JP7649685B2 - Door hole seal manufacturing method - Google Patents

Description

The present invention relates to a door hole seal that is attached to an inner door panel of a vehicle door, and a method for manufacturing the door hole seal.

Conventionally, door hole seals have been used to close door holes, which are openings for work or the like, formed in the door inner panel of a vehicle door. For example, Patent Document 1 discloses a door hole seal equipped with a member storage section. The member storage section has a pillar section extending from a side wall forming the outer edge of the opening formed in the elastic sheet toward the inside of the vehicle, and a covering member that covers the vehicle member inserted in the opening and the pillar section. For example, Patent Document 2 discloses an automobile door hole seal material equipped with a resin sheet and a sheet-shaped foamed elastic material, and a through hole is formed in the resin sheet in a portion corresponding to the tip side of the projection direction of the impact absorbing member.

JP 2018-47802 A JP 2018-58402 A

The door hole seal disclosed in Patent Document 1 requires that the covering member be thick to obtain rigidity, and that the covering member be large enough to store the vehicle components. This means that the covering member is not sufficient in terms of cost. In addition, the manufacturing process requires additional steps to erect the pillars and cover the pillars with the covering member, which is time-consuming and not sufficient in terms of manufacturing costs.

The door hole seal disclosed in Patent Document 2 is not sufficient in terms of manufacturing costs because part of the sheet-shaped foamed elastic material is loose and an additional step is required in the manufacturing process to loosen the part of the sheet-shaped foamed elastic material. In addition, the covering part made of part of the sheet-shaped foamed elastic material is easily damaged by aging deterioration, stress concentration, etc. in the part that comes into contact with the shock absorbing material.

One aspect of the present invention aims to ensure the strength of specific parts of the door hole seal while reducing costs and simplifying manufacturing operations.

In order to solve the above problem, a door hole seal according to one aspect of the present invention is a door hole seal attached to a door inner panel of a vehicle door, and includes a sheet that covers the door inner panel from the inside of the vehicle, and a part of the sheet is configured as a storage section that stores a protrusion that protrudes from a door hole formed in the door inner panel to the inside of the vehicle, and the storage section has a side wall that extends from a first surface of the sheet on the inside of the vehicle to surround the side of the protrusion, and a top wall that covers the tip of the protrusion from the inside of the vehicle, and a first resin member that surrounds the base of the side wall is bonded to the first surface, and a second resin member is bonded to a second surface on the inside of the vehicle at the connection portion between the side wall and the top wall.

With the above configuration, since the storage section having side walls and a top wall is made from a part of the sheet, the main part of the storage section can be manufactured simply by deforming a part of the sheet to form the side walls and the top wall. This reduces material costs compared to when the storage section is formed from a separate material from the sheet. In addition, since the process of adhering the storage section formed from a separate material to the sheet can be omitted, the manufacturing process is simplified and manufacturing costs can be reduced.

The connection portion between the side wall and the top wall of the storage section is easily damaged due to aging, stress concentration, and the like. However, with the above-described configuration, since the second resin member is adhered to the connection portion, the connection portion is reinforced by the second resin member, and the strength of the connection portion can be ensured. In addition, since the second resin member is adhered to the second surface of the connection portion, the adhesion work of the second resin member can be easily performed.

In a door hole seal according to one aspect of the present invention, at least a portion of the sidewall portion bonded to the sidewall-side region of the second surface of the second resin member may be bonded to the base of the sidewall, and at least a portion of the portion may be connected to the first resin member. This configuration makes it easier to maintain not only the shape of the connection portion but also the shape of the entire sidewall. In addition, it is possible to ensure the strength of not only the connection portion but also the strength of the entire sidewall.

In a door hole seal according to one aspect of the present invention, the portion of the first resin member on the storage section side may be at least partially adhered to a third surface that connects to the first surface of the side wall. This configuration makes it easier to maintain not only the shape of the connection portion but also the shape of the entire side wall. In addition, it is possible to ensure the strength of not only the connection portion but also the strength of the entire side wall.

