Hole Sealing Material for Automobile Doors and Method for Manufacturing the Same

Abstract

To make it possible to suppress deformation of a solid resin such as an outer peripheral lip part due to thermal shrinkage as much as possible.SOLUTION: A hole seal material 5 for an automobile door 1 is a same molding material of a foam body part 6 configured from a foam resin and an outer peripheral lip part 7 configured from a solid resin, and is fixed so that a tip 721 of the outer peripheral lip part 7 is pressed against an outer peripheral part 43 of an opening 41 of an inner panel 4 so as to contact therewith. A standing wall 63 is circumferentially provided on an outer side of a core back scar groove 64 in the foam body part 6, a non-foam standing wall part 631 configured from a solid resin is formed on an outer side of the standing wall part 63, and the outer peripheral lip part 7 is so formed as to project to an outer side from the non-foam standing wall part 631.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present invention relates to a hole sealing material for sealing an opening of an inner panel of an automobile door and a method for manufacturing the same.

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 attaching these various components. The opening is closed using a hole sealing material as in Patent Documents 1 and 2.

[0003] In the structures of Patent Documents 1 and 2, a hole sealing material is composed of a sheet-like sealing body formed of a foaming material and a synthetic resin film laminated and fixed to the sealing 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 sealing agent, and the opening is closed with the hole sealing 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] Incidentally, as a door hole seal structure for sealing the opening of the inner panel, in addition to the structures of Patent Documents 1 and 2, as shown in FIG. 6, a hole seal material 101 which is a single molding material of a foam main body portion 102 made of a foamed resin and an outer peripheral lip portion 103 mainly made of an unfoamed resin is formed, the hole seal material 101 is arranged so as to close the opening 202 of the inner panel 201, and the tip portion 104 of the outer peripheral lip portion 103 of the hole seal material 101 is elastically biased against the outer peripheral portion 203 of the opening 202 of the inner panel 201, thereby ensuring a sealing property.

[0006] Such a hole seal material 101 can be formed by filling a cavity 300 partitioned by fixed molds 301 and 302 and a movable mold 303 with a foaming molten resin, as shown in FIG. 7(a), and core-backing the movable mold 303 in the direction of the thick solid arrow shown in the figure.

[0007] However, in the hole seal material 101 formed by core-backing, a non-contact region 105 that does not contact either the movable mold 303 or the fixed mold 302 is generated when the movable mold 303 is core-backed. In the foamed resin molding by core-backing, the resin in the region in contact with the mold is cooled by contact with the mold, while the resin in the non-contact region 105 is not cooled and remains in a high-temperature state. Therefore, when the hole seal material 101 molded by core-backing is naturally cooled, as shown by the two-dot chain line in FIG. 7(b), the outer peripheral lip portion 103 is deformed so as to warp more greatly than the intended shape due to the thermal shrinkage of the non-contact region 105.

[0008] In the case of the hole seal material 101 that has undergone such significant thermal deformation, it becomes difficult to ensure sealing performance by elastically biasing the tip portion 104 of the outer peripheral lip portion 103 against the outer peripheral portion 203 of the inner panel 201. Therefore, a hole seal material that can suppress deformation of the outer peripheral lip portion due to thermal shrinkage as much as possible is desired. Further, for example, when forming an unfoamed resin portion such as an attachment location of the hole seal material in a region surrounded in a donut shape by the foamed resin portion, generation of a non-contact region similar to the above and deformation into an unintended shape due to thermal shrinkage also occur. Therefore, it is also desired to prevent such deformation.

[0009] The present invention is proposed in view of the above problems, and an object thereof is to provide a hole seal material and a method for manufacturing the same that can suppress as much as possible the occurrence of deformation of an unintended shape due to thermal shrinkage at the boundary between the unfoamed resin and the foamed resin.

