the length of the arm portion 3 can be, for example, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, or 150 cm, and may also be within the range of any two of the values ​​exemplified here. In this embodiment, the length of the arm portion 3 is 61 cm.

[0021] If the length of the arm portion 3 is L1 and the length of the main body portion 2 in the first direction D1 is L2, then the value of L1 / L2 is, for example, 0.5 to 2. Specifically, the value of L1 / L2 is, for example, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, and it may also be within the range of any two of the values ​​exemplified here.

[0022] The width of the arm portion 3 (length in the second direction D2) is, for example, 3 cm to 15 cm, preferably, for example, 5 cm to 10 cm. The width of the arm portion 3 refers to the length of the shortest part in the second direction D2 between the base end of the arm portion 3 and the exhaust port 3c (described later). Specifically, the width of the arm portion 3 is, for example, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15 cm, and may also be within the range of any two of the values ​​exemplified here. In this embodiment, the width of the arm portion 3 is 7.6 cm.

[0023] As shown in Figure 3, if the width of the arm portion 3 is L3, the value of L3 / L1 is, for example, 0.05 to 0.15. Specifically, the value of L3 / L1 is, for example, 0.05, 0.06, 0.07, 0.08, 0.09, 0.10, 0.11, 0.12, 0.13, 0.14, 0.15, and it may also be within the range of any two of the values ​​exemplified here.

[0024] The thickness of the arm portion 3 (length in the third direction D3) is, for example, 1.5 cm to 7.5 cm, preferably, for example, 2.5 cm to 5.0 cm. The thickness of the arm portion 3 refers to the length of the shortest part in the third direction D3 between the base end of the arm portion 3 and the exhaust port 3c. Specifically, the thickness of the arm portion 3 is, for example, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 7.5 cm, and may also be within the range of any two of the values ​​exemplified here. In this embodiment, the thickness of the arm portion 3 is 3.8 cm.

[0025] As shown in Figure 3, if the thickness of the arm portion 3 is L4, the value of L4 / L1 is, for example, 0.02 to 0.08. Specifically, the value of L4 / L1 is, for example, 0.02, 0.025, 0.03, 0.035, 0.04, 0.045, 0.05, 0.055, 0.06, 0.065, 0.07, 0.075, 0.08, and it may also be within the range of any two of the values ​​exemplified here.

[0026] The arm portion 3 includes a flat surface 3a and an inclined surface 3b. The flat surface 3a is a surface that extends substantially parallel to the main body portion 2. The flat surface 3a is a surface that intersects (for example, perpendicular to) the third direction D3. The inclined surface 3b is a surface that is inclined with respect to the flat surface 3a. The inclined surface 3b is inclined from the flat surface 3a toward the inside of the second direction D2 of the ceiling duct 1.

[0027] The arm portion 3 includes an exhaust port 3c (second exhaust port). The exhaust port 3c discharges air introduced from the air intake port 2b. The exhaust port 3c is, for example, rectangular in shape. However, the shape of the exhaust port 3c is not particularly limited. The exhaust port 3c is provided at the tip portion 3d of the arm portion 3. The exhaust port 3c is provided at the end of the arm portion 3 opposite to the main body portion 2. The exhaust port 3c is provided on the inclined surface 3b.

[0028] Since the ceiling duct 1 has multiple arm sections 3, and these arm sections 3 are spaced apart from each other in the second direction D2, the number of exhaust ports 3c increases compared to the case where the ceiling duct 1 has only one arm section 3. Furthermore, the multiple exhaust ports 3c are positioned spaced apart from each other in the second direction D2. As a result, air can be blown over an even wider area.

[0029] Since the exhaust port 3c is located at the tip 3d of the arm portion 3, the exhaust port 3c is positioned away from the main body portion 2. This allows for airflow over a wider area.

[0030] As shown in Figure 4, the ceiling duct 1 includes a ventilation passage 1a (first ventilation passage), a ventilation passage 1b (second ventilation passage), and a hollow section 1c. The ventilation passage 1a communicates with the air intake port 2a and the exhaust port 2c. The ventilation passage 1a is provided in the main body 2. In this embodiment, the ceiling duct 1 includes a plurality (for example, two) of ventilation passages 1a. One ventilation passage 1a communicates with the air intake port 2a and two exhaust ports 2c. The remaining ventilation passage 1a communicates with the air intake port 2a and the remaining two exhaust ports 2c. In other words, the ventilation passage 1a fluidly connects the air intake port 2a and the exhaust ports 2c.