In order to solve the above problem, a method for manufacturing a door hole seal according to one aspect of the present invention includes a sheet that is attached to an inner door panel of a vehicle door and covers the inner door panel from the inside of the vehicle, and a portion of the sheet is configured as a storage section for storing a protrusion protruding from a door hole formed in the inner door panel to the inside of the vehicle, and the storage section has a side wall that extends from a first surface of the sheet on the inside of the vehicle to surround the side of the protrusion, and a top wall that covers the tip of the protrusion from the inside of the vehicle. The method includes a manufacturing process of manufacturing the storage section by deforming a portion of the sheet to form the side wall and the top wall, and a bonding process of bonding a second resin member to a second surface on the inside of the vehicle at a connection portion between the side wall and the top wall. With the above configuration, a door hole seal can be manufactured with guaranteed strength at the connection portion. In addition, costs can be reduced and manufacturing operations can be made easier.

The method for manufacturing a door hole seal according to one aspect of the present invention further includes a step of placing the second resin member on a fourth surface on the vehicle interior side that corresponds to the second surface of a portion of the sheet, and in the step of placing, the second resin member may be placed on the fourth surface so that a separation portion that is separated from the fourth surface is formed in the second resin member.

According to the above configuration, for example, when the sheet is stretched along the outer shape of the lower mold after the placement step and before the manufacturing step, the separated portion becomes an extension allowance. As a result, when a portion of the sheet is shaped into the side wall and top wall by the lower mold in the manufacturing step, the second resin member adheres closely to the second surface of the connection portion, so that the second resin member can be bonded to the second surface without any gaps.

According to one aspect of the present invention, it is possible to reduce costs and simplify manufacturing operations, while ensuring the strength of specific parts of the door hole seal.

1 is a diagram showing the structure of an inner side of a door inner panel to which a door hole seal according to one embodiment of the present invention is attached. Reference numeral 201 is a plan view showing a storage portion of the door hole seal shown in Fig. 1 and its vicinity. Reference numeral 202 is a cross-sectional view taken along line II-II of the storage portion shown in reference numeral 201 and its vicinity. Reference numeral 301 is a cross-sectional view showing a state in which the sheet and the first and second resin members are set in a welding device, and reference numeral 302 is a cross-sectional view showing a state in which welding of the first and second resin members shown in reference numeral 301 has been completed. Reference numeral 401 is a schematic diagram of an upper mold of the welding device shown in Fig. 3 as viewed from the tip side of each heating member. Reference numeral 402 is a schematic diagram of a lower mold of the welding device shown in Fig. 3 as viewed from the top surface of the lower mold. Reference numeral 501 is a plan view showing a storage portion of a door hole seal according to a first modified example of the present invention and its vicinity. Reference numeral 502 is a cross-sectional view taken along line V-V of the storage portion shown in reference numeral 501 and its vicinity. FIG. 11 is a side view showing the state of the seal and the first and second resin members after completion of a placement step in the manufacturing method for a door hole seal according to the first modified example of the present invention. Reference numeral 701 is a plan view showing a storage portion of a door hole seal according to another modified example of the present invention and its vicinity. Reference numeral 702 is a cross-sectional view taken along line VI-VI of the storage portion shown in reference numeral 701 and its vicinity. 13A to 13C are plan views illustrating modified examples of the first and second resin members before they are welded together. Reference numeral 901 is a cross-sectional view showing a state in which the sheet and each of the modified first and second resin members shown in Fig. 8 are set in a welding device. Reference numeral 902 is a cross-sectional view showing a state in which welding of each of the modified first and second resin members shown in reference numeral 901 is completed.

