Door hole seal structure

Abstract

To make it possible to prevent generation of allophone due to a hole seal material, and can achieve improvement in producibility and reduction in cost of manufacture.SOLUTION: A door hole seal structure has a foam body part 6 configured from a foam resin, and a hole seal material 5 which a molding material same as that of an outer peripheral lip part 7 configured from a solid resin. The hole seal material 5 is so located as to block an opening 41 of an inner panel 4, the foam body part 6 is mechanically fixed to the inner panel 4, a tip 721 of the outer peripheral lip part 7 is arranged at a position corresponding to a peripheral edge of the hole seal material 5, and the tip 721 of the outer peripheral lip part 7 is pressed against an outer peripheral part 43 of the inner panel 4 with elastic energization, and a contact state is maintained.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a door hole seal structure for sealing an opening of an inner panel of an automobile door.

Background Art

[0002] In the space between the inner panel and the outer panel of an automobile door, various components such as a speaker device and a door lock device are provided, and an opening is formed in the inner panel for mounting these various components. And this opening is closed by a door hole seal structure as in Patent Documents 1 and 2.

[0003] In the door hole seal structures of Patent Documents 1 and 2, a hole seal material is composed of a sheet-like seal body formed of a foaming material and a synthetic resin film laminated and fixed to the seal body, and the peripheral edge of the synthetic resin film is adhered to the peripheral edge of the opening of the inner panel with a butyl sealant to close the opening with the hole seal material.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0005] By the way, in a structure where a hole seal material composed of a sheet-like seal body of a foamed material and a synthetic resin film laminated and fixed to the seal body is adhered to the peripheral edge of an opening of an inner panel, there is a problem that abnormal noise (rattling noise) is generated due to vibration of the synthetic resin film around the opening. Further, in this structure, since it is necessary to perform an operation of applying and adhering a butyl sealant to a synthetic resin film that easily deforms, there is also a problem that the manufacturing efficiency is inferior and the manufacturing cost is high.

[0006] The present invention is proposed in view of the above problems, and an object thereof is to provide a door hole seal structure that can prevent the generation of abnormal noise caused by the hole seal material and can improve the manufacturing efficiency and reduce the manufacturing cost.

Means for Solving the Problems

[0007] The door hole seal structure of the present invention includes a foamed main body portion made of a foamed resin and an outer peripheral lip portion made of an unfoamed resin The foamed resin that is formed and has a hole seal material which is a molding material. The hole seal material is arranged to close an opening of an inner panel of an automobile door. The foamed main body portion is mechanically fixed to the inner panel, and a tip portion of the outer peripheral lip portion is disposed at a position that becomes the periphery of the hole seal material. The tip portion of the outer peripheral lip portion is elastically biased against an outer peripheral portion of the opening of the inner panel and is maintained in a contact state. Here, "mechanically fixed" means fixation by a mechanical action such as latching fixation, bolt tightening, screwing, caulking fixation, press-fitting fixation, etc., and does not include chemical fixation such as adhesion. According to this, the tip of the outer peripheral lip portion of the hole seal material is elastically biased and pressed against the outer peripheral portion of the opening of the inner panel, so that a surface pressure is always applied without generating a gap, and the tip of the outer peripheral lip portion is pressed against the outer peripheral portion of the inner panel with a pressure exceeding the excitation force of vibration from the outside to suppress the vibration, and it is possible to prevent the generation of abnormal noise (rattling noise) or rattling due to external force. Furthermore, the synthetic resin film adhered to the periphery of the opening of the inner panel does not vibrate and generate abnormal noise, and it is possible to prevent the generation of abnormal noise caused by the hole seal material. And it can exhibit a sound insulation effect and a sound shielding effect for both the high frequency range and the low frequency range such as road noise. In addition, since an operation such as applying and adhering a butyl sealant to a synthetic resin film that is easily deformed is not required, it is possible to improve the manufacturing efficiency and reduce the manufacturing cost. Further, by elastically biasing and pressing the tip of the outer peripheral lip portion against the outer peripheral portion of the opening of the inner panel to maintain the contact state, the sealing property and waterproof property between the outer peripheral portion of the hole seal material and the outer peripheral portion of the opening of the inner panel can be ensured without adhering the outer peripheral portion of the hole seal material and the outer peripheral portion of the opening of the inner panel.