[0031] The ventilation passage 1b communicates with the air intake port 2b and the exhaust port 3c. The ventilation passage 1b is provided in the main body 2 and the arm portion 3. In this embodiment, the ceiling duct 1 includes the same number of ventilation passages 1b as the arm portion 3. The ventilation passage 1b fluidly connects the air intake port 2b and the exhaust port 3c. In a plan view, the ventilation passage 1b is located outside the ventilation passage 1a. The height of the ventilation passage 1b (length in the third direction D3) is approximately equal to the height of the ventilation passage 1a. The width of the ventilation passage 1b (length in the second direction D2) is smaller than the width of the ventilation passage 1a.

[0032] The hollow section 1c is provided in the main body 2. The hollow section 1c is located inside the ventilation passage 1a. The hollow section 1c is a hollow body that forms a space. The width of the hollow section 1c is greater than the width of the ventilation passages 1a and 1b. The height of the hollow section 1c is less than the height of the ventilation passages 1a and 1b.

[0033] As shown in Figure 5, the ceiling duct 1 is composed of an upper wall 1d and a lower wall 1e. The upper wall 1d and the lower wall 1e are made of, for example, resin. The upper wall 1d and the lower wall 1e are spaced apart from each other. For example, when the ceiling duct 1 is mounted on a vehicle, the upper wall 1d is located further from the cabin than the lower wall 1e, and the lower wall 1e is exposed to the cabin space. The lower wall 1e overlaps the upper wall 1d in a third direction D3. Both ends of the upper wall 1d in a second direction D2 are connected to both ends of the lower wall 1e in a second direction D2.

[0034] Between the upper wall 1d and the lower wall 1e, a ventilation passage 1a, a ventilation passage 1b, and a hollow section 1c are formed. The ventilation passages 1a and 1b are formed by welding parts of the upper wall 1d and the lower wall 1e to each other. The ventilation passages 1a and 1b are fluidly separated from each other.

[0035] A welded section 1f is provided between the ventilation passage 1a and the ventilation passage 1b, where the upper wall 1d and the lower wall 1e are welded together. The welded section 1f is provided between the ventilation passage 1a and the ventilation passage 1b, and between the ventilation passage 1a and the hollow section 1c. The welded section 1f airtightly separates the ventilation passage 1a and the ventilation passage 1b. The welded section 1f airtightly separates the ventilation passage 1a and the hollow section 1c. In the welded section 1f, the upper wall 1d is recessed toward the lower wall 1e, and the upper wall 1d reaches the lower wall 1e. As a result, the upper wall 1d is recessed in the welded section 1f, while the lower wall 1e is substantially flat. As described above, the lower wall 1e is exposed to the space of the cabin, for example. By making the lower wall 1e substantially flat, the aesthetic appearance can be improved, and the lower wall 1e can be used as an interior material as is.

[0036] [2. Configuration of the manufacturing apparatus 10] Next, Figure 6 will be used to describe the manufacturing apparatus 10 used in the production of the ceiling duct 1. The manufacturing apparatus 10 includes an extruder (not shown), a head 10a, and a mold 10b. The extruder pushes the raw material resin for the ceiling duct 1 into the head 10a. The configuration of the extruder is not particularly limited. The raw material resin is, for example, a polyolefin. Examples of polyolefins include polypropylene (homopolypropylene, random polypropylene, block polypropylene, etc.) and polyethylene.

[0037] The head 10a has a slit. The head 10a pushes the raw resin extruded from the extruder through the slit to form a parison P. The shape of the slit is, for example, annular. When the shape of the slit is annular, the head 10a forms a cylindrical parison P.

[0038] The mold 10b forms the parison P. The mold 10b is, for example, a split mold 10b1, 10b2 that can be opened and closed. The parison P formed by the head 10a is guided between the split molds 10b1, 10b2.

[0039] The configuration of the manufacturing apparatus 10 described above is merely an example and can be modified as appropriate. For example, the manufacturing apparatus 10 may include an accumulator for storing raw material resin. The accumulator may, for example, store a certain amount of raw material resin extruded from the extruder, and then extrude it from the head 10a to form a parison P. In this case, the extrusion speed of the parison P can be increased.

