JP5455574B2 - Automotive floor spacer integrated floor duct - Google Patents

Description

  The present invention relates to an automotive floor spacer integrated floor duct in which a floor spacer and a floor duct are integrated.

  Conventionally, a floor spacer 61 and a floor duct 65 are separately disposed between a floor panel 51 and a floor carpet 55 on the floor of an automobile as shown in FIG. FIG. 14 is a perspective view of an example of a conventional floor spacer 61 and floor duct 65. The floor spacer 61 is a plate that is placed on the floor panel 51 to flatten the floor surface of the automobile, and is made of polyurethane foam or the like. On the other hand, the floor duct 65 is formed of a synthetic resin tubular body, and one end 66 is connected to an air conditioner of the vehicle and the other end 67 is connected to an air outlet or the like in the vehicle and used for air conditioning in the vehicle. In addition, between the floor duct 65 and the floor panel 51, the floor duct 65 and the floor panel 51 are prevented from being rubbed due to vibrations of the automobile or the like, or abnormal noise is generated, or temperature-controlled air passing through the floor duct 65. In order to prevent dew condensation caused by the above, a cushioning material 68 such as felt or polyurethane foam is provided.

  However, conventionally, since the floor spacer and the floor duct are configured as separate bodies, the arrangement work on the floor of an automobile is troublesome. In addition, a floor spacer made of a single polyurethane foam has a low rigidity, and thus has a problem of buckling (partially deforming) when stepped on by a passenger's foot. Thus, deformation resistance is improved by laminating a resin plate-like body on a polyurethane foam. However, there is a problem that an extra work of stacking and integrating the polyurethane foam and the resin plate-like body is required, and there is a problem that the number of parts increases and the cost increases. Further, in order to make it difficult for noise outside the vehicle to be transmitted into the vehicle, the floor spacer is required to have good sound absorption.

Japanese Patent Laid-Open No. 10-181468 JP 2007-83904 A JP 2002-225538 A

  The present invention has been made in view of the above points, and the layout work of the floor spacer and the floor duct on the floor of the automobile is simplified, and the buckling (partial deformation) of the floor spacer is suppressed. An object of the present invention is to provide an automotive floor spacer integrated floor duct that can reduce the number of parts and can improve sound absorption.

Invention of Claim 1 consists of the floor duct arrange | positioned on the floor surface of a motor vehicle, and a floor spacer, The said floor duct is equipped with the plate-shaped part protruded outward from the side part of the tubular duct main-body part, The floor spacer is made of a porous foam integrally provided with the floor duct on the side of the duct main body, the porous foam is made of polyurethane foam, and the plate-like portion of the floor duct is Embedded in the floor spacer, or located on the upper surface of the floor spacer, a hollow portion for engagement having a foam intrusion opening in part is formed in the plate-like portion of the floor duct, and the foam intrusion opening The polyurethane foam of the floor spacer penetrates into the engagement hollow portion .

Invention of Claim 2 consists of the floor duct arrange | positioned on the floor surface of a motor vehicle, and a floor spacer, The said floor duct is equipped with the plate-shaped part protruded outward from the side part of the tubular duct main-body part, The floor spacer is made of a porous foam provided integrally with the floor duct on the side of the duct main body, and the plate-like portion of the floor duct is embedded in the floor spacer, or of the floor spacer. A sound absorbing part consisting of a hollow chamber is formed on one surface of the plate-like part of the floor duct, and the sound absorbing part is exposed from the floor spacer .

According to a third aspect of the present invention, in the second aspect, the porous foam is made of a polyurethane foam, and an engagement hollow portion having a foam intrusion opening partly is formed in the plate-like portion of the floor duct. The polyurethane foam of the floor spacer has penetrated into the engagement hollow portion from the foam intrusion opening .

A fourth aspect of the present invention is characterized in that, in the first or third aspect , a communicating portion is formed on one side of the plate-like portion of the floor duct so as to pass through the inside of the duct main body portion and the engaging hollow portion .

  According to a fifth aspect of the present invention, in any one of the first to fourth aspects, a bottom outer surface member made of a porous foam is provided on the outer surface of the bottom of the duct main body.