[Door hole seal overview and installation example]
With reference to FIG. 1, an overview and an example of installation of a door hole seal 1 according to an embodiment of the present invention will be described. In the example of FIG. 1, the upper side corresponds to the vertical upper side, the lower side corresponds to the vertical lower side, the left side corresponds to the front side (front side of the vehicle), the right side corresponds to the rear side (rear side of the vehicle), the near side corresponds to the inside of the vehicle (inside of the vehicle), and the far side corresponds to the outside of the vehicle (outside of the vehicle). FIG. 1 is a view of a front door 100 seen from the inside of the vehicle. However, the example of FIG. 1 does not limit the manner in which the door hole seal 1 is installed on the vehicle, and the door hole seal 1 may be installed from any direction, for example, on the vehicle.

The front door 100 is an example of a vehicle door, and is attached to a front door opening (not shown) of the vehicle so as to be able to open and close. The front door 100 is molded integrally with a door frame. The door frame includes a door outer panel (not shown) and a door inner panel 101, and a door hole 101x is formed in the door inner panel 101.

The door hole 101x is an opening through which a worker can insert his/her hands or tools to assemble various vehicle parts 102 (see reference numeral 202 in FIG. 2) arranged inside the front door 100. An example of a vehicle part 102 is a functional part such as an inner handle. After assembly, a part of the vehicle part 102 protrudes from the door hole 101x toward the inside of the vehicle (see reference numeral 202 in FIG. 2).

A door hole seal 1 is attached to the interior surface of the door inner panel 101. The door hole seal 1 blocks the door hole 101x from the inside of the vehicle, preventing rainwater or the like that has entered the inside of the front door 100 from entering the vehicle through the door hole 101x. As shown in FIG. 1, the door hole seal 1 includes a sheet 1x and a storage section 10.

The sheet 1x is adhered to the surface of the door inner panel 101 on the vehicle interior side, thereby directly covering the door inner panel 101 from the vehicle interior side. The thickness of the sheet 1x is not limited, but can be, for example, about 10 mm. An adhesive such as butyl sealant is used to adhere the sheet 1x. In this specification, "adhesion" includes the concepts of "adhesion," "pressure bonding," "welding," etc.

Examples of materials for forming the sheet 1x include elastomers and composites containing elastomers. Examples of elastomers include rubbers such as ethylene propylene diene rubber (EPDM) and thermoplastic elastomers (TPEs). Examples of TPEs include olefin-based thermoplastic elastomers (TPOs). The sheet 1x is preferably formed of a foamed elastic body obtained by foaming the above-mentioned elastomers or composites containing elastomers. Using such materials can improve the soundproofing and waterproofing properties of the sheet 1x.

The storage section 10 is made up of a part of the sheet 1x, and is formed in a location that overlaps with the door hole 101x in the sheet 1x. When the door hole seal 1 is attached to the door inner panel 101, the storage section 10 stores a portion of the vehicle part 102 that protrudes from the door hole 101x toward the inside of the vehicle (protrusion; hereinafter, "protruding portion of the vehicle part 102"). A first resin member 20 as shown in FIG. 1 is welded around the base of the storage section 10 (specifically, the base 10x-1 of the side wall 10x, which will be described later). The storage section 10 and the first resin member 20 will be described in detail later.

The above-mentioned installation of the door hole seal 1 is merely one example. For example, the vehicle door to which the door hole seal 1 is installed is not limited to the front door 100 shown in the example of FIG. 1, but may be any type of vehicle door. Therefore, the door hole seal 1 may be installed, for example, on a rear door or a sliding door. In addition, the vehicle to which the door hole seal 1 is installed may be any type of vehicle, including hardtop cars and convertible cars.

The number of storage sections 10 is not limited to the example shown in FIG. 1. A plurality of storage sections 10 can be provided according to the number of door holes 101x, i.e., the number of protrusions protruding from the door holes 101x toward the inside of the vehicle.

[Containment area and surrounding structure]
The structure of the storage section 10 and its vicinity will be described with reference to Fig. 2. In the example of reference numeral 202 in Fig. 2, as well as the examples of reference numeral 502 in Fig. 5 and reference numeral 702 in Fig. 7 described later, the upper side in the plane of the paper corresponds to the inside of the vehicle, the lower side corresponds to the outside of the vehicle, the right side corresponds to the front side, the left side corresponds to the rear side, the near side corresponds to the vertically upper side, and the far side corresponds to the vertically lower side.