Means for Solving the Problems

[0010] The hole seal material for an automobile door of the present invention is , hair a single molded material of a foamed resin portion and an unfoamed resin portion, , front and a standing wall portion is provided at the boundary between the foamed resin portion and the unfoamed resin portion, provided characterized in that an unfoamed standing wall portion made of an unfoamed resin is formed at a position closer to the unfoamed resin portion side of the standing wall portion. According to this, during core back, a region that becomes non-contact with the mold and has a higher temperature than the contact region is blocked by the standing wall portion, and the influence of thermal shrinkage can be significantly reduced. Therefore, at the boundary between the unfoamed resin and the foamed resin, it is possible to suppress as much as possible the occurrence of deformation of an unintended shape due to thermal shrinkage, and a hole seal material for an automobile door with the intended shape can be reliably obtained.

[0011] The hole sealing material for an automotive door of the present invention is a single molded material composed of a foamed main body portion made of a foamed resin and an outer peripheral lip portion made of an unfoamed resin, and the tip portion of the outer peripheral lip portion is fixed so as to be elastically biased and pressed against the outer peripheral portion of the opening of the inner panel to come into contact therewith. The hole sealing material for an automotive door is characterized in that a standing wall portion is provided around the outside of the core back mark groove of the foamed main body portion, an unfoamed standing wall portion made of an unfoamed resin is formed on the outer side of the standing wall portion, and the outer peripheral lip portion is formed so as to protrude outward from the unfoamed standing wall portion. According to this, by adopting a configuration in which a standing wall portion having an outwardly offset unfoamed standing wall portion is provided around the outside of the core back mark groove of the foamed main body portion, a region that becomes non-contact with the mold and hotter than the contact region during core back can be retained inside the standing wall portion, and the influence of thermal shrinkage on the outer peripheral lip portion can be blocked by the standing wall portion and significantly reduced. Therefore, it is possible to extremely suppress the deformation of the outer peripheral lip portion due to thermal shrinkage. In other words, at the boundary between the unfoamed resin and the foamed resin, it is possible to extremely suppress the occurrence of unintended shape deformation due to thermal shrinkage, and it can be used as a hole seal material that can reliably press the outer peripheral lip portion against the inner panel by elastic biasing. Also, the standing wall portion can prevent the region of the foamed resin formed by core back from reaching near the base of the outer peripheral lip portion, and can prevent the formation of a foamed resin portion on the outer peripheral lip portion and a decrease in strength. Further, in the door hole seal structure composed of this hole seal material, the tip of the outer peripheral lip portion of the hole seal material can be elastically biased and pressed against the outer peripheral portion of the opening of the inner panel, and a state where surface pressure is always applied without gaps can be achieved. The tip of the outer peripheral lip portion is pressed against the outer peripheral portion of the inner panel with a pressure exceeding the exciting force of vibration from the outside to suppress vibration, and the generation of abnormal noise (rattling noise) or rattling caused by external force can be prevented. Furthermore, the synthetic resin film adhered around the opening of the inner panel does not vibrate to generate abnormal noise, and the generation of abnormal noise caused by the hole seal material can also be prevented. Furthermore, in this door hole seal structure, 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 performance and waterproof performance 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.

[0012] The hole seal material for an automobile door of the present invention is characterized in that the outer peripheral lip portion is composed of 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 composed of an unfoamed resin connecting the unfoamed standing wall portion and the standing wall portion so as to have a substantially H shape in cross section. According to this, the strength of the outer peripheral portion of the hole seal material including the outer peripheral lip portion can be increased by the substantially H-shaped cross-section composed of the unfoamed vertical wall portion made of unfoamed resin, the vertical wall, and the crosslinked portion. Further, due to this substantially H-shaped cross-section, 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, in the door hole seal structure composed of this hole seal material, the effects of more reliably preventing the generation of abnormal noise and ensuring the sealing performance and waterproof performance can be obtained.