According to the first aspect of the present invention, since the floor spacer and the floor duct are integrated, the work for arranging the floor spacer and the floor duct on the floor surface of the automobile can be performed easily and quickly. In addition, since the plate-like portion protruding outward from the side portion of the duct main body portion is embedded in the floor spacer, or located on the upper surface, buckling of the floor spacer can be suppressed by the plate-like portion. Furthermore, since the plate-like portion embedded in the floor spacer or located on the upper surface is a part of the duct, the number of parts can be reduced and the product cost can be reduced. Moreover, since the porous foam which comprises a floor spacer has innumerable bubble (cell), the sound absorption property of a floor spacer can be made favorable.
According to the first aspect of the present invention, since the polyurethane foam of the floor spacer has entered the engaging hollow portion formed in the plate-like portion, the plate-like portion and the floor spacer are securely coupled, and the floor spacer is separated. There is no fear.

According to the second aspect of the present invention, since the floor spacer and the floor duct are integrated, the work for arranging the floor spacer and the floor duct on the floor surface of the automobile can be performed easily and quickly. In addition, since the plate-like portion protruding outward from the side portion of the duct main body portion is embedded in the floor spacer, or located on the upper surface, buckling of the floor spacer can be suppressed by the plate-like portion. Furthermore, since the plate-like portion embedded in the floor spacer or located on the upper surface is a part of the duct, the number of parts can be reduced and the product cost can be reduced. Moreover, since the porous foam which comprises a floor spacer has innumerable bubble (cell), the sound absorption property of a floor spacer can be made favorable.
According to the second aspect of the present invention, the sound absorption can be improved by the sound absorbing portion made of the hollow chamber formed on one surface of the plate-like portion of the floor duct, and the number and size of the sound absorbing portions made of the hollow chamber can be changed. Thus, it is possible to adjust the frequency band where good sound absorption is obtained. The hollow chamber is also referred to as a chamber, and it has already been known that it has a sound absorbing effect (see, for example, JP-A-2004-168173).

According to the invention of claim 3, since the polyurethane foam of the floor spacer has entered the engaging hollow portion formed in the plate-like portion, the plate-like portion and the floor spacer are securely coupled, and the floor spacer is separated. There is no fear.

According to invention of Claim 4, since the inside and outside of a duct main-body part are connected via the polyurethane foam of a communication part and the hollow part for engagement, the noise by the air which passes the inside of a duct main-body part can be reduced. In addition, it is a well-known technique to construct a part of the duct wall with a porous member such as polyurethane foam to improve sound absorption (see, for example, Japanese Patent Laid-Open No. 2001-193587).

  According to the invention of claim 5, the noise generated by rubbing between the duct body portion and the floor panel due to vibration of the automobile or the like by the bottom outer surface member made of a porous foam formed on the outer surface of the bottom portion of the duct body portion. Can be prevented, and the occurrence of condensation on the outer surface of the bottom of the duct body can be suppressed.

It is a perspective view of the floor spacer integrated floor duct for vehicles concerning the 1st reference form . It is 2-2 sectional drawing of FIG. It is the top view and back view which show a part of floor duct of the 1st reference form. It is a perspective view of the floor spacer integrated floor duct for motor vehicles concerning a 2nd embodiment of the present invention. It is 5A-5A, 5B-5B sectional drawing of FIG. It is the top view and back view which show a part of floor duct of 2nd Embodiment. It is 7A-7A of FIG. 6, and 7B-7B sectional drawing. It is a perspective view of the floor spacer integrated floor duct for motor vehicles concerning a 3rd embodiment of the present invention. It is 9A-9A, 9B-9B, 9C-9C, 9D-9D sectional drawing of FIG. It is a reverse view which shows a part of floor duct integrated with the floor spacer for motor vehicles of 3rd Embodiment. It is the top view and back view which show a part of floor duct of 3rd Embodiment. It is 12A-12A, 12B-12B, 12C-12C, 12D-12D sectional drawing of FIG. It is sectional drawing of the floor part of the motor vehicle in which the conventional floor duct and the floor spacer are arrange | positioned. It is a perspective view of the conventional floor duct and a floor spacer.