[0008] The door hole seal structure of the present invention is characterized in that the tip of the outer peripheral lip portion is formed in a bead shape. According to this, by making the tip of the outer peripheral lip portion into a bead shape, the strength of the tip of the outer peripheral lip portion can be increased and breakage can be prevented. Furthermore, the contact area due to the contact between the tip of the outer peripheral lip portion and the outer peripheral portion of the opening of the inner panel can be increased, and by this increase in the contact area, the pressing force of the tip of the outer peripheral lip portion can be increased, and the generation of abnormal noise or rattling can be more reliably prevented. Also, by this increase in the contact area, the sealing property and waterproof property between the outer peripheral portion of the hole seal material and the outer peripheral portion of the opening of the inner panel can be further enhanced.

[0009] The door hole seal structure of the present invention is characterized in that an unfoamed standing wall portion made of unfoamed resin is formed on the outer periphery of the foamed main body portion, and the outer peripheral lip portion includes a standing wall extending in the thickness direction of the foamed main body portion, a lip edge formed to incline outward from the standing wall toward the inner panel side, and a crosslinked portion made of unfoamed resin that connects the unfoamed standing wall portion and the standing wall so as to have a substantially H-shaped cross section in a sectional view. According to this, due to the substantially H-shaped cross section formed by the unfoamed standing wall portion, the standing wall, and the crosslinked portion, which are made of unfoamed resin, the strength of the outer peripheral lip portion or the outer peripheral portion of the hole seal material can be increased. Furthermore, due to this substantially H-shaped cross section in a sectional view, the elasticity of the outer peripheral lip portion can be increased, and the elastic force and surface pressure with which the tip of the outer peripheral lip portion is elastically biased against the outer peripheral portion of the opening of the inner panel can be further increased. Therefore, the effects of more reliably preventing the generation of abnormal noises and ensuring the sealing performance and waterproof performance can be obtained.

[0010] The door hole seal structure of the present invention is characterized in that the crosslinked portion is formed at a position closer to the inner panel side than the center of the unfoamed standing wall portion in the thickness direction of the foamed main body portion. According to this, by forming the crosslinked portion at a position closer to the inner panel side than the center of the unfoamed standing wall portion, the elasticity of the outer peripheral lip portion can be further increased, and the elastic force and surface pressure with which the tip of the outer peripheral lip portion is elastically biased against the outer peripheral portion of the opening of the inner panel can be further increased.

[0011] The door hole seal structure of the present invention is characterized in that a force for pulling the foamed main body portion toward the opening side of the inner panel is applied, and the foamed main body portion is hooked and fixed to the peripheral edge of the opening of the inner panel. According to this, by hooking and fixing the foamed main body portion to the periphery of the inner panel, the hole seal material can be easily fixed to the inner panel. Further, by hooking and fixing the foamed main body portion so that a force for pulling it toward the opening side of the inner panel is applied, the elastic force and surface pressure with which the tip portion of the outer peripheral lip portion is elastically biased against the outer peripheral portion of the opening of the inner panel can be further increased.

Effects of the Invention

[0012] According to the door hole seal structure of the present invention, it is possible to prevent the generation of abnormal noises caused by the hole seal material and the generation of abnormal noises caused by external forces, and it is possible to improve the manufacturing efficiency and reduce the manufacturing cost.

Brief Description of the Drawings

[0013]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Modes for Carrying Out the Invention

[0014] 〔Door Hole Seal Structure of the Embodiment〕 The door hole seal structure according to the embodiment of the present invention is provided on the inner panel 4 disposed between the outer panel 2 and the door trim 3 in the automotive door 1 as shown in FIGS. 1 to 3, and is composed of a hole seal material 5 which is the same molding material as a foamed main body portion 6 made of a foamed resin and an outer peripheral lip portion 7 made of an unfoamed resin.

[0015] The foam main body portion 6 of the hole seal material 5 is composed of a foam core layer 61 and a skin layer 62 formed outside the foam core layer 61. Further, a standing wall portion 63 is formed on the outer periphery of the foam main body portion 6, and the outer side of the standing wall portion 63 is an unfoamed standing wall portion 631 composed of unfoamed resin. The standing wall portion 63 is provided around the outside of the core back mark groove 64 that is a circumferential groove.