As shown in FIG. 2, the storage section 10 has a generally quadrangular pyramid shape that corresponds to the outer shape and size of the protruding portion of the vehicle part 102, and has a side wall 10x and a top wall 10y. The side wall 10x is a wall that extends from the first surface 1x-1 of the seat 1x on the vehicle interior side toward the vehicle interior side, and surrounds the entire side surface 102x of the protruding portion of the vehicle part 102, as shown by reference numeral 202 in FIG. 2. The top wall 10y is a wall that covers the tip 102y of the protruding portion of the vehicle part 102 from the vehicle interior side.

The four corners of the base 10x-1 of the side wall 10x and the four corners of the top wall 10y are rounded in plan view, as shown by reference numeral 201 in FIG. 2. The opposing surfaces of the side wall 10x and the top wall 10y that face the protruding portion of the vehicle component 102 are in contact with the protruding portion, as shown by reference numeral 202 in FIG. 2.

The shape and size of the storage section 10 are not limited to the example shown in FIG. 2 and may be changed as appropriate to match, for example, the shape and size of the protruding portion of the vehicle part 102. In addition, the opposing surfaces of the side wall 10x and the top wall 10y may not be in contact with the protruding portion of the vehicle part 102, and a gap may be formed between at least one of the opposing surfaces and the protruding portion.

The first resin member 20 is welded to the first surface 1x-1 as shown in FIG. 2, and is disposed so as to surround the base 10x-1 of the side wall 10x. As shown by reference numeral 201 in FIG. 2, the external shape of the first resin member 20 is a substantially rectangular shape in plan view that corresponds to the shape of the base 10x-1 of the side wall 10x, and the four corners are rounded.

The first resin member 20 is in a sheet shape as shown by reference numeral 202 in FIG. 2. The thickness of the first resin member 20 is thinner than the thickness of the sheet 1x, and can be, for example, about 0.1 mm. Examples of materials for forming the first resin member 20 and the second resin member 21 described below include synthetic resins, and thermoplastic resins are preferable as synthetic resins. Examples of thermoplastic resins include PE (polyethylene), PP (polypropylene), PVA (polyvinyl alcohol), and ABS (acrylonitrile butadiene styrene). The material for forming the first resin member 20 and the material for forming the second resin member 21 may be the same or different.

By surrounding the base 10x-1 of the side wall 10x with the first resin member 20, combined with the welding of the second resin member 21 to the storage section 10 described below, it becomes easier to maintain the side wall 10x in a raised state toward the inside of the vehicle. This in turn makes it easier to maintain the shape of the connection portion 10z (described in detail later) in the storage section 10.

The storage section 10 has a second resin member 21 as shown in FIG. 2. Specifically, as shown by reference numeral 202 in FIG. 2, the second resin member 21 is welded to the second surface 10z-1 on the vehicle interior side of the connection portion 10z between the side wall 10x and the top wall 10y. The connection portion 10z is formed by connecting the end of the side wall 10x on the vehicle interior side to the side end of the top wall 10y. In a side view, the connection portion 10z has a bent shape corresponding to the shape of the corner at the tip of the protruding portion of the vehicle part 102. As shown by reference numeral 201 in FIG. 2, the second resin member 21 has a side wall side portion 21x and a top wall side portion 21y.

The sidewall portion 21x has a rectangular sheet shape and is a portion of the second resin member 21 that is welded to the sidewall 10x. Specifically, as shown in FIG. 2, the sidewall portion 21x is welded to the sidewall side area (hereinafter, "sidewall area") of the second surface 10z-1 of the connection portion 10z. In this embodiment, the second resin member 21 has four sidewall portions 21x, and one sidewall portion 21x is welded to each of the four wall portions that make up the sidewall 10x.