[0040] [3. Manufacturing method of ceiling duct 1] Next, the manufacturing method of the ceiling duct 1 according to the embodiment of this disclosure will be explained with reference to Figures 6 to 9. This method comprises a forming step, a cooling step, and a processing step.

[0041] [3-1. Formation process] In the forming process, an intermediate 12 (see Figure 8) is formed. In the forming process, the parison P is molded using a mold 10b to form the intermediate 12. In this process, the parison P is molded into a flattened shape that spreads in both the first direction D1 and the second direction D2. First, the extruder pushes the raw resin into the head 10a. Then, the raw resin is pushed out from the head 10a to form the parison P. The parison P is guided between the divided molds 10b1 and 10b2. After closing the divided molds 10b1 and 10b2, the parison P is molded in the cavity of mold 10b.

[0042] The molding method using mold 10b is, for example, blow molding, in which air is blown into the cavity of mold 10b to perform the molding. Alternatively, the molding method may be vacuum molding, in which the parison P is formed by reducing the pressure inside the cavity from the inner surface of the cavity of mold 10b, or a combination of these methods may be used. Furthermore, a surface material (for example, carpet material such as nonwoven fabric) may be placed between mold 10b and parison P before closing the divided molds 10b1 and 10b2. The surface material is attached, for example, in a position visible from the cabin when the ceiling duct 1 is installed in the vehicle. The position in which the surface material is attached is not particularly limited.

[0043] Next, when the split molds 10b1 and 10b2 are opened and the burrs are removed, the intermediate body 11 shown in Figure 7 is formed. The burrs are formed, for example, around the entire circumference of the intermediate body 12 and in the area surrounded by the support portion 12a, the arm portion 3, and the main body portion 2. The burrs are removed immediately after opening the split molds 10b1 and 10b2. This is because the burrs can be easily removed by removing them before the resin constituting the intermediate body 12 cools and solidifies. In this embodiment, the support portion 12a is not removed when the burrs are removed from the intermediate body 12.

[0044] The intermediate body 11 differs from the intermediate body 12 in that a bag portion 11a is formed at the locations where the air intake ports 2a, 2b and exhaust ports 2c, 3c are formed. Furthermore, the configuration of the bag portion 11a is the same for the air intake ports 2a, 2b and the exhaust ports 2c, 3c. Therefore, in Figure 7, only the area around the air intake port 2a is shown, and the other configurations are omitted.

[0045] The bag portion 11a is a bag-shaped member formed to close the opening (simply referred to as the "opening") which becomes the air intake port 2a. The internal space of the bag portion 11a is in communication with the opening. The bag portion 11a protrudes from the opening. In a cross section perpendicular to the third direction D3, the cross-sectional shape of the bag portion 11a is the same as the shape of the opening.

[0046] After forming the intermediate body 11, the bag portion 11a is removed from the intermediate body 11. The method of removing the bag portion 11a is not particularly limited. For example, the bag portion 11a may be removed from the intermediate body 11 by cutting the base of the bag portion 11a. As a result, the opening is exposed, forming the air intake port 2a. Similarly, by removing the bag portion 11a from the air intake port 2b and exhaust ports 2c and 3c, the intermediate body 12 shown in Figure 8 is obtained.

[0047] The intermediate body 12 includes a main body 2, a plurality of arm portions 3, and a support portion 12a. The support portion 12a is a member that connects the plurality of arm portions 3 to each other. The support portion 12a is a rod-shaped member that extends in the second direction D2. The support portion 12a is provided on the side of the exhaust port 3c from the center of the first direction D1 of the arm portion 3. The support portion 12a is provided on the side of the main body 2 from the exhaust port 3c. As will be described later, the support portion 12a is removed from the intermediate body 12 in a later process. If the support portion 12a is provided on the side of the main body 2 from the exhaust port 3c, the possibility of the shape of the exhaust port 3c being distorted by the removal of the support portion 12a can be reduced.

[0048] The width of the support portion 12a (length in the first direction D1) is greater than the width of the arm portion 3. The width of the support portion 12a is, for example, 3 cm to 20 cm, preferably 5 cm to 15 cm. Specifically, the width of the support portion 12a is, for example, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20 cm, and may also be within the range of any two of the values ​​exemplified here. In this embodiment, the width of the support portion 12a is 10 cm.