[0016] The outer peripheral lip portion 7 is composed of a standing wall 71 extending in the thickness direction of the foam main body portion 6, a lip edge 72 formed to incline outward from the standing wall 71 toward the inner panel 4 side, and a cross-linked portion 73 composed of unfoamed resin that connects the unfoamed standing wall portion 631 and the standing wall 71 so as to have a substantially H shape in cross section. The lip edge 72 in the illustrated example is formed to curve in a substantially arc shape and incline from the end of the standing wall 71, and its tip portion 721 is disposed at a position that becomes the peripheral edge of the hole seal material 5 and is formed in a bead shape. Further, the cross-linked portion 73 in the illustrated example is formed at a position closer to the inner panel 4 side than the center of the unfoamed standing wall portion 631 in the thickness direction of the foam main body portion 6 and is installed between the unfoamed standing wall portion 631 and the standing wall 71.

[0017] On the surface of the foam main body portion 6 on the inner panel 4 side in the present embodiment, a plurality of engaging holes 65 for a latching tool, each composed of a portion protruding in a substantially U shape, and latching hooks 66 formed with claws facing outward are provided at a plurality of predetermined locations, and are integrally formed as a part of the skin layer 62 of the foam main body portion 6. A latching tool 8 of a separate member is inserted and engaged in the engaging holes 65 for a latching tool.

[0018] Then, the hole seal member 5 is arranged to close the opening 41 of the inner panel 4, and the foamed main body portion 6 is mechanically fixed to the inner panel 4. In the present embodiment, the latching hook 66 is hooked inside the peripheral edge 42 of the opening 41 of the inner panel 4, and the tip hook 81 of the latching tool 8 engaged with the latching tool engagement hole 65 is hooked and latched inside the peripheral edge 42 of the opening 41 of the inner panel 4 (see FIGS. 2 to 4). That is, a force is applied to pull the foamed main body portion 6 toward the opening 41 side of the inner panel 4, and the foamed main body portion 6 is latched and fixed to the peripheral edge 42 of the opening 41 of the inner panel 4.

[0019] The tip portion 721 of the outer peripheral lip portion 7 of the hole seal member 5 mechanically fixed to the inner panel 4 by latching is elastically biased and pressed against the outer peripheral portion 43 of the opening 41 of the inner panel 4, and the contact state is maintained. In the illustrated example, the tip portion 721 in the shape of a bead edge is elastically biased and pressed against the outer peripheral portion 43 of the opening 41 of the inner panel 4, which is formed to incline and curve in a substantially arc shape toward the passenger compartment side from the peripheral edge 42 extending in the substantially vertical direction, and the contact state is maintained.

[0020] When manufacturing the hole seal member 5 used in the door hole seal structure of the present embodiment, for example, as shown in FIG. 5(a), a cavity 90 composed of an outer peripheral lip portion 7, a standing wall portion 63, and a cavity having a shape corresponding to a substrate surrounded by the standing wall portion 63 and having a thickness thinner than the height of the standing wall portion 63 is partitioned and formed by fixed molds 91, 92 and a movable mold 93. When the foaming molten resin is molded, the movable mold 93 is arranged to retreat in the direction of the thick two-dot chain line arrow shown in the figure. The fixed mold 92 is arranged on the surface of the cavity in the shape of the standing wall portion 63 on the side where the movable mold 93 retreats, and the side surface of the movable mold 93 is arranged on the inner surface of the cavity in the shape of the standing wall portion 63.

[0021] Next, as shown in FIG. 5(b), the foaming molten resin MR is injected into the cavity 90 from the injection path of the foaming molten resin (not shown) and filled. For this foaming molten resin, an appropriate material applicable to the hole seal member 5 of the automotive door 1 can be used. For example, olefin resins such as PP (polypropylene) and PE (polyethylene), amorphous resins such as ABS (acrylonitrile-butadiene-styrene copolymer) and a mixed resin of PC (polycarbonate) and ABS, thermoplastic elastomers such as olefin-based ones, or synthetic rubbers such as EPDM (ethylene propylene diene rubber), SBR (styrene butadiene rubber), CR (chloroprene rubber), and NBR (nitrile rubber) are suitable. In this embodiment, a gap 911 corresponding to the shape of the substantially U-shaped portion constituting the latch engaging hole 65 and a gap 912 corresponding to the shape of the latch hook 66 are provided in the fixed mold 91, and the foaming molten resin MR is also filled in the gaps 911 and 912. A metal bar that can move forward and backward within the fixed mold 91 or can be detachably attached to the fixed mold 91 is installed at a portion corresponding to the latch engaging hole 65. During the injection and filling of the foaming molten resin MR, it is blocked by the metal bar so that a shape corresponding to the latch engaging hole 65 is formed.

