Vehicle-mounted structures

Abstract

To provide a vehicle installation structure which can inhibit increase of manufacturing costs and the weight and can be easily installed and disassembled to enable easy recycling.SOLUTION: A vehicle installation structure of the invention has: a vehicle interior material; and a raising member provided in at least a part of a space between a vehicle body panel and the vehicle interior material. The raising member includes a buffer layer and a lattice-like resin molding is provided in at least a part of the buffer layer.SELECTED DRAWING: Figure 2

Description

Technical Field

[0006] , ,

[0001] The present invention relates to a laying structure for a vehicle laid on a vehicle body panel.

Background Art

[0002] On a vehicle body panel such as a floor panel in a vehicle, a floor carpet is laid to smooth the unevenness of the vehicle body panel in the vehicle interior and to reduce the noise in the vehicle interior. The floor carpet includes a cushioning material for smoothing and reducing noise in the vehicle interior and an interior material for a vehicle such as a carpet.

[0003] For example, Patent Document 1 describes a floor carpet in which a cushioning material made of a non-woven fabric and an interior material for a vehicle are integrally formed.

Prior Art Documents

Patent Documents

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Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] The floor carpet described in Patent Document 1 described above has a configuration in which a fiber molded product or a urethane molded product formed corresponding to the unevenness of the vehicle body panel (floor panel) and the shape of the interior surface is adhered and integrated, and is carried onto the floor panel and laid. Therefore, since the floor carpet described in Patent Document 1 tends to increase in weight and size, laying on the floor panel may be difficult due to restrictions such as the upper limit of the weight that an operator can carry and the size of the vehicle body opening when loading into the vehicle body.

[0006] In addition, such a configuration (ASSY) adhered and integrated has a problem that separation and disassembly are not easy and recycling is difficult when the vehicle is disassembled or the parts are disassembled. ​​

[0007] Furthermore, creating uneven surfaces by varying the plate thickness and weight to conform to the vehicle body panels requires specialized molding equipment, molds, and molding processes, as well as processes for bonding and integrating the molded products, which presents challenges in terms of increased manufacturing costs.

[0008] This invention was made to solve the problems of the background technologies described above, and aims to provide a vehicle-mounted structure that is easy to install and dismantle, easy to recycle, and can suppress increases in manufacturing costs and weight. [Means for solving the problem]

[0009] To achieve the above objective, the vehicle laying structure of the present invention comprises a vehicle interior material and It has a raising member provided in at least a portion of the space between the vehicle body panel and the interior material for the vehicle, The aforementioned raising member includes a buffer layer. A lattice-shaped resin molded body is provided in a part of the buffer layer. And, The buffer layer includes at least one of the upper layer or the lower layer. At least one of the upper layer or the lower layer is made of fiber, The aforementioned lattice-shaped resin molded body is provided between at least a portion of the upper layer and the lower layer, The upper layer and the grid-shaped resin molded body, and the grid-shaped resin molded body and the lower layer are not bonded together. It is structured. [Effects of the Invention]

[0010] According to the present invention, a vehicle-mounted structure can be obtained that is easy to install and dismantle, easy to recycle, and can suppress increases in manufacturing costs and weight. [Brief explanation of the drawing]

[0011] [Figure 1] Figure 1 is a perspective view showing one example configuration of a vehicle laying structure according to the first embodiment. [Figure 2] Figure 2 is a side cross-sectional view of the vehicle-mounted structure shown in Figure 1. [Figure 3] Figure 3 is a perspective view showing one example of the configuration of the resin molded body shown in Figure 2. [Figure 4] Figure 4 is a side cross-sectional view showing an example of the installation procedure for the vehicle-mounted structure of the present invention. [Figure 5] Figure 5 is a side cross-sectional view showing an example configuration of a vehicle-mounted structure according to the second embodiment. [Modes for carrying out the invention]

[0012] Next, the present invention will be described with reference to the drawings. (First Embodiment) Figure 1 is a perspective view showing an example configuration of a vehicle laying structure according to the first embodiment, and Figure 2 is a side cross-sectional view of the vehicle laying structure shown in Figure 1. Figure 3 is a perspective view showing an example configuration of a resin molded body shown in Figure 2. Figure 2 schematically shows a cross-section of the vehicle laying structure when cut at a position corresponding to line AA shown in Figure 1. FRONT, REAR, LEFT, RIGHT, UP, and DOWN shown in Figure 1 indicate the front, rear, left, right, top, and bottom sides of the vehicle, respectively. The positional relationship between the left and right sides is based on the direction of viewing the front of the vehicle. Figures 1 to 3, and Figures 4 and 5 described later, schematically show the components of the present invention and do not accurately show the dimensions, shape, structure, position, etc. of each component.