[0013] The manufacturing method of the hole seal material for an automobile door of the present invention is a method for manufacturing the hole seal material for an automobile door of the present invention, including partitioning and forming, by a fixed mold and a movable mold, a cavity composed of the outer peripheral lip portion, the vertical wall portion, and a cavity having a shape corresponding to a substrate surrounded by the vertical wall portion and having a thickness thinner than the height of the vertical wall portion, arranging the fixed mold on the side of the movable mold that retreats in the cavity having the shape of the vertical wall portion, and arranging the side surface of the movable mold on the inner surface of the cavity having the shape of the vertical wall portion in a first step; a second step of filling the cavity with a foaming molten resin; and a third step of core-backing the movable mold to foam the foaming molten resin to form the hole seal material. According to this, when the movable mold is core-backed to foam the foaming molten resin, the portion that foams corresponding to the movable mold is formed while contacting and integrating with the resin that becomes the vertical wall portion located on the outside. Therefore, the region that becomes non-contact with the mold and has a high temperature corresponding to the core-back mark groove formed on the side of the movable mold of the hole seal material can be made very small, and the influence of thermal shrinkage on the outer peripheral lip portion can be more greatly reduced. Further, since the high-temperature non-contact region corresponding to the core-back mark groove is formed adjacent to the vertical wall portion whose outside except the inside is in contact with the mold, the cooling of the non-contact region can be promoted during core-back, and from this point as well, the influence of thermal shrinkage on the outer peripheral lip portion can be more greatly reduced.

Effects of the Invention

[0014] According to the present invention, it is possible to obtain a hole seal material that can suppress as much as possible the occurrence of unintended shape deformation due to thermal shrinkage at the boundary between the unfoamed resin and the foamed resin.

Brief Description of the Drawings

[0015] [Figure 1] Front view of an automotive door having a door hole seal structure using the hole seal material according to an embodiment of the present invention. [Figure 2] Cross-sectional view of a door hole seal structure using the hole seal material according to an embodiment of the present invention. [Figure 3] (a) is an enlarged view of part A in FIG. 2, and (b) is an enlarged view of part B in FIG. 2. [Figure 4] (a) to (c) are process explanatory diagrams for explaining the manufacturing process of the hole seal material according to the embodiment. [Figure 5] (a) to (c) are enlarged partial views corresponding to (a) to (c) in FIG. 4, respectively. [Figure 6] Cross-sectional explanatory view showing a state where the outer peripheral lip portion of the hole seal material of the comparative example is pressed against the inner panel. [Figure 7] (a) is a cross-sectional explanatory view for explaining the manufacturing process of the hole seal material of the comparative example, and (b) is a cross-sectional explanatory view for explaining the thermal deformation of the outer peripheral lip portion in the hole seal material of the comparative example.

Embodiments for Carrying Out the Invention

[0016] 〔Hole Seal Material for Automotive Door of Embodiment〕 The hole seal material 5 for an automotive door according to an embodiment of the present invention is used in a door hole seal structure provided on an inner panel 4 disposed between an outer panel 2 and a door trim 3 in an automotive door 1, as shown in FIGS. 1 to 3. The hole seal material 5 is composed of the same molding material including a foamed main body portion 6 made of a foamed resin and an outer peripheral lip portion 7 made of an unfoamed resin.

[0017] The foam main body 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 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 trace groove 64 of the peripheral groove provided in the foam main body 6.

[0018] The outer peripheral lip portion 7 is formed so as to protrude outward from the unfoamed standing wall portion 631, and includes an upright wall 71 extending in the thickness direction of the foam main body 6, a lip edge 72 formed to incline outward from the upright wall 71 toward the inner panel 4 side, and a crosslinked portion 73 composed of unfoamed resin connecting the unfoamed standing wall portion 631 and the upright wall 71 so as to have a substantially H-shaped cross section. The lip edge 72 in the illustrated example is formed to be curved and inclined in a substantially arc shape from the end of the upright 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 crosslinked 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 6 and is installed between the unfoamed standing wall portion 631 and the upright wall 71.

