Cargo room trim and trim manufacturing method

Abstract

The present invention provides cargo room trim and a trim manufacturing method which allow formation from a front side portion to a rear side portion of a plate material constituting the cargo room trim by using a single plate, while securing noise absorption performance in a high-frequency range.　Provided is cargo room trim (1) which is located in at least one of a lateral direction and an upward direction with respect to a rear wheel (103) of a vehicle (100) and which forms a side wall of a cargo room (102), the cargo room trim (1) comprising: a first plate part (10) which is formed from resin having an elongation ratio of 120% or greater and which has an outward-facing recess (11) recessed from the inside to the outside of the cargo room (102) and an inward-facing recess (12) continuous with the outward-facing recess (11) in the longitudinal direction of the cargo room (102) and recessed from the outside to the inside of the cargo room (102); a second plate part (20) disposed along the first plate part (10); and a sound-absorbing material (30) disposed between the first plate part (10) and the second plate part (20).

Description

Technical Field

[0001] The present disclosure relates to a cargo room trim and a trim manufacturing method.

Background Art

[0002] Patent Document 1 discloses a cargo room trim in which an apron (described as "trunk side trim" in Patent Document 1) is arranged on the front side of a vehicle, a lid portion is arranged on the rear side of the vehicle, and a sound absorption member is arranged outside these aprons.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] For example, regarding the front part of the cargo room trim such as the aforementioned apron, a fiber-reinforced sheet containing glass fiber is used as a wall material facing the cargo room for the sound absorption effect. This fiber-reinforced sheet mainly absorbs tire pattern noise in the high-frequency range because of its sound absorption characteristics.

[0005] Regarding the rear part of the cargo room trim such as the aforementioned lid portion, it is a part where deep drawing is desired to increase the volume of the cargo room. However, since the elongation rate of the fiber-reinforced sheet is not high, it is necessary to separately use a resin with a high elongation rate or an INJ molding resin (injection molding resin).

[0006] In this case, although the front part of the cargo room trim can be formed with a member having a low elongation rate, the rear part of the cargo room trim needs to be formed with a member having a high elongation rate, and the front part and the rear part will be formed separately.

[0007] The present invention has been made in view of such circumstances, and an object thereof is to provide a cargo room trim and a trim manufacturing method capable of forming a single plate from the front side portion to the rear side portion of a plate material constituting the cargo room trim while ensuring the sound absorption performance of noise in the high frequency range.

Means for Solving the Problems

[0008] In order to solve such problems, the cargo room trim of the present invention is a cargo room trim disposed at least in either the lateral direction or the upward direction of the rear wheels of a vehicle and constituting a side wall of the cargo room, and is composed of a resin having an elongation rate of 120% or more, an outward concave portion that is recessed from the inside to the outside of the cargo room, and an inward concave portion that is continuous in the front-rear direction of the cargo room with respect to the outward concave portion and is recessed from the outside to the inside of the cargo room. It has a first plate portion, a second plate portion disposed along the first plate portion, and a sound absorbing material disposed between the first plate portion and the second plate portion.

[0009] According to this cargo room trim, the double wall structure of the first plate portion and the second plate portion and the sound absorbing material between the first plate portion and the second plate portion absorb the tire pattern noise in the high frequency range. Further, since the first plate portion is formed of a resin having an elongation rate of 120% or more, even if drawing or the like is performed, the member of the front side portion of the first plate portion constituting the cargo room trim can be used as the material of the member of the rear side portion without breaking. As a result, while ensuring the sound absorption performance of noise in the high frequency range, it is possible to form a single plate from the front side portion to the rear side portion of the plate material constituting the cargo room trim.

Effects of the Invention

[0010] According to the present invention, while ensuring the sound absorption performance of noise in the high frequency range, it is possible to form a single plate from the front side portion to the rear side portion of the cargo room trim.