[0013] The vehicle installation structure of the first embodiment is configured to be installed on a floor panel (vehicle body panel 1) (not shown) in the passenger compartment floor of a vehicle, as shown in Figure 1. Figure 1 shows an example of the overall shape of the vehicle interior material 2, which will be described later, provided by the vehicle installation structure of the present invention. The vehicle installation structure can be installed not only in the passenger compartment floor of a vehicle, but also in the passenger compartment side wall, passenger compartment ceiling, deck floor, dashboard, engine hood, fender, etc.

[0014] As shown in FIG. 2, the vehicle laying structure of the first embodiment has a vehicle interior material 2 and a raising member 3 provided at at least a part between the vehicle body panel 1 and the vehicle interior material 2. The vehicle interior material 2 and the raising member 3 have sizes and shapes corresponding to the unevenness of the vehicle body panel 1 and the shape of the interior surface at the laying part of the vehicle laying structure. The vehicle interior material 2 is, for example, a carpet made of a fiber molded product. A well-known vehicle floor mat or the like may be further laid on the vehicle interior material 2.

[0015] The raising member 3 has a buffer layer 4 composed of an upper layer 41 and a lower layer 42, and a resin molded body 5 for raising and reducing noise in the vehicle interior, and the resin molded body is provided at at least a part between the upper layer 41 and the lower layer 42. For the buffer layer 4, for example, a fiber felt or the like can be used. Since the vehicle interior material 2 can also function as the buffer layer 4 depending on its material, thickness, etc., the upper layer 41 of the buffer layer 4 may not be provided. On the other hand, in a configuration where the resin molded body 5 contacts the vehicle body panel 1, there is a possibility that vibration noise is generated by the resin molded body 5 and the vehicle body panel 1. Therefore, it is desirable that the vehicle body panel 1 side of the resin molded body is covered with the lower layer 42 of the buffer layer 4.

[0016] As shown in FIG. 3, the resin molded body 5 has a plurality of vertical walls 51 arranged in a grid pattern and parallel to the thickness direction of the raising member 3, and a plurality of horizontal walls 52 arranged in a grid pattern and provided in a direction orthogonal or intersecting with each of the plurality of vertical walls 51. By arranging the plurality of vertical walls 51 parallel to the thickness direction of the raising member 3 in this way, the load from the vehicle interior to the resin molded body 5 can be efficiently received, so the load-bearing capacity of the resin molded body 5 is improved. As shown in FIG. 3, since the resin molded body 5 is a structure combining a plurality of hollow materials formed by the plurality of vertical walls 51 and the plurality of horizontal walls 52, it can be manufactured relatively lightweight.

[0017] When the outer surface of the resin molded body 5 is flat, if the vehicle interior material 2 is stepped on with the foot, the position of the resin molded body 5 may shift, resulting in a deteriorated feeling under the foot and the possibility of not obtaining the desired sound insulation performance. In the present embodiment, since the resin molded body 5 includes a plurality of vertical walls 51 arranged in a lattice shape, the buffer layer 4 (both the upper layer 41 and the lower layer 42) enters into the lattice of the vertical walls 51, thereby preventing the displacement of the resin molded body 5 when the vehicle interior material 2 is stepped on. Further, this eliminates the need to fix the buffer layer 4 and the resin molded body 5 using an adhesive or the like, so that the processing cost of the bulkhead member 3 can be reduced.