[0022] Thereafter, as shown in FIG. 5(c), the movable mold 93 is core-backed in the direction of the thick arrow shown in the figure to foam the foaming molten resin MR, and the hole seal member 5 composed of the foamed main body portion 6 and the outer peripheral lip portion 7 is formed. At this time, in this embodiment, the substantially U-shaped portion constituting the latch engaging hole 65 and the latch hook 66 are also formed in the formed hole seal member 5.

[0023] According to the door hole seal structure of the present embodiment, the tip 721 of the outer peripheral lip portion 7 of the hole seal material 5 is elastically biased and pressed against the outer peripheral portion 43 of the opening 41 of the inner panel 4, and a surface pressure is always applied without creating a gap between the outer peripheral portion 43 and the tip 721. The tip 721 of the outer peripheral lip portion 7 is pressed against the outer peripheral portion 43 of the inner panel 4 with a pressure exceeding the exciting force of vibration from the outside to suppress the vibration, and it is possible to prevent the generation of abnormal noise (rattling noise) or rattling due to external force. Furthermore, the synthetic resin film adhered around the opening 41 of the inner panel 4 does not vibrate and generate abnormal noise, and it is also possible to prevent the generation of abnormal noise caused by the hole seal material 5. And it can exhibit a sound insulation effect and a noise shielding effect for both the high frequency range and the low frequency range such as road noise.

[0024] Also, in the door hole seal structure of the present embodiment, since it is not necessary to perform an operation of applying a butyl sealant to a synthetic resin film that is easily deformed and adhering it to the inner panel, it is possible to improve the manufacturing efficiency and reduce the manufacturing cost. Further, by elastically biasing and pressing the tip 721 of the outer peripheral lip portion 7 against the outer peripheral portion 43 of the opening 41 of the inner panel 4 to maintain the contact state, even without adhering the outer peripheral portion of the hole seal material 5 and the outer peripheral portion 43 of the opening 41 of the inner panel 4, the sealing performance and waterproof performance between the outer peripheral portion of the hole seal material 5 and the outer peripheral portion 43 of the opening 41 of the inner panel 4 can be ensured.

[0025] Also, by making the tip 721 of the outer peripheral lip portion 7 into a bead shape, the strength of the tip 721 of the outer peripheral lip portion 7 can be increased to prevent breakage. Furthermore, the contact area due to the contact between the tip 721 of the outer peripheral lip portion 7 and the outer peripheral portion 43 of the opening 41 of the inner panel 4 can be increased. By this increase in the contact area, the pressing force of the tip 721 of the outer peripheral lip portion 7 can be increased, and the generation of abnormal noise or rattling can be more reliably prevented. Also, by this increase in the contact area, the sealing performance and waterproof performance between the outer peripheral portion of the hole seal material 5 and the outer peripheral portion 43 of the opening 41 of the inner panel 4 can be further enhanced.

[0026] In addition, the strength of the outer peripheral lip portion 7 or the outer peripheral portion of the hole sealing material 5 can be increased by the substantially H-shaped cross-section formed by the unfoamed standing wall portion 631 made of unfoamed resin, the standing wall 71, and the cross-linking portion 73. Further, due to this substantially H-shaped cross-section, the elasticity of the outer peripheral lip portion 7 can be increased, and the elastic force and surface pressure with which the tip portion 721 of the outer peripheral lip portion 7 is elastically biased against the outer peripheral portion 43 of the opening 41 of the inner panel 4 can be further increased. Therefore, the effects of more surely preventing the generation of abnormal noises and ensuring the sealing property and waterproof property can be obtained.

[0027] Also, by forming the cross-linking portion 73 at a position closer to the inner panel 4 side than the center of the unfoamed standing wall portion 631, the elasticity of the outer peripheral lip portion 7 can be further increased, and the elastic force and surface pressure with which the tip portion 721 of the outer peripheral lip portion 7 is elastically biased against the outer peripheral portion 43 of the opening 41 of the inner panel 4 can be further increased.

[0028] In addition, by hooking and fixing the foamed main body portion 6 to the peripheral edge 42 of the inner panel 4, the hole sealing material 5 can be easily fixed to the inner panel 4. Also, by hooking and fixing the foamed main body portion 6 so that a force for pulling it toward the opening 41 side of the inner panel 4 is applied, the elastic force and surface pressure with which the tip portion 721 of the outer peripheral lip portion 7 is elastically biased against the outer peripheral portion 43 of the opening 41 of the inner panel 4 can be further increased.