Brief Description of the Drawings

[0011]

Figure 1

Figure 2

Figure 3

Figure 4

[0012] Hereinafter, the present invention will be described in accordance with preferred embodiments. Note that the present invention is not limited to the embodiments shown below, and can be appropriately modified without departing from the gist of the present invention. Further, in the embodiments shown below, there are some parts where the illustration and description of some configurations are omitted. However, it goes without saying that well-known or publicly known techniques are appropriately applied within the range that does not conflict with the content described below regarding the details of the omitted techniques.

[0013] FIG. 1 is a perspective view of a vehicle 100 in which a cargo room trim 1 according to the present embodiment is applied, as viewed obliquely from the rear. The cargo room trim 1 constitutes a side wall of a cargo room 102 behind a rear seat 101 of the vehicle 100. In FIG. 1, the cargo room trim 1 is shown in a state as viewed from the inside of the cargo room 102.

[0014] FIG. 2 is a perspective view of the cargo room trim 1 as viewed from the outside. FIG. 3 is an exploded perspective view of the cargo room trim 1. FIG. 4(a) is a conceptual diagram showing the configuration of the cargo room trim 1. In FIGS. 2 and 3, the cargo room trim 1 is shown at an angle when viewed from the outside of the cargo room 102. The cargo room trim 1 is disposed at least in either the lateral direction or the upward direction of a rear wheel 103 of the vehicle (see FIG. 4(a)) and constitutes a side wall of the cargo room 102 (see FIG. 1). The cargo room trim 1 includes a first plate portion 10, a second plate portion 20, a sound-absorbing material 30, and a third plate portion 40.

[0015] The first plate portion 10 is made of a resin having an elongation rate of 120% or more. The resin of the first plate portion 10 includes 40% by weight or more and 90% by weight or less of polypropylene, 10% by weight or more and 30% by weight or less of polyethylene terephthalate, and 0% by weight or more and 10% by weight or less of talc. Incidentally, it is more desirable that the first plate portion 10 is made of a resin having an elongation rate of 150% or more. The first plate portion 10 is joined to the third plate portion 40.

[0016] The first plate portion 10 has an outward recess 11 on the rear side in the cargo room trim 1. The outward recess 11 is formed by drawing so as to recess from the inside to the outside of the cargo room 102 (see FIG. 1). Incidentally, the outward recess 11 may be formed by protruding. Also, the drawing may be deep drawing or shallow drawing.

[0017] Further, the first plate portion 10 has an inward recess 12 that is continuous with the outward recess 11 on the front side (front-rear direction) in the cargo room trim 1 and recesses from the outside to the inside of the cargo room 102. In this case, the continuity means that the inward recess 12 may be directly continuous with the outward recess 11 or may be indirectly continuous with the outward recess 11 with another portion interposed therebetween. The first plate portion 10 has a part to be inserted 13 in the inward recess 12. A hole 13a is formed in the part to be inserted 13. The second supported portion 23, which will be described later, of the second plate portion 20 is inserted into the hole 13a of the part to be inserted 13.

[0018] The second plate portion 20 is made of a resin having an elongation rate of 120% or more. The second plate portion 20 is arranged along the first plate portion 10. The resin of the second plate portion 20 includes 40% by weight or more and 90% by weight or less of polypropylene, 10% by weight or more and 30% by weight or less of polyethylene terephthalate, and 0% by weight or more and 10% by weight or less of talc. Incidentally, it is more desirable that the second plate portion 20 is made of a resin having an elongation rate of 150% or more.

[0019] The second plate portion 20 has a facing portion 21, a first supported portion 22, a second supported portion 23, a contact portion 24, and a protruding portion 25. The facing portion 21 is a portion disposed at a distance from the first plate portion 10. The facing portion 21 faces the sound-absorbing material 30 with the sound-absorbing material 30 filled between the facing portion 21 and the first plate portion 10.

[0020] The first supported portion 22 is a portion that extends from the facing portion 21 to the first plate portion 10 and is supported by the first plate portion 10 when the tip of the first supported portion 22 is welded to the first plate portion 10. A plurality of the first supported portions 22 are formed on the upper portion of the facing portion 21. The first supported portion 22 has extending portions 22a and 22b that extend from the facing portion 21 to the first plate portion 10, and a welded portion 22c (tip portion) that extends from the tip of the extending portion 22a and is welded (see FIG. 4(a)).