[0049] The thickness of the support portion 12a is less than the thickness of the arm portion 3. The thickness of the support portion 12a is, for example, 1 cm to 15 cm, preferably 2 cm to 10 cm. Specifically, the thickness of the support portion 12a is, for example, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15 cm, and may be within the range of any two of the values ​​exemplified here. In this embodiment, the thickness of the support portion 12a is 3 mm.

[0050] A thin-walled portion is formed between the support portion 12a and the arm portion 3, which is thinner than the welded portion 1f (see Figure 5). The thin-walled portion may be formed by crushing the parison P with pinch-off portions provided in the divided molds 10b1 and 10b2.

[0051] [3-2. Cooling process] In the cooling process, the intermediate 12 is cooled for a predetermined period of time. In the cooling process, for example, the intermediate 12 formed in the forming process is cooled at room temperature. This period is, for example, 1 hour or more, preferably 12 hours or more. There is no particular upper limit to the period, but for example, 3 days. At this time, molding shrinkage of the resin occurs, and a force is applied to each of the multiple arm portions 3 in a direction toward the center of the second direction D2 of the intermediate 12. The support portion 12a supports each of the multiple arm portions 3 and suppresses deformation of the arm portions 3. The above period should be long enough so that molding shrinkage of the resin no longer occurs.

[0052] [3-3. Processing process] In the manufacturing process, as shown in Figure 9, the ceiling duct 1 is formed by removing the support portion 12a from the intermediate body 12 after the cooling process. The method for removing the support portion 12a is not particularly limited. For example, the support portion 12a may be removed from the intermediate body 12 by cutting the connection portion between the support portion 12a and the arm portion 3. After these steps, the manufacturing of the ceiling duct 1 is completed.

[0053] As described above, the ceiling duct 1 is manufactured by forming the parison P into a flattened shape that extends in both the first direction D1 and the second direction D2 (see, for example, Figure 5). As a result, in the ceiling duct 1, the upper wall 1d and lower wall 1e derived from the parison P overlap in the third direction D3.

[0054] The above describes an example of a method for manufacturing the ceiling duct 1. However, the content and order of each step can be modified as appropriate without departing from the spirit of this disclosure.

[0055] [4. Effects and Benefits] As described above, the arm portion 3 extending from the main body portion 2 in the first direction D1 includes the exhaust port 3c. Therefore, compared to the case where air is discharged only from the exhaust port 2c, it is possible to blow air over a wider area. In addition, since the exhaust port 3c discharges air introduced from an air intake port 2b, which is different from the air intake port 2a, the possibility that the amount of air discharged from the exhaust port 3c will be less than the amount of air discharged from the exhaust port 2c can be reduced. As a result, air can be discharged stably from both the exhaust ports 2c and 3c. Thus, the efficiency of air blowing can be improved.

[0056] As described above, a welded section 1f is provided between the ventilation passages 1a and 1b, where the upper wall 1d and the lower wall 1e are welded together. In this way, the ventilation passages 1a and 1b are formed by welding the two upper walls 1d and the lower wall 1e together, so the ceiling duct 1 can be manufactured more easily compared to, for example, the case where the ventilation passages 1a and 1b are manufactured separately.

[0057] When an intermediate body 11 without the support portion 12a is manufactured, and the bag portion 11a is removed from the intermediate body 11 to manufacture the ceiling duct 1, the arm portion 3 may deform toward the center of the intermediate body 11 in the second direction D2 due to resin molding shrinkage. In the above embodiment, an intermediate body 12 including the support portion 12a is formed, and the support portion 12a is removed after the intermediate body 12 has cooled and no more molding shrinkage occurs. Since the support portion 12a supports the arm portion 3 against molding shrinkage, deformation of the arm portion 3 can be suppressed.

[0058] Since the support portion 12a is a rod-shaped member extending in the second direction D2, the cutting distance at the connection point between the support portion 12a and the arm portion 3 is shortened. Therefore, the support portion 12a can be easily removed from the intermediate body 12.

[0059] Since the support portion 12a is located on the exhaust port 3c side of the center of the arm portion 3 in the first direction D1, multiple arm portions 3 can be firmly supported against molding shrinkage that occurs during the cooling process. Therefore, deformation of the arm portions 3 can be suppressed even more reliably.