The sidewall region is divided into four regions (hereinafter, "sidewall region portions"), one for each wall portion described above. In this embodiment, the sidewall region portion 21x is welded to approximately the center of the sidewall region portion. By welding the sidewall region portion 21x in this arrangement, it becomes difficult for a bias to occur between the portions of the connection portion 10z where the shape is maintained and the portions where the shape is not maintained, and the shape of the connection portion 10z can be maintained in a well-balanced manner overall.

The shape, size, number, and arrangement of the side wall side portions 21x are not limited to the example in FIG. 2. For example, the side wall side portions 21x may be welded to any location in the side wall side region. Also, for example, one side wall side portion 21x may be welded so as to cover the entire side wall side region. Welding in this manner makes it even easier to maintain a well-balanced overall shape of the connection portion 10z.

The top wall side portion 21y is a sheet-like portion having a substantially rectangular outer shape, and is welded to the top wall 10y of the second resin member 21. Specifically, the top wall side portion 21y is welded so as to cover the entire top wall side area of the second surface 10z-1 (hereinafter, the "top wall side area"). The shape, size, number, and arrangement of the top wall side portion 21y are not limited to the example in FIG. 2. For example, the top wall side portion 21y may have at least one of its four corners not connected in a plan view, and a space may be formed in the unconnected area. Also, for example, the top wall side portion 21y may cover the entire surface of the vehicle interior side of the top wall 10y (including the top wall side area).

In this embodiment, the thickness of the second resin member 21 and the thickness of the first resin member 20 are the same, but they do not have to be the same. Also, the second resin member 21 may have different thicknesses at the side wall portion 21x and the top wall portion 21y. However, it is preferable that the thickness of the second resin member 21 is thinner than the thickness of the sheet 1x.

Furthermore, the first and second resin members 20 and 21 do not have to be welded together. The first resin member 20 only needs to be adhered to the first surface 1x-1 of the sheet 1x. The second resin member 21 may be adhered to the second surface 10z-1 of the connection portion 10z in the storage section 10 with, for example, an epoxy resin adhesive. In other words, the second resin member 21 only needs to be adhered to the extent that the shape of the connection portion 10z can be maintained.

However, in order to reduce the number of manufacturing steps for the door hole seal 1 and thereby simplify manufacturing and reduce manufacturing costs, it is preferable that the first and second resin members 20 and 21 are bonded in a single process. From this perspective, it is preferable that the bonding mode of the first resin member 20 and the bonding mode of the second resin member 21 are the same (both are welded in this embodiment), as in this embodiment.

[Method of manufacturing door hole seal]
An example of a manufacturing method of the door hole seal 1 will be described with reference to Fig. 3 and Fig. 4. Fig. 3 and Fig. 4 are diagrams for explaining the welding process of the first and second resin members 20 and 21 in the manufacturing process of the door hole seal 1. The steps other than the welding process in the manufacturing process of the door hole seal 1 are the same as the steps included in the manufacturing process of a general door hole seal, so the description thereof will be omitted.

<Welding device>
In the welding process, a welding device 50 as shown in Fig. 3 is used. The welding device 50 includes an upper movable platen 51, a lower fixed platen 52, and a driving device 53. The upper movable platen 51 is driven in the vertical direction by the driving device 53. As shown by reference numeral 401 in Figs. 3 and 4, the upper movable platen 51 has an upper mold constituted by a first heating member 51x, a second heating member 51y, and a third heating member 51z. Specifically, the upper mold is provided on the lower surface of the upper movable platen 51.

As shown by reference numeral 302 in FIG. 3 and reference numeral 401 in FIG. 4, the shape and size of the tip of the first heating member 51x are substantially the same as the shape and size of the first resin member 20 in a plan view (see also FIG. 2). The first heating member 51x is provided on the underside of the upper movable platen 51 so that the tip is positioned at the position where the first resin member 20 should be positioned when the storage section 10 is completed (see reference numeral 302 in FIG. 3).