As shown in FIGS. 1 to 3, the floor duct integrated with an automobile floor spacer 10 of the first reference embodiment includes a floor duct 11 and floor spacers 31 and 33, and the floor panel on the floor surface of the automobile shown in FIG. 12. 51 and the floor carpet 55.

The floor duct 11 is made of a synthetic resin such as polypropylene or polyethylene, and includes a tubular duct main body portion 13 and plate-like portions 21 and 23 protruding outward from the side portions 17 and 18 of the duct main body portion 13. Become. The floor duct 11 of this reference form is formed by known blow molding.
The duct main body 13 is formed in a tubular shape having a predetermined cross-sectional shape, and one end 14 side is connected to an air conditioner of the vehicle, and the other end 15 side is connected to an air outlet in the vehicle.

  The plate-like portions 21 and 23 are provided for reinforcing the floor spacers 31 and 33. In the illustrated example, the plate-like portion 21 is positioned on the upper surface of the floor spacer 31 for the side portion 17 on one side of the duct body portion 13, while the floor spacer is provided for the side portion 18 on the opposite side. The plate-like portion 23 is embedded in 31. Note that the plate-like portion on either side may be positioned on the upper surface of the floor spacer or embedded in the floor spacer. The plate-like portions 21 and 23 are preferably large enough to cover the upper surface of the corresponding floor spacer, or large enough to be embedded in the entire floor spacer. Further, the thickness of the plate-like portions 21 and 23 is set so that the plate-like portions 21 and 23 are not easily deformed by pressing by an occupant. An example of the thickness of the plate-like portions 21 and 23 is about 3 to 5 mm. In addition, depending on the arrangement position of the duct main body 12 on the floor of the automobile, a floor spacer may be provided only on one side of the duct main body 13. In that case, the said plate-shaped part is formed only in the side part of the duct main-body part in which a floor spacer is provided. Moreover, the front-end | tip of one plate-shaped part 21 becomes the bending part 22 bent downward, The engagement property (integration) of the plate-shaped part 21 and the floor spacer 31 is improved with the said bending part 22. Yes. Reference numerals 26 and 27 are fixing portions used when the automobile floor spacer integrated floor duct 10 is fixed to the floor surface, and project from the duct main body portion 13.

In the illustrated example, a bottom outer surface member 30 is provided on the outer surface of the bottom portion 19 of the duct main body portion 13. It said bottom outer surface member 30 is a porous foam, in this preferred embodiment is extended from the floor spacer 31, 33. Examples of the porous foam include polyurethane foam and polyethylene foam. The bottom outer surface member 30 is for the purpose of preventing abnormal noise generated by rubbing the duct main body 13 and the floor panel due to vibrations of the automobile and the like, and suppressing the occurrence of condensation on the outer surface of the bottom 19 of the duct main body 13. It is provided and has a predetermined thickness, for example, about 2 mm to 10 mm.

  The floor spacers 31 and 33 are provided on the side portions 17 and 18 of the floor duct body 13 and are formed integrally with the floor duct 11. The floor spacer is made of a porous foam. Examples of the porous foam include polyurethane foam and polyethylene foam. In particular, a polyurethane foam is preferable because it can be easily integrated with the floor duct by insert molding as will be described later.

In this preferred embodiment, the floor spacer 31, 33 consists of a polyurethane foam which is foamed forming a plate-like portion 21 and 23 of the floor duct 11 as an insert. Insert molding of polyurethane foam is integrated with the insert by molding the polyurethane foam, setting the insert (reinforcing member, etc.) in the mold (mold), filling the mold with polyurethane foam raw material and foaming. This is a method of forming a polyurethane foam, and is a molding method that has been widely used. In the case of this reference embodiment, after setting the plate-like portions 21 and 23 and the duct main body portion 13 as inserts in a mold, the mold is filled with a polyurethane foam raw material and foamed, whereby the floor spacers 31 and 33 and The bottom outer member 30 can be formed integrally with the floor duct 11. The floor spacers 31 and 33 can be bonded to the floor duct 11 by the adhesiveness when foaming polyurethane foam. However, when more reliable integration is required, or the floor duct 11 is polyurethane foamed. When the material is inferior in adhesion to the body, it is preferable to insert a polyurethane foam by applying a primer in advance to the surface of the floor duct 11 forming the polyurethane foam. Further, the floor spacers 31 and 33 in the first reference embodiment may be bonded to the floor duct by a known means such as adhesion or fusion, instead of insert molding, separately foamed porous foam. . In this case, when the floor duct is made of polypropylene or polyethylene, the bonding strength between the floor spacer and the floor duct can be increased by forming the floor spacer with a polyethylene foam having good compatibility with polypropylene or polyethylene. .