[0021] The second supported portion 23 is a portion that is supported by the first plate portion 10 by being inserted into the hole 13a of the inserted portion 13 of the first plate portion 10.

[0022] The contact portion 24 is a portion that further extends from the extending portion 22b extending from the facing portion 21 to the first plate portion 10 and is in contact with the first plate portion 10. The contact portion 24 is in contact with the first plate portion 10 without being welded thereto.

[0023] The protruding portion 25 is a portion that protrudes in a direction away from the first plate portion 10 from the contact position where the contact portion 24 contacts the first plate portion 10 and is capable of contacting the vehicle body panel 50 (see FIG. 4(a)). The protruding portion 25 has an extending portion 25a that extends from the first plate portion 10 side to the facing portion 21 side, and a contactable portion 25b that can contact the vehicle body panel 50.

[0024] FIG. 4(b) is a partially enlarged conceptual diagram of the second plate portion 20. The second plate portion 20 has a base material portion 20a and a coating portion 20b. The coating portion 20b is formed integrally with the base material portion 20a from a softer material than the base material portion 20a, faces the vehicle body panel 50, and covers the base material portion 20a. The coating portion 20b is laminated on the base material portion 20a by extrusion lamination.

[0025] The sound-absorbing material 30 is disposed between the facing portion 21 of the first plate portion 10 and the second plate portion 20. The sound-absorbing material 30 has a first sound-absorbing portion 31 that covers the outward concave portion 11 and a second sound-absorbing portion 32 that covers the inward concave portion 12 (see Fig. 3). Note that the sound-absorbing material 30 is thick before being sandwiched between the second plate portion 20 and the first plate portion 10, and becomes thin when sandwiched between the second plate portion 20 and the first plate portion 10.

[0026] Next, the operation of the cargo room trim 1 of the present embodiment will be described. Among the noises N generated from the rear wheels 103 (see Fig. 4(a)), the high-frequency tire pattern noise passes through the second plate portion 20, is attenuated between the second plate portion 20 and the first plate portion 10, and is absorbed by the sound-absorbing material 30. Among the noises N generated from the rear wheels 103, the low-frequency road noise is reflected by the second plate portion 20 and is sound-insulated. Therefore, the noise reaching the cargo room 102 is reduced, and the sound insulation inside the cargo room 102 is realized.

[0027] According to the cargo room trim 1 of the present embodiment described above, the high-frequency tire pattern noise is absorbed by the double-wall structure of the first plate portion 10 and the second plate portion 20 and the sound-absorbing material 30 between the first plate portion 10 and the second plate portion 20. Further, since the first plate portion 10 is formed of a resin having an elongation rate of 120% or more, even if drawing or the like is performed, the member of the rear side portion can be manufactured with the material of the front side portion of the first plate portion 10 constituting the cargo room trim 1 without breaking. As a result, while ensuring the sound absorption performance of high-frequency noise, the front side portion to the rear side portion of the cargo room trim 1 can be formed as a single plate.

[0028] In the double-wall structure of the first plate portion 10 and the second plate portion 20, by filling the sound-absorbing material 30 between the first plate portion 10 and the second plate portion 20, it is possible to suppress a decrease in transmission loss due to the coincidence effect and resonance transmission.

[0029] Further, according to the cargo room trim 1 of the present embodiment, weight reduction is achieved as compared with the prior art, the manufacturing cost is reduced, the moldability of the cargo room trim is improved as compared with the prior art, and the rigidity is stronger than the prior art.

[0030] That is, even if a high specific gravity rubber sheet is not provided outside the first plate portion 10, by forming a double wall structure by the opposing portion 21 between the first plate portion 10 and the second plate portion 20, sound absorption performance is ensured while achieving the above-described weight reduction. Further, by not using a rubber sheet, cost reduction is achieved.