[0018] The resin molded body 5 shown in FIG. 3 shows a configuration example in which a plurality of vertical walls 51 form a plurality of quadrilaterals when viewed from above, and they are arranged without gaps. The shape formed by the vertical walls 51 is not limited to a quadrilateral, and may be a polygon such as a triangle or a hexagon. A structure in which a plurality of vertical walls 51 form a plurality of hexagons when viewed from above and they are arranged without gaps (so-called honeycomb structure) can enhance the load-bearing capacity of the resin molded body 5 more than a structure in which a plurality of quadrilaterals are formed by vertical walls 51 of the same size and thickness. Further, since the fluidity of the resin is better in a hexagon than in a quadrilateral, there is an effect that it is difficult for a lack of resin to occur during the molding of the resin molded body 5. On the other hand, a quadrilateral is advantageous in terms of cost because the processing cost of the mold is lower than that of a hexagon or the like. The area per polygon or the length of one side formed by the vertical walls 51 may be appropriately changed according to design requirements and processing requirements. The length of one side of the polygon is preferably 5 to 100 mm, particularly 10 to 50 mm. When the length of one side of the polygon exceeds 100 mm, the heel enters into the lattice (polygon) of the resin molded body 5 under the vehicle interior material 2 when stepped on with the foot, resulting in a deteriorated feeling under the foot. On the other hand, when the length of one side of the polygon is 5 mm or less, the amount of resin constituting the resin molded body 5 increases, so that the weight of the resin molded body 5 increases. Therefore, if the length of one side of the polygon is 10 to 50 mm, a resin molded body 5 with a good balance between the feeling under the foot and the weight can be obtained. When the place where the vehicle laying structure is installed is other than the vehicle cabin floor part of the vehicle, since it is not stepped on with the foot, the length of one side of the polygon may exceed 100 mm.

[0019] Figure 3 shows an example configuration in which multiple horizontal walls 52 are provided in the same position on multiple vertical walls 51, one row at a time. However, the position and number of rows of each horizontal wall 52 relative to the vertical walls 51 may differ depending on the shape of the vehicle body panel 1 and the depth of the irregularities. Also, as shown in Figure 2, the resin molded body 5 may have parts that only have horizontal walls 52. Alternatively, the resin molded body 5 may have a configuration in which there are no horizontal walls 52 at all. By providing horizontal walls 52 to the resin molded body 5, not only is the effect of sound insulation against noise entering the vehicle from outside to inside the vehicle obtained, but the strength of the resin molded body 5 is also improved. The resin molded body 5 can be manufactured using a well-known resin molding method using plastics or resins such as polypropylene (PP), olefin elastomer (TPO), or polyvinyl chloride resin (PVC).

[0020] As shown in Figure 3, the side walls 52 of the resin molded body 5 are provided with openings 53. In this configuration, where the side walls 52 have openings 53, the resin molded body 5 also functions as a sound-absorbing material due to the well-known Helmholtz effect, thereby further enhancing the sound insulation effect inside the vehicle. The openings 53 may be provided in all of the side walls 52 within a plurality of polygons formed by the vertical walls 51, or in some of the side walls 52 within a plurality of polygons formed by the vertical walls 51. The size and position of the multiple openings 53 may be the same or different. The shape of the openings 53 may be a circle, a semicircle, a sector, or a polygon such as a triangle or a square, as shown in Figure 3. The sound insulation performance (frequency range and volume of sound insulation) and sound absorption performance (frequency range and volume of sound absorption) of the resin molded body 5 can be adjusted by the thickness and size of the vertical walls 51 and side walls 52, as well as the size, position, and shape of the openings 53.

[0021] In this embodiment, by combining the buffer layer 4 (lower layer 42) and the side walls 52 of the resin molded body 5, a good balance between sound insulation performance and sound absorption performance can be obtained. When installing a vehicle-mounted structure in a location where sound insulation and sound absorption performance are not required, the weight of the resin molded body 5 may be reduced by eliminating the side walls 52.

[0022] The thickness and size of the vertical walls 51 and horizontal walls 52 should be optimally designed considering the required load-bearing capacity and the weight of the resin molded body 5. For example, the thickness of the vertical walls 51 should be approximately 0.5 to 3.0 mm. By setting the thickness of the vertical walls 51 to approximately 0.5 to 3.0 mm, it is possible to reduce the weight of the resin molded body 5 while suppressing a decrease in load-bearing capacity. The thickness of the horizontal walls 52 should be set to approximately the same thickness as the vertical walls 51, for example. The thickness and size of the vertical walls 51 and horizontal walls 52 may be the same across the entire installation surface, or they may be different for predetermined areas to obtain the required sound insulation performance, load-bearing capacity, and good treading comfort.