The polyurethane foam constituting the floor spacers 31 and 33 is easily deformed if the density is too low. On the other hand, if the density is too high, it is disadvantageous for the demand for weight reduction of the automobile. Therefore, the density (JIS K722) Is preferably 40 to 100 kg / m ³ . Further, the thickness of the floor spacers 31 and 33 is set to an appropriate value, for example, about 30 to 50 mm, according to the floor surface of the automobile. Further, in this preferred embodiment, the floor spacer 31 on one side is thinner than the other side of the floor spacer 33.

Since the floor spacers 31 and 33 and the floor duct 11 of the first reference embodiment are integrated with the floor spacers 31 and 33, the work for arranging the floor spacer and the floor duct on the floor of the automobile is performed. Can be performed more easily and quickly than when separate floor spacers and floor ducts are arranged. In addition, the floor spacers 31 and 33 are embedded in the plate-like portions 21 and 23 protruding outward from the side portions of the duct main body portion 13 or are located on the upper surface. The floor spacers 31 and 33 are reinforced, and the buckling of the floor spacers 31 and 33 can be suppressed. Further, since the plate-like portions 21 and 23 embedded in the floor spacers 31 and 33 or located on the upper surface are part of the floor duct, the number of product parts can be reduced, and the product cost can be reduced. Is possible. Moreover, since the polyurethane foam which comprises the said floor spacers 31 and 33 has an infinite number of air bubbles (cell), the sound absorption property of the said floor spacers 31 and 33 can be made favorable.

Next, an automotive floor spacer integrated floor duct 10A of the second embodiment will be described. As shown in FIGS. 4 to 7, the automobile floor spacer integrated floor duct 10 </ b> A according to the second embodiment includes a foam intrusion opening 29 </ b> A in a part of a plate-like portion 23 </ b> A on one side of the floor duct 11 </ b> A. Conjunction hollow portion 28A is formed, said different from the foam invading opening 29A polyurethane foam 34A is a first reference embodiment in that it penetrates the floor spacer 33A to the engaging hollow portion 28A, other configurations The same as in the first reference embodiment. Reference numeral 13A denotes a duct body part, 14A denotes one end of the duct body part, 15A denotes the other end, 17A and 18A denote side parts of the duct body part, 19A denotes a bottom part of the duct body part, 21A and 23A denote plate-like parts, and 22A denotes a plate. The bent portions 26A and 27A at the tip of the shape portion 21A are fixed portions. Reference numeral 30A denotes a bottom outer member, and 31A and 33A denote floor spacers made of polyurethane foam.

  The engaging hollow portion 28A is partially formed with a foam intrusion opening 29A, and the inside and outside of the engaging hollow portion 28A communicate with each other through the foam intrusion opening 29A. In the present embodiment, the engaging hollow portion 28A is constituted by a tubular portion formed along the length direction of the duct main body portion 13A at the tip of the plate-like portion 23A, and the central position of the engaging hollow portion 28A. The foam intrusion opening 29A is formed. The polyurethane foam 34A enters the engagement hollow portion 28A when the polyurethane foam of the floor spacer 33A is foamed using the plate-like portion 23A as an insert, and the engagement hollow portion 29A is inserted through the foam entry opening 29A. This is performed by the polyurethane foam raw material entering and foaming into the portion 28A. The position of the engaging hollow portion 28A is a position embedded in the floor spacer 33A. Further, the size of the engaging hollow portion 28A is set so as not to protrude from the floor spacer 33A. Further, the engagement hollow portion 28A is not limited to the plate-like portion 23A on the one side portion 18A of the duct main body portion 13A, but may be formed on the plate-like portion 21A on the other side portion 17A, or on both side plate-like portions. The portions 21A and 23A may be formed.