As shown by reference numeral 302 in FIG. 3, the inner side surface of the lower portion of the second heating member 51y is inclined at approximately the same angle as the inclination angle of the side wall 10x when the storage unit 10 is completed. As shown by reference numeral 302 in FIG. 3 and reference numeral 401 in FIG. 4, the shape and size of the inner side surface of the second heating member 51y are approximately the same as the shape and size of the side wall portion 21x in a plan view (see also FIG. 2). Four second heating members 51y are provided on the lower surface of the upper movable platen 51 so that the inner side surface is positioned at the position where the side wall portion 21x of the second resin member 21 should be positioned when the storage unit 10 is completed (see reference numeral 302 in FIG. 3).

As shown by reference numeral 302 in FIG. 3 and reference numeral 401 in FIG. 4, the shape and size of the tip of the third heating member 51z are substantially the same as the shape and size of the top wall portion 21y of the second resin member 21 in a plan view (see also FIG. 2). The third heating member 51z is provided on the underside of the upper movable platen 51 so that the tip is positioned where the top wall portion 21y should be positioned when the storage section 10 is completed (see reference numeral 302 in FIG. 3).

The lower fixed platen 52 has a lower die 52x as shown by reference numeral 402 in FIG. 3 and FIG. 4. Specifically, the lower die 52x is provided on the upper surface of the lower fixed platen 52. The lower die 52x is a die having a substantially quadrangular pyramid shape that is substantially the same as the shape and size of the protruding portion of the vehicle component 102.

<Welding process>
The welding process will be described below. First, as shown by reference numeral 301 in Fig. 3, the upper movable platen 51 is raised by the driving device 53, and then the sheet 1x is placed on the upper surface of the lower fixed platen 52 and the upper surface of the lower die 52x. Then, the resin member 22 is placed on a first desired region on the first surface 1x-1 of the sheet 1x. The resin member 22 is a sheet made of the same material as the first resin member 20, has the same thickness as the first resin member 20, and has an outer area larger than that of the first resin member 20 in a plan view.

The resin member 22 has an opening of approximately the same shape and size as the shape and size of the boundary line between the sheet 1x and the side wall 10x. By placing the resin member 22 in the first desired area on the first surface 1x-1, the upper surface of the lower die 52x is positioned within the aforementioned opening. Here, the "first desired area" refers to the area where the opening of the resin member 22 surrounds the base 10x-1 of the side wall 10x when the storage section 10 is completed.

The second resin member 21 is placed on the second desired area 1x-2 (fourth surface) on the first surface 1x-1 (the above is the placing process). Here, the "second desired area 1x-2" refers to an area included in the surface of a portion of the sheet 1x that will form the side wall 10x and top wall 10y in the completed state, and is an area that will become the second surface 10z-1 of the connection portion 10z when the storage section 10 is completed. Hereinafter, the portion of the sheet 1x that will form the side wall 10x and top wall 10y in the completed state is referred to as the "specific portion." When the placing process is completed, the lower mold 52x causes the portion of the sheet 1x where the storage section 10 is to be formed and its vicinity to rise vertically upward.

Next, while the sheet 1x is kept stretched along the contour of the lower die 52x, the upper movable platen 51 is lowered by the driving device 53. Then, as shown by reference numeral 302 in FIG. 3, the tip of the first heating member 51x is pressed against the outer edge of the opening in the resin member 22. At the same time, the inner side surface of the second heating member 51y is pressed against the side wall portion 21x of the second resin member 21, and the tip of the third heating member 51z is pressed against the top wall portion 21y of the second resin member 21. These pressing forces deform specific portions of the sheet 1x to form the side walls 10x and top wall 10y, and the storage section 10 is produced (production process).

In addition, simultaneously with the aforementioned pressing by the first to third heating members 51x to 51z (hereinafter referred to as "pressing by the heating members"), the outer edge portion of the opening in the resin member 22 is heated by the first heating member 51x. Similarly, the side wall portion 21x is heated by the second heating member 51y, and the top wall portion 21y is heated by the third heating member 51z. Hereinafter, these heating operations are collectively referred to as "heating by the heating members".