[0031] In addition, since the welded portion 22c of the first supported portion 22 is welded to the first plate portion 10, the second plate portion 20 can be attached to the first plate portion 10 without an adhesive. Further, since the second plate portion 20 is supported by the first plate portion 10 when the second supported portion 23 is inserted into the hole 13a of the inserted portion 13, the second plate portion 20 can be attached to the first plate portion 10 without an adhesive. Since it can be attached without an adhesive in this way, the above-described reduction in manufacturing cost is achieved.

[0032] In addition, by the resin of the first plate portion 10 and the second plate portion 20 including 40% by weight or more and 90% by weight or less of polypropylene, 10% by weight or more and 30% by weight or less of polyethylene terephthalate, and 0% by weight or more and 10% by weight or less of talc, sound insulation performance of low-frequency load noise is ensured. Since such resin of the first plate portion 10 and the second plate portion 20 has a high elongation rate, the above-described improvement in moldability is achieved.

[0033] In addition, even if the protruding portion 25 of the second plate portion 20 contacts the vehicle body panel 50 and a load is applied to the protruding portion 25, the protruding portion 25 maintains the interval between the first plate portion 10 and the second plate portion 20. Due to such a protruding portion 25, the rigidity of the cargo room trim 1 is enhanced. In addition, conventionally, chip urethane was disposed between the fiber-reinforced sheet and the vehicle body panel to enhance the rigidity, but that chip urethane becomes unnecessary, and the above-described reduction in manufacturing cost is achieved.

[0034] In addition, since the covering portion 20b of the soft material of the second plate portion 20 contacts the vehicle body panel 50, the impact sound when the second plate portion 20 hits the vehicle body panel 50 is reduced.

[0035] The present invention has been described based on the embodiments. However, the present invention is not limited to the above embodiments, and modifications may be made without departing from the spirit of the present invention, or other technologies may be appropriately combined within the possible range. For example, in the foregoing embodiments, the second plate portion 20 was configured not to cover the outward concave portion 11 of the first plate portion 10 and the first sound absorption portion 31 of the sound absorption material 30. However, the present invention is not limited to the above embodiments, and the second plate portion 20 may be configured to cover the outward concave portion 11 of the first plate portion 10 and the first sound absorption portion 31 of the sound absorption material 30.

[0036] Also, in the foregoing embodiments, the welded portion 22c of the first supported portion 22 was configured to be welded to the first plate portion 10. However, the present invention is not limited to the above embodiments, and a inserted portion 13 having a hole 13a may be formed in the first plate portion 10 at a position corresponding to the welded portion 22c of the first supported portion 22, and the tip of the first supported portion 22 may be inserted into the hole 13a of such an inserted portion 13. In this way, if the connection between the first plate portion 10 and the second plate portion 20 is configured such that the tip of the second plate portion 20 is inserted into the hole 13a of the inserted portion 13 of the first plate portion 10 at all locations, not only may no adhesive be required, but also a configuration where welding is not necessary can be achieved.

[0037] Also, in the foregoing embodiments, the method of manufacturing the trim of the cargo room trim was not separately described. However, the trim manufacturing method may include, for example, a drawing process of forming the outward concave portion 11 in the first plate portion 10 by drawing, a sound absorption material arranging process of arranging the sound absorption material 30 on the outer surface of the cargo room 102 of the first plate portion 10, and a second plate portion arranging process of arranging the second plate portion 20 on the outer surface of the sound absorption material 30 of the cargo room 102.