[0023] The resin molded body 5 may be divided into multiple parts and laid on the vehicle body panel 1, or it may be laid on the vehicle body panel 1 without being divided, depending on its size and weight, and the shape of the vehicle body panel 1. Similarly, the buffer layer 4 may be divided into multiple parts and laid on the vehicle body panel 1, or it may be laid on the vehicle body panel 1 without being divided, depending on its size and weight, and the shape of the vehicle body panel 1. For example, the vehicle interior material 2 shown in Figure 1 has a shape with a convex portion 21 in the center in the left-right direction, so the buffer layer 4 and the resin molded body 5 may be divided into two parts each for the right and left sides of the vehicle, avoiding the convex portion 21, and laid. Also, since the vehicle interior material 2 may have a shape without a convex portion 21, the buffer layer 4 and the resin molded body 5 can be laid in a shape that covers the entire vehicle body panel 1. Alternatively, the buffer layer 4 and the resin molded body 5 may be divided into two parts each for the front and rear sides of the vehicle and laid. The buffer layer 4 and the resin molded body 5 are not limited to being divided into two parts, but may also be divided into three or more parts and laid on the vehicle body panel 1.

[0024] In this configuration, the procedure for laying the vehicle-mounted structure shown in Figure 2 will now be explained using Figure 4. Figure 4 is a side cross-sectional view showing an example of the procedure for laying the vehicle-mounted structure of the present invention.

[0025] When laying the vehicle laying structure of the present invention, first, as shown in Figure 4(a), the lower layer 42 of the buffer layer 4 is placed on the vehicle body panel 1. The lower layer 42 may be flat when not laid on the vehicle body panel 1, or it may be a molded product as long as it has a certain plate thickness and weight. The lower layer 42 is mounted on the vehicle body panel 1 so as to cover the laying surface of the vehicle body panel 1.

[0026] Next, as shown in Figure 4(b), the resin molded body 5 is placed on the lower layer 42 of the buffer layer 4, and the lower layer 42 is sandwiched between the vehicle body panel 1 and the resin molded body 5. By positioning the resin molded body 5 in this way, the lower layer 42 can be made to conform to the unevenness and shape of the vehicle body panel 1.

[0027] Next, as shown in Figure 4(c), the upper layer 41 of the buffer layer 4 is mounted on the resin molded body 5. As mentioned above, the upper layer 41 of the buffer layer 4 is optional.

[0028] Finally, as shown in Figure 4(d), the vehicle interior material 2 is installed on the upper layer 41 of the buffer layer 4, thereby laying the vehicle installation structure shown in Figure 2 on the vehicle body panel 1.

[0029] According to the vehicle laying structure of the first embodiment, the upper layer 41 and lower layer 42 of the buffer layer 4 are planar or molded when not laid on the vehicle body panel 1. In the case of a planar structure, it is not formed using a mold, thus eliminating the need for molding machinery and molds. Furthermore, even if it is a molded product, if it is a molded product with a certain plate thickness and basis weight, it can be molded using relatively inexpensive existing press molding equipment, thus suppressing cost increases.

[0030] Furthermore, the upper layer 41 and lower layer 42 of the buffer layer 4, the resin molded body 5, and the vehicle interior material 2 are not integrated by adhesive or the like. The lower layer 42 is mounted on the vehicle body panel 1, the upper layer 41 is mounted on the resin molded body 5, and the vehicle interior material 2 is mounted on either the upper layer 41 or the resin molded body 5. Therefore, when dismantling a vehicle, it can be easily disassembled into its individual material components compared to conventional molded products that are laminated and bonded together, making recycling easier.

[0031] Furthermore, the upper layer 41 and lower layer 42 of the buffer layer 4 are made of soft and lightweight fibers, and can conform to the unevenness of the vehicle body panel 1 due to the weight of the resin molded body 5, thereby reducing molding costs. In addition, the vehicle laying structure of this embodiment can achieve the required strength in the longitudinal (thickness) direction and the feel underfoot using a lightweight resin molded body 5 compared to conventional molded products (fiber-based or urethane-based), thus contributing to the weight reduction of the vehicle.