[0019] On the surface of the foam main body 6 on the inner panel 4 side in the present embodiment, a plurality of engaging holes 65 for a fastener, each composed of a portion protruding in a substantially U shape, and a plurality of engaging hooks 66 formed with claws facing outward are provided at predetermined positions and are integrally formed as a part of the skin layer 62 of the foam main body 6. A fastener 8 of a separate member is inserted and engaged in the engaging hole 65 for a fastener.

[0020] Then, the hole sealing material 5 is disposed so as to close the opening 41 of the inner panel 4, and the foamed main body 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 engaging hole 65 is hooked inside the peripheral edge 42 of the opening 41 of the inner panel 4 and is latched and fixed (see FIGS. 2 and 3). That is, a force is applied to draw the foamed main body 6 toward the opening 41 side of the inner panel 4, and the foamed main body 6 is latched and fixed to the peripheral edge 42 of the opening 41 of the inner panel 4.

[0021] The tip portion 721 of the outer peripheral lip portion 7 of the hole sealing material 5 mechanically fixed to the inner panel 4 by latching and fixing 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 is elastically biased and pressed against the outer peripheral portion 43 of the opening 41 of the inner panel 4, which is formed to be inclined so as to curve substantially arcuately toward the passenger compartment side from the peripheral edge 42 extending in the substantially vertical direction, and the contact state is maintained.

[0022] When manufacturing the hole sealing material 5 used in the door hole seal structure of the present embodiment, for example, as shown in FIGS. 4(a) and 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 adapted to retreat in the direction of the thick two-dot chain line arrow in FIG. 4(a). The fixed mold 92 is disposed on the surface 901 on the retreating side of the movable mold 93 in the cavity having the shape of the standing wall portion 63, and the side surface of the movable mold 93 is disposed on the inner surface 903 of the cavity having the shape of the standing wall portion 63.

[0023] Next, as shown in FIGS. 4(b) and 5(b), the foaming molten resin MR is injected into the cavity 90 from an injection path (not shown) and filled. An appropriate material applicable to the hole sealing material 5 of the automobile door 1 can be used for this foaming molten resin. For example, it is favorable to use 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), NBR (nitrile rubber), etc. In addition, in this embodiment, a gap 911 corresponding to the shape of the substantially U-shaped portion constituting the latching tool engagement hole 65 and a gap 912 corresponding to the shape of the latching 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 advance and retreat within the fixed mold 91 or can be detachably attached to the outside of the fixed mold 91 is installed at a portion corresponding to the latching tool engagement hole 65. When the foaming molten resin MR is injected and filled, it is blocked by the metal bar so that a shape corresponding to the latching tool engagement hole 65 is formed.

[0024] Thereafter, as shown in FIGS. 4(c) and 5(c), the movable mold 93 is core backed in the direction of the thick solid arrow shown in the figure to foam the foaming molten resin MR, and the hole seal material 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 latching tool engagement hole 65 and the latching hook 66 are also formed together in the formed hole seal material 5. In the hole seal material 5 formed in this way, at a position corresponding to the side surface of the movable mold 93, a core back trace groove 64 is formed on the surface of the foamed main body portion 6 on the side of the movable mold 93, and a standing wall portion 63 having an unfoamed standing wall portion 631 on the outside thereof and an outer peripheral lip portion 7 are formed.

[0025] According to the hole seal material 5 for an automotive door 1 of the present embodiment, by the configuration of surrounding the core back trace groove 64 of the foam main body portion 6 with a standing wall portion 63 having an outwardly offset unfoamed standing wall portion 631 on the outside, a region that does not come into contact with the mold and becomes hotter than the contact region during core back can be retained inside the standing wall portion 63. The influence of thermal shrinkage on the outer peripheral lip portion 7 can be blocked by the standing wall portion 63 and significantly reduced. Therefore, deformation of the outer peripheral lip portion 7 due to thermal shrinkage can be suppressed as much as possible, and the outer peripheral lip portion 7 can be reliably pressed against the inner panel 4 by elastic biasing. Also, the standing wall portion 63 can prevent the region of the foamed resin formed by core back from reaching near the base of the outer peripheral lip portion 7, and prevent the formation of a foamed resin portion on the outer peripheral lip portion 7 and a decrease in strength.