[0060] [5. Variant] In the above embodiment, an example was described in which the main body 2 includes air intake ports 2a and 2b. However, the main body 2 may include only one air intake port (for example, only one of air intake ports 2a or 2b). In this case, exhaust ports 2c and 3c may discharge the air introduced from the air intake port.

[0061] In the above embodiment, an example was described in which the exhaust port 3c is provided at the tip portion 3d of the arm portion 3. However, the exhaust port 3c may be provided at a portion of the arm portion 3 other than the tip portion 3d. For example, the exhaust port 3c may be provided at the base end of the arm portion 3.

[0062] In the above embodiment, an example was described in which the main body 2 includes multiple exhaust ports 2c. However, the main body 2 may include only one exhaust port 2c.

[0063] In the above embodiment, an example was described in which the support portion 12a is provided on the exhaust port 3c side of the center in the first direction D1 of the arm portion 3. However, the support portion 12a may also be provided on the exhaust port 2c side of the center in the first direction D1 of the arm portion 3.

[0064] In the above embodiment, an example was described in which the support portion 12a is a rod-shaped member extending in the second direction D2. However, the configuration of the support portion 12a is not limited to anything other than being capable of supporting multiple arm portions 3.

[0065] In the above embodiment, an example was described in which a ceiling duct 1 is manufactured by molding a cylindrical parison P using a mold 10b. However, the ceiling duct 1 may also be manufactured by molding two resin sheets as parison P using the mold 10b. In this case, for example, the manufacturing apparatus 10 may include a pair of extruders and heads 10a provided on each of the pair of extruders. Each of the pair of heads 10a may hang down a resin sheet toward the mold 10b. However, by molding a cylindrical parison P, only one extruder and one head 10a are needed, thus simplifying the configuration of the manufacturing apparatus 10. [Explanation of Symbols]

[0066] 1: Ceiling duct 1a: Ventilation channel (first ventilation channel) 1b: Ventilation channel (second ventilation channel) 1c: Hollow part 1d: Upper wall 1e: Lower wall 1f: Welded part 2: Main body 2a: Air intake (first air intake) 2b: Air intake (second air intake) 2c: Exhaust port (first exhaust port) 3: Arm section 3a:Flat surface 3b: Inclined surface 3c: Exhaust port (second exhaust port) 3d:Tip 10: Manufacturing equipment 10a: Head 10b: Mold 10b1: Split mold 10b2: Split mold 11: Intermediate 11a: Bag part 12: Intermediate 12a: Support part D1: 1st direction D2 :Second direction D3: Third direction L1: Length L2: Length L3:Width L4: Thickness P: Parison

Claims

1. It comprises a forming step, a cooling step, and a processing step, In the above forming step, a parison is formed using a mold to create an intermediate, The intermediate body includes a main body having a length in a first direction, a plurality of arm portions extending in the first direction from the end of the main body, and a support portion connecting the plurality of arm portions. The main body includes a first exhaust port for discharging air, The arm portion includes a second exhaust port for discharging air. In the cooling step, the intermediate is cooled for a predetermined period of time. A method for manufacturing a ceiling duct for a vehicle, wherein in the processing step, after the cooling step, the support portion is removed from the intermediate body to form a ceiling duct for a vehicle.

2. The method according to claim 1, The main body includes a first air intake and a second air intake. The first air intake and the second air intake introduce air into the main body. The first exhaust port discharges the air introduced from the first intake port. A method for discharging the air introduced from the second air intake port, wherein the second exhaust port discharges the air introduced from the second air intake port.

3. The method according to claim 2, The aforementioned ceiling duct for the vehicle is composed of upper and lower walls that are spaced apart from each other. Between the upper wall and the lower wall, A first ventilation passage connecting the first air intake and the first exhaust port, A second ventilation passage is formed connecting the second air intake port and the second exhaust port. A method wherein the first ventilation passage and the second ventilation passage are fluidly separated from each other.

4. A method according to any one of claims 1 to 3, The method wherein the second exhaust port is provided at the tip of the arm portion.

5. A method according to any one of claims 1 to 3, The support portion is provided on the side of the second exhaust port that is closer to the center of the arm portion in the first direction.

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