[0029] 〔Scope of the Invention Disclosed in this Specification〕 The invention disclosed in this specification includes, in addition to each invention and embodiment listed as the invention, within the applicable range, those obtained by changing some of these contents to other contents disclosed in this specification and specifying them, or those obtained by adding other contents disclosed in this specification to these contents and specifying them, or those obtained by deleting some of these contents to the extent that partial operational effects can be obtained and generalizing them to a higher concept. And the invention disclosed in this specification also includes the following modification examples and added contents.

[0030] For example, in the door hole seal structure of the above embodiment, the foamed main body 6 is configured to be hooked and fixed to the inner panel 4. However, the door hole seal structure of the present invention includes an appropriate configuration for mechanically fixing the foamed main body to the inner panel in addition to hooking and fixing. Here, "mechanically fixing" means fixing by a mechanical action such as hooking and fixing, bolt tightening, screwing, caulking fixing, press-fitting fixing, etc., and does not include chemical fixing such as adhesion.

[0031] In addition, although the shape of the tip portion 721 of the outer peripheral lip portion 7 in the above embodiment is formed in a bead shape, the present invention also includes those in which the shape of the tip portion of the outer peripheral lip portion is other than the bead shape. Also, the shape of the outer peripheral lip portion in the present invention is also appropriate within the scope of the gist of the present invention and is not limited to the substantially H-shaped cross-section of the above embodiment.

Industrial Applicability

[0032] The present invention can be used when closing the opening of the inner panel of an automobile door.

Explanation of Reference Numerals

[0033] 1... Automobile door 2... Outer panel 3... Door trim 4... Inner panel 41... Opening 42... Peripheral edge 43... Outer peripheral portion 5... Hole seal material 6... Foamed main body 61... Foamed core layer 62... Skin layer 63... Standing wall portion 631... Unfoamed standing wall portion 64... Core back mark groove 65... Hooking tool engagement hole 66... Hooking hook 7... Outer peripheral lip portion 71... Standing wall 72... Lip edge 721... Tip portion 73... Crosslinked portion 8... Hooking tool 81... Tip hook 90... Cavity 91... Fixed mold 911, 912... Gap 92... Fixed mold 93... Movable mold MR... Foamable molten resin

Claims

1. A hole seal material which is a foamed resin molding material having a foamed main body portion made of a foamed resin and an outer peripheral lip portion made of an unfoamed resin, wherein the foamed main body portion is composed of a foamed core layer and a skin layer formed outside the foamed core layer, the hole seal material is arranged to close an opening of an inner panel of an automobile door, the foamed main body portion is mechanically fixed to the inner panel, a tip portion of the outer peripheral lip portion is disposed at a position that becomes a peripheral edge of the hole seal material, and the tip portion of the outer peripheral lip portion is elastically biased against an outer peripheral portion of the opening of the inner panel to maintain a contact state. A door hole seal structure characterized by this.

2. A hole seal material which is a foamed resin molding material having a foamed main body portion made of a foamed resin and an outer peripheral lip portion made of an unfoamed resin, the hole seal material is arranged to close an opening of an inner panel of an automobile door, the foamed main body portion is mechanically fixed to the inner panel, a tip portion of the outer peripheral lip portion is disposed at a position that becomes a peripheral edge of the hole seal material, the tip portion of the outer peripheral lip portion is elastically biased against an outer peripheral portion of the opening of the inner panel to maintain a contact state, and an unfoamed standing wall portion made of an unfoamed resin is formed on an outer periphery of the foamed main body portion, the outer peripheral lip portion is composed of a standing wall extending in a thickness direction of the foamed main body portion, a lip edge formed to be inclined outward from the standing wall toward the inner panel side, and a crosslinked portion made of an unfoamed resin connecting the unfoamed standing wall portion and the standing wall so as to have a substantially H shape in a cross-sectional view. A door hole seal structure characterized by this.

3. The door hole seal structure according to claim 2, wherein the bridging portion is formed at a position closer to the inner panel side than the center of the unfoamed vertical wall portion in the thickness direction of the foamed main body portion.

4. The door hole seal structure according to any one of claims 1 to 3, wherein the tip of the outer peripheral lip portion is formed in a bead shape.

5. The door hole seal structure according to any one of claims 1 to 4, wherein the foamed main body portion is attracted to the opening side of the inner panel, and the foamed main body portion is hooked and fixed to the periphery of the opening of the inner panel.

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