[0026] Also, in the door hole seal structure composed of the hole seal material 5, the tip portion 721 of the outer peripheral lip portion 7 of the hole seal material 5 is pressed against the outer peripheral portion 43 of the opening portion 41 of the inner panel 4 by elastic biasing, and a state where surface pressure is constantly applied without gaps can be achieved. The tip portion 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 vibration, and the generation of abnormal noise (rattling noise) or rattling due to external force can be prevented. Furthermore, the synthetic resin film adhered around the opening portion 41 of the inner panel 4 does not vibrate to generate abnormal noise, and the generation of abnormal noise caused by the hole seal material 5 can also be prevented. Furthermore, in this door hole seal structure, by pressing the tip portion 721 of the outer peripheral lip portion 7 against the outer peripheral portion 43 of the opening portion 41 of the inner panel 4 by elastic biasing and maintaining the contact state, 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 portion 41 of the inner panel 4 can be ensured.

[0027] In addition, the substantially H-shaped cross-section formed by the unfoamed vertical wall portion 631 made of unfoamed resin, the vertical wall 71, and the crosslinking portion 73 can enhance the strength of the outer peripheral lip portion 7 or the outer peripheral portion of the hole seal material 5. Further, due to this substantially H-shaped cross-section, the elasticity of the outer peripheral lip portion 7 can be enhanced, 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, in the door hole seal structure composed of the hole seal material 5, the effects of more reliably preventing the generation of abnormal noises and ensuring the sealing performance and waterproof performance can be obtained.

[0028] Also, according to the method for manufacturing the hole seal material 5 of the above embodiment, when the movable mold 93 is core-back and the foamable molten resin MR is foamed, the portion that foams corresponding to the movable mold 93 is formed while being in contact with and integrated with the resin that becomes the outer vertical wall portion 63 located on the outside. Therefore, the region that becomes non-contact with the mold and has a high temperature corresponding to the core-back trace groove 64 formed on the surface of the hole seal material 5 on the side where the movable mold 93 retreats can be made very small, and the influence of thermal shrinkage on the outer peripheral lip portion 7 can be more greatly reduced. Further, since the high-temperature non-contact region corresponding to the core-back trace groove 64 is formed adjacent to the vertical wall portion 63 whose outer side other than the inner side is in contact with the mold, the cooling of the non-contact region during core-back can be promoted, and from such a point, the influence of thermal shrinkage on the outer peripheral lip portion 7 can be more greatly reduced.

[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, or those obtained by adding other contents disclosed in this specification to these contents, or those obtained by deleting some of these contents to a degree where 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 additional contents.

[0030] For example, in the door hole seal structure using the hole seal material 5 of the above embodiment, the foamed main body portion 6 is configured to be hooked and fixed to the inner panel 4. However, when configuring the door hole seal structure using the hole seal material 5 of the present invention, for the fixing of the hole seal material 5, a suitable fixing structure can be used within the scope of the gist of the present invention. In particular, it is preferable to use fixing by mechanical action such as hooking and fixing, bolt tightening, screwing, caulking fixing, press-fitting fixing, etc., that is, mechanical fixing. For example, a partial protrusion is provided on the inner panel side of the foamed main body portion of the hole seal material in the present invention, and this protrusion can also be chemically fixed, such as by adhesion, to the periphery of the opening of the inner panel.

[0031] Also, in the above embodiment, the shape of the tip portion 721 of the outer peripheral lip portion 7 is formed in a bead shape from the viewpoints of strength improvement, damage prevention, and increase in the contact area due to contact with the inner panel 4. However, those in which the shape of the tip portion of the outer peripheral lip portion is other than the bead shape are also included in the present invention. Further, the shape of the outer peripheral lip portion protruding outward from the unfoamed standing wall 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.