In the automobile floor spacer integrated floor duct 10A of the second embodiment, the following effects are obtained in addition to the effects described in the first reference embodiment. In the automobile floor spacer integrated floor duct 10A of the second embodiment, since the polyurethane foam 34A of the floor spacer 33A has entered the engaging hollow portion 28A, the plate-like portion 23A and the floor spacer 33A are integrated. Has become stronger. Furthermore, in this embodiment, since the floor spacers 31A and 33A on both sides of the duct main body portion 13A are arranged in series via the bottom outer surface member 30A, not only the floor spacer 33A on one side but also the other side The floor spacer 33A and the bottom outer surface member 30A are also securely coupled to the floor duct 11A by the penetration of the polyurethane foam 34A into the engagement hollow portion 28A, and there is no possibility of separation from the floor duct 11A.

  Next, an automotive floor spacer integrated floor duct 10B according to a third embodiment will be described. As shown in FIGS. 8 to 12, the floor duct integrated floor duct 10 </ b> B for an automobile according to the third embodiment has a hollow portion for engagement with the inside of the duct body portion 13 on one side of the plate-like portion 23 </ b> B on one side of the floor duct 11 </ b> B. The second embodiment is the same as the second embodiment in that a communication part 25B passing through the interior of 28B and a sound absorbing part 24B composed of a hollow chamber are formed. Reference numeral 13B is a duct body, 14B is one end of the duct body, 15B is the other end, 17B and 18B are sides of the duct body, 19B is a bottom of the duct body, 21B and 23B are plate-like parts, and 22B is a plate The bent portion at the tip of the shaped portion 21B, 26B and 27B are fixing portions, 28B are engagement hollow portions, and 29B is a foam intrusion opening. Reference numeral 30B denotes a bottom outer surface member, 31B and 33B denote floor spacers, and 34B denotes a polyurethane foam which has entered the engaging hollow portion 28B.

  The communication portion 25B is configured as a tunnel-shaped passage, is formed between the duct main body portion 13B and the engagement hollow portion 28B, and communicates between the duct main body portion 13B and the engagement hollow portion 28B. . The cross-sectional size of the communication part 25B is preferably about 6 to 10 mm in diameter in order to reduce the influence on the flow rate of the air flowing through the duct main body part 13B. In the present embodiment, the two communication portions 25B are formed, but other numbers may be used.

  In the present embodiment, the sound absorbing portion 24B formed of the hollow chamber is formed of a substantially cubic room. By changing the number and size of the sound absorbing portions 24B, it is possible to adjust the frequency band in which good sound absorbing properties can be obtained. The sound absorbing portion 24B is provided so as to be exposed from the polyurethane foam of the floor spacer 33B in the plate-like portion 23B. Since the sound absorbing portion 24B is exposed from the polyurethane foam of the floor spacer 33B, the vibration in the sound absorbing portion 24B becomes good and the sound absorbing property is improved. The sound absorbing portion 24B is not limited to the plate-like portion 23B in the side portion 18B on one side of the duct main body portion 13B, but is formed in the plate-like portion 21B in the side portion 17B on the other side, or the plate-like portions on both sides. You may form in 21B and 23B.

In the automobile floor spacer integrated floor duct 10B of the third embodiment, in addition to the effects described in the first reference embodiment and the second embodiment, the following effects are obtained. The automobile floor spacer integrated floor duct 10B of the third embodiment communicates with the inside and outside of the duct body portion 13B through the polyurethane foam in the communication portion 25B and the engagement hollow portion 28B. Noise due to air passing through the can be reduced. Furthermore, by changing the number and size of the sound absorbing portions 24B made of the hollow chambers, it is possible to adjust the frequency band where good sound absorbing properties can be obtained, and to obtain sound absorbing properties suitable for automobiles. Moreover, in the said 3rd Embodiment, although both the said sound absorption part 24B and the said communication part 25B were provided, you may provide only any one.