[0032] Therefore, a vehicle-mounted structure can be obtained that is easy to install and dismantle, easy to recycle, and has reduced manufacturing costs and weight. (Second Embodiment) Figure 5 is a side cross-sectional view showing an example configuration of a vehicle-mounted structure according to the second embodiment.

[0033] As shown in Figure 5, the vehicle installation structure of the second embodiment has a configuration in which rails 6 for sliding the seats in the front-rear direction of the vehicle are fixed on the vehicle body panel 1. The rails 6 are fixed to the left (LEFT) and right (RIGHT) sides of the vehicle body panel 1 in the front-rear direction, respectively. The other configurations and the method of installing the vehicle installation structure are the same as in the first embodiment, so their explanation will be omitted.

[0034] In the second embodiment, the lower layer 42 of the buffer layer 4 is laid on the vehicle body panel 1, and then the rails 6 are attached to the vehicle body panel 1. Since the lower layer 42 of the buffer layer 4 is made of soft and light fibers such as felt, it can be easily laid on the vehicle body panel 1 even if it is large in size, and the rails 6 can be attached to the vehicle body panel 1 from there. In the second embodiment, the buffer layer 4 (lower layer 42) with small holes (small opening ratio) for attaching the rails 6 etc. to the vehicle body panel 1 can be placed between the rails 6 and the vehicle body panel 1, so that noise and vibration leaking from outside the vehicle into the vehicle interior through the vehicle body panel 1 is reduced by the buffer layer 4. As a result, the vehicle's NV (Noise and Vibration) performance can be improved.

[0035] The resin molded body 5 may be fixed to the rail 6 by forming an engagement portion 54 with the rail 6. In this case, the rail cover 61 that covers the upper surface of the rail 6 and the resin molded body 5 may be integrated. In the configuration in which the rail cover 61 and the resin molded body 5 are integrated, it is necessary to eliminate the upper layer 41 of the buffer layer 4 corresponding to the position of the rail 6. The resin molded body 5 may be configured to be separated to avoid the rail 6, or it may be configured to be integrated by connecting it on the lower surface of the rail 6.

[0036] According to the vehicle installation structure of the second embodiment, in addition to the same effects as the vehicle installation structure of the first embodiment, members that are fixed to the vehicle body panel 1, such as seat rails 6, can be attached with a buffer layer 4 (lower layer 42) in between. Therefore, the vehicle's NV (Noise and Vibration) performance can be improved. [Explanation of symbols]

[0037] 1. Body panel 2. Vehicle interior materials 3. Raising member 4 Buffer layer 5. Resin molded body 6 rails 21 Convex part 41 Upper layer 42 Lower layer 51 Vertical wall 52 Side wall 53 Aperture 54 Engagement part 61 Rail cover

Claims

1. Vehicle interior materials, It has a raising member provided in at least a portion of the space between the vehicle body panel and the interior material for the vehicle, The aforementioned raising member includes a buffer layer. A lattice-shaped resin molded body is provided in a part of the aforementioned buffer layer. The buffer layer includes at least one of the upper layer or the lower layer. At least one of the upper layer or the lower layer is made of fiber, The aforementioned lattice-shaped resin molded body is provided between at least a portion of the upper layer and the lower layer, A vehicle laying structure in which the upper layer and the grid-like resin molded body and the grid-like resin molded body and the lower layer are not bonded together.

2. The vehicle laying structure according to claim 1, wherein at least one of the upper layer and the lower layer is planar when not laid on the vehicle body panel.

3. The grid of the aforementioned lattice-shaped resin molded body has a configuration in which multiple vertical walls are combined, The thickness of the aforementioned vertical wall is 0.5 to 3.0 mm. The vehicle installation structure according to claim 1, wherein the vertical wall is parallel to the thickness direction of the raising member.

4. The vehicle laying structure according to claim 3, wherein at least a portion of the grid has a horizontal wall.

5. The vehicle laying structure according to claim 4, wherein an opening is provided in at least a portion of the side wall.

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