[0032] Also, in the above embodiment, the foamed main body portion composed of foamed resin as the foamed resin portion and the outer peripheral lip portion composed of unfoamed resin as the unfoamed resin portion were described as examples. However, for the hole seal material of the automobile door of the present invention, a standing wall portion is provided at the boundary between the foamed resin portion and the unfoamed resin portion, and an unfoamed standing wall portion composed of unfoamed resin is formed at a position closer to the unfoamed resin portion side of the standing wall portion. Appropriate hole seal materials for automobile doors are included. For example, when forming an unfoamed resin portion such as an attachment location of the hole seal material in a region surrounded by a donut shape in the foamed resin portion, a standing wall portion is provided at the boundary between the foamed resin portion and the unfoamed resin portion, and an unfoamed standing wall portion composed of unfoamed resin is provided at a position closer to the unfoamed resin portion side such as the attachment location of the hole seal material of the standing wall portion. It may be used as a hole seal material for an automobile door having such a structure. According to such a hole seal material for an automobile door of the present invention, at the boundary between the unfoamed resin and the foamed resin, it is possible to extremely suppress the occurrence of unintended shape deformation due to heat shrinkage.

Industrial Applicability

[0033] The present invention can be used as a hole seal material for closing an opening in an inner panel of an automobile door.

Explanation of Signs

[0034] 1…Automobile door 2…Outer panel 3…Door trim 4…Inner panel 41…Opening 42…Periphery 43…Outer peripheral part 5…Hole seal material 6…Foamed body part 61…Foamed core layer 62…Skin layer 63…Standing wall part 631…Unfoamed standing wall part 64…Core back mark groove 65…Latching tool engagement hole 66…Latching hook 7…Outer peripheral lip part 71…Upright wall 72…Lip edge 721…Tip part 73…Crosslinked part 8…Latching tool 81…Tip hook 90…Cavity 901…Surface on the side where the movable mold retreats 902…Inner surface 91…Fixed mold 911, 912…Clearance 92…Fixed mold 93…Movable mold MR…Foamable molten resin 101…Hole seal material 102…Foamed body part 103…Outer peripheral lip part 104…Tip part 105…Non-contact area 201…Inner panel 202…Opening 203…Outer peripheral part 301, 302…Fixed mold 303…Movable mold

Claims

1. An integral molding material comprising a foamed main body portion made of a foamed resin and an outer peripheral lip portion made of an unfoamed resin, wherein the tip of the outer peripheral lip portion is fixed by being elastically biased against and contacting the outer peripheral portion of the opening of the inner panel, and is a hole sealing material for an automotive door, A standing wall portion is provided around the outside of the core back trace groove of the foamed main body portion, An unfoamed standing wall portion made of an unfoamed resin is formed on the outer side of the standing wall portion, The hole sealing material for an automotive door is characterized in that the outer peripheral lip portion is formed so as to protrude outward from the unfoamed standing wall portion.

2. The hole sealing material for an automotive door according to claim 1, wherein the outer peripheral lip portion is composed of 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 an unfoamed resin connecting the unfoamed standing wall portion and the standing wall so as to have a substantially H shape in cross section.

3. A method for manufacturing a hole sealing material for an automotive door according to any one of claims 1 or 2, A cavity composed of the outer peripheral lip portion, the standing wall portion, and a cavity having a shape corresponding to a substrate surrounded by the standing wall portion and having a thickness thinner than the height of the standing wall portion is partitioned and formed by a fixed mold and a movable mold. A first step of disposing the fixed mold on the side of the movable mold that retreats in the cavity having the shape of the standing wall portion and disposing the side surface of the movable mold on the inner surface of the cavity having the shape of the standing wall portion; A second step of filling the cavity with a foaming molten resin; A third step of core-backing the movable mold to foam the foaming molten resin to form the hole sealing material. The method for manufacturing a hole sealing material for an automotive door is characterized by comprising the steps.

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