In the first reference embodiment , the second embodiment , and the third embodiment, if the polyurethane foam as the porous foam constituting the floor spacer and the bottom outer surface member has a high proportion of open cells, sound absorption is achieved. On the other hand, if the polyurethane foam has a high ratio of closed cells, heat insulation can be improved.

In the reference embodiment and each embodiment, a part of the floor duct is not covered with the polyurethane foam, but the entire floor duct is covered with the polyurethane foam except for the sound absorbing portion. It may be a configuration. Furthermore, one plate-like part 21, 21A, 21B in the reference form and each embodiment has bent parts 22, 22A, 22B at the tip, and the plate-like part 21 is formed by the bent parts 22, 22A, 22B. , 21A, 21B and the floor spacers 31, 31A, 31B are enhanced in engagement (integration), and the dimensional accuracy of the floor ducts integrated with the automobile floor spacers is improved, but the bent portions 22, 22A, 22B Alternatively, an engagement hollow portion similar to the engagement hollow portions 28A and 28B in the second and third embodiments may be provided, or the bent portions 22, 22A and 22B may be combined with the engagement hollow portion. Good.

  Further, the foam intrusion openings 29A and 29B in the engaging hollow portions 28A and 28B are not limited to one, and a plurality of openings may be provided. Further, the engaging hollow portions 28A and 28B may be in communication (continuous) or may not be in communication (continuous). Further, the engaging hollow portions 28A and 28B may be formed at a plurality of positions of the plate-like portions 23A and 23B, and foam engaging openings may be formed in the respective engaging hollow portions.

10, 10A, 10B Automotive floor spacer integrated floor duct 11, 11A, 11B Floor duct 13, 13A, 13B Duct main body 17, 17A, 17B, 18, 18A, 18B Duct main body side 19, 19A, 19B Duct Bottom part of main body part 21, 21A, 21B 23, 23A, 23B Plate-like part 24B Sound absorbing part 25B Communication part 28A, 28B Engaging hollow part 29A, 29B Foam entry opening 30, 30A, 30B Bottom outer surface member 31, 31A, 31B, 33, 33A, 33B Floor spacer

Claims (5)

It consists of floor ducts and floor spacers that are placed on the floor of an automobile.
The floor duct includes a plate-like portion protruding outward from a side portion of a tubular duct main body portion,
The floor spacer is made of a porous foam provided integrally with the floor duct on the side of the duct body.
The porous foam comprises a polyurethane foam;
The plate-like portion of the floor duct is embedded in the floor spacer, or is located on the upper surface of the floor spacer ,
An engagement hollow portion having a foam intrusion opening in part is formed in the plate-like portion of the floor duct, and the polyurethane foam of the floor spacer enters the engagement hollow portion from the foam intrusion opening. automotive floor spacer integrally floor duct, characterized in that is. It consists of floor ducts and floor spacers that are placed on the floor of an automobile.
The floor duct includes a plate-like portion protruding outward from a side portion of a tubular duct main body portion,
The floor spacer is made of a porous foam provided integrally with the floor duct on the side of the duct body.
The plate-like portion of the floor duct is embedded in the floor spacer, or is located on the upper surface of the floor spacer ,
A floor duct integrated with a floor spacer for an automobile , wherein a sound absorbing portion comprising a hollow chamber is formed on one surface of a plate-like portion of the floor duct, and the sound absorbing portion is exposed from the floor spacer. The porous foam comprises a polyurethane foam;
An engagement hollow portion having a foam intrusion opening in part is formed in the plate-like portion of the floor duct, and the polyurethane foam of the floor spacer enters the engagement hollow portion from the foam intrusion opening. The floor duct integrated with a floor spacer for an automobile according to claim 2 , wherein the floor duct is integrated with a floor spacer. 4. A floor duct integrated with a floor spacer for automobiles according to claim 1, wherein a communicating portion is formed on one surface of the plate-like portion of the floor duct so as to pass through the inside of the duct body and the hollow portion for engagement. .   The floor spacer integrated floor duct for automobiles according to any one of claims 1 to 4, wherein a bottom outer surface member made of a porous foam is provided on the outer surface of the bottom of the duct main body.

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