Here, "simultaneously" in this specification does not mean that the completion of pressing by each heating member (the point at which the descent of the upper movable platen 51 is completed) and the start of heating must be exactly the same time. In this specification, "simultaneously" includes, for example, the case where heating by each heating member is started at any point from when the tip of each heating member starts to contact a specific point of the first and second resin members 20 and 21 until pressing by each heating member is completed. It also includes, for example, the case where heating by each heating member is started immediately after pressing by each heating member is completed.

Regarding the timing at which heating by each heating element begins, there is no particular limitation on the relationship between the first to third heating elements 51x to 51z (for example, whether they begin at the same time or at different times). However, from the viewpoint of shortening the overall heating time of the first to third heating elements 51x to 51z, and thus shortening the manufacturing time of the door hole seal 1, it is preferable for each heating element to begin heating at approximately the same time. Heating by each heating element causes the resin member 22 to be welded to the first surface 1x-1 of the sheet 1x, and the second resin member 21 to be welded to the second surface 10z-1 of the connection portion 10z (welding (adhesion) process).

Next, although not shown, the outer edge portion of the opening in the resin member 22 is separated from the other portions, so that the outer edge portion becomes the first resin member 20 (separation process). This separation may be performed, for example, by forming a perforation at the boundary between the outer edge portion and the other portions, and then cutting off the other portions of the resin member 22 in the separation process. Alternatively, the boundary between the outer edge portion and the other portions may be cut with a tool or the like.

In this embodiment, the manufacturing process and the welding process are performed simultaneously. Also, due to the structure of the welding device 50, heating by the first to third heating members 51x to 51z is also performed simultaneously in the welding process. By adopting such a method, the manufacturing of the storage section 10 and the welding of the first and second resin members 20 and 21 can be performed at the same time. This makes it possible to simplify the manufacturing process of the door hole seal 1 and reduce manufacturing costs. Note that the manufacturing process and the welding process may be performed separately, and the heating by the first to third heating members 51x to 51z may also be performed at different times. Alternatively, a device, tool, etc. different from the welding device 50 may be used.

[Modifications]
5 to 9, modified examples of the door hole seal 1 and modified examples of the manufacturing method of the door hole seal 1 will be described. For convenience of explanation, the same reference numerals are given to members having the same functions as those described in the above embodiment, and the description thereof will not be repeated.

<First Modification of Door Hole Seal>
First, a door hole seal in which the second resin member 21-1 is welded to the storage section 10 as shown in FIG. 5 is assumed as a first modified example of the door hole seal 1 (hereinafter, abbreviated as "first modified example"). In the first modified example, as shown in FIG. 5, all of the side wall side portions 21x-1 of the four second resin members 21-1 are welded to the base 10x-1 of the side wall 10x. Also, all of the four side wall side portions 21x-1 are connected to the first resin member 20. Also, the four side wall side portions 21x-1 are welded one by one to approximately the center of the inner surface of the four wall portions constituting the side wall 10x.

By welding the second resin member 21x-1 having the side wall portion 21x-1 as described above to the storage section 10, it becomes easier to maintain not only the shape of the connection portion 10z but also the shape of the entire side wall 10x. In addition, it is possible to ensure the strength of not only the connection portion 10z but also the strength of the entire side wall 10x. Furthermore, it is possible to maintain the overall shape of the side wall 10x in a well-balanced manner.

It is not necessary that all of the side wall portions 21x-1 are welded to the base 10x-1 of the side wall 10x and connected to the first resin member 20 as in the first modified example. It is sufficient that at least a portion of the second resin member 21x-1 welded to the storage section 10 is welded to the base 10x-1 of the side wall 10x and connected to the first resin member 20. In addition, the side wall portion 21x-1 does not have to be welded to approximately the center of the inner surface of the four wall portions described above, but only needs to be welded to any area of that surface.