Explanation of Reference Numerals

[0038] 1 Cargo room trim 10 First plate portion 11 Outward concave portion 12 Inward concave portion 13 Inserted portion 13a Hole 20 Second plate portion 20a Base material portion 20b Coating portion 21 Opposite part 22 First supported part 22a Extension part 22b Extension part 22c Welded part (tip part) 23 Second supported part 24 Contact part 25 Protrusion part 25a Extension part 25b Contactable part 30 Sound-absorbing material 31 First sound-absorbing part 32 Second sound-absorbing part 40 Third plate part 50 Vehicle body panel 100 Vehicle 101 Rear seat 102 Cargo room 103 Rear wheel N Noise

Claims

1. A cargo room trim that is disposed at least either laterally or upwardly of the rear wheels of a vehicle and constitutes a side wall of a cargo room, comprising a first plate portion made of a resin having an elongation rate of 120% or more, an outward concave portion that is recessed from the inside to the outside of the cargo room, and an inward concave portion that is continuous with the outward concave portion in the front-rear direction of the cargo room and is recessed from the outside to the inside of the cargo room, a second plate portion disposed along the first plate portion, and a sound-absorbing material disposed between the first plate portion and the second plate portion, wherein the second plate portion has an opposing portion that faces the sound-absorbing material disposed between the second plate portion and the first plate portion, and a second supported portion that extends from the opposing portion to the first plate portion and is supported by the first plate portion, the first plate portion has a portion to be inserted, in which a hole for inserting the second supported portion is formed, and the second supported portion is supported by the first plate portion by being inserted into the hole of the portion to be inserted. The cargo room trim is characterized by this.

2. A cargo room trim that is disposed at least either laterally or upwardly of the rear wheels of a vehicle and constitutes a side wall of a cargo room, comprising a first plate portion made of a resin having an elongation rate of 120% or more, an outward concave portion that is recessed from the inside to the outside of the cargo room, and an inward concave portion that is continuous with the outward concave portion in the front-rear direction of the cargo room and is recessed from the outside to the inside of the cargo room, a second plate portion disposed along the first plate portion, and a sound-absorbing material disposed between the first plate portion and the second plate portion, wherein the second plate portion is made of a resin having an elongation rate of 120% or more, and the resins of the first plate portion and the second plate portion comprise 40% by weight or more and 90% by weight or less of polypropylene, 10% by weight or more and 30% by weight or less of polyethylene terephthalate, and 0% by weight or more and 10% by weight or less of talc. The cargo room trim is characterized by this.

3. A cargo room trim that is disposed at least either laterally or upwardly of the rear wheels of a vehicle and constitutes a side wall of a cargo room, comprising a first plate portion made of a resin having an elongation rate of 120% or more, an outward concave portion that is recessed from the inside to the outside of the cargo room, and an inward concave portion that is continuous with the outward concave portion in the front-rear direction of the cargo room and is recessed from the outside to the inside of the cargo room, a second plate portion disposed along the first plate portion, a sound-absorbing material disposed between the first plate portion and the second plate portion The second plate portion has a protruding portion that protrudes in a direction away from the first plate portion from the contact position with the first plate portion and can contact the vehicle body panel. The cargo room trim is characterized by this.

4. The second plate portion has an opposing portion that opposes the sound-absorbing material disposed between the second plate portion and the first plate portion, and a first supported portion that extends from the opposing portion to the first plate portion and is supported by the first plate portion. The tip of the first supported portion is welded to the first plate portion. The cargo room trim according to any one of claims 2 or 3 is characterized by this.

5. The second plate portion a base material portion a covering portion that is formed integrally with the base material portion from a material softer than the base material portion, faces the vehicle body panel, and covers the base material portion The cargo room trim according to any one of claims 1 to 4 is characterized by having this.

6. A trim manufacturing method for manufacturing a cargo room trim that is disposed at least in either the lateral direction or the upward direction of the rear wheels of a vehicle and constitutes a side wall of the cargo room, a drawing process for forming the outward concave portion by drawing, among the first plate portions made of a resin having an elongation rate of 120% or more, the outward concave portion that is recessed from the inside to the outside of the cargo room and the inward concave portion that is continuous in the front-rear direction of the cargo room with respect to the outward concave portion and is recessed from the outside to the inside of the cargo room a sound-absorbing material arranging process for arranging a sound-absorbing material on the outer surface of the first plate portion of the cargo room a second plate portion arranging process for arranging a second plate portion on the outer surface of the sound-absorbing material of the cargo room The trim manufacturing method is characterized by including this.

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