When manufacturing the first modified example, the first and second resin members 20 and 21-1 may be placed as shown in FIG. 6 during the placement process. Specifically, during the placement process, the first resin member 20 is placed on the first desired region so that a plurality of first separated portions 20z that are separated from the first desired region are formed in the first resin member 20. Similarly, the second resin member 21-1 is placed on the second desired region 1x-2 so that a plurality of second separated portions 21z that are separated from the second desired region 1x-2 are formed in the second resin member 21-1. In this case, each of the first and second resin members 20 and 21-1 has a bellows shape in a side view at the end of the placement process.

By placing the first and second resin members 20 and 21-1 in this manner during the placement process, the first and second separated portions 20z and 21z become extension margins when the sheet 1x is later stretched along the contour of the lower mold 52x. As a result, when a portion of the sheet 1x is shaped into the shape of the side wall 10x and the top wall 10y by the lower mold 52x, the first and second resin members 20 and 21-1 each come into close contact with a portion of the sheet 1x, and these resin members can be welded to the desired locations without gaps. Note that in the example of the placement process in FIG. 6, it is not necessary to form the first separated portion 20z in the first resin member 20, and it is sufficient to form at least one or more second separated portions 21z in the second resin member 21-1.

<Second Modification of Door Hole Seal>
Next, a door hole seal in which a first resin member 20-1 is welded to the sheet 1x and the storage section 10 as shown in Fig. 7 is assumed as a second modified example of the door hole seal 1 (hereinafter, abbreviated as "second modified example"). In the second modified example, as shown in Fig. 7, a portion 20y on the sheet 1x side of the first resin member 20-1 (hereinafter, "seat side portion 20y") is welded to the first surface 1x-1 of the sheet 1x. The sheet side portion 20y has the same shape and size as the first resin member 20 according to this embodiment, except that four storage section side portions 20x (portions on the storage section side) are formed in a part of the end portion on the side wall 10x side.

The storage section side portion 20x is a portion of the first resin member 20-1 that is disposed closer to the storage section 10 than the sheet side portion 20y, and more specifically, is welded to the third surface 10x-2 of the side wall 10x. The third surface 10x-2 is a surface that connects to the first surface 1x-1 of the sheet 1x, as shown by reference numeral 602 in FIG. 7, and in the second modified example, is disposed closer to the base 10x-1 of the side wall 10x than the side wall side region.

In the second modified example, as described above, the first resin member 20-1 has four storage section side portions 20x, and one storage section side portion 20x is welded to each of the four wall portions constituting the side wall 10x. The third surface 10x-2 is divided into four regions (hereinafter, "third surface side regions"), one for each of the wall portions described above. In the second modified example, the storage section side portion 20x is welded to approximately the center of the third surface side region, and the end of the storage section side portion 20x on the base 10x-1 side is connected to the end of the seat side portion 20y on the side wall 10x side.

By welding the first resin member 20-1 having the storage section side portion 20x as described above to the sheet 1x, it becomes easier to maintain not only the shape of the connection portion 10z but also the shape of the entire side wall 10x. In addition, it is possible to ensure the strength of not only the connection portion 10z but also the strength of the entire side wall 10x. Furthermore, it is possible to maintain the overall shape of the side wall 10x in a well-balanced manner.

The shape, size, number, and arrangement of the storage section side portions 20x are not limited to the example in FIG. 7, as with the side wall side portions 21x according to this embodiment. In other words, it is sufficient that the first resin member 20-1 has the storage section side portion 20x in at least a portion of the end portion of the sheet side portion 20y on the side wall 10x side.

Although not shown, the door hole seal 1 according to this embodiment may include both a configuration in which the storage section side portion 20x is welded to the third surface 10x-2, and a configuration in which the side wall side portion 21x-1 is welded up to the base 10x-1 of the side wall 10x and connected to the first resin member 20. For example, of the four wall portions constituting the side wall 10x, the storage section side portion 20x may be welded to the third surface 10x-2 of two opposing wall portions, and the side wall side portion 21x-1 may be welded up to the base 10x-1 of the other two opposing wall portions.

<Modification of the manufacturing method of the door hole seal>
In the manufacturing of the door hole seal 1 according to the present embodiment, for example, a method as shown in Fig. 9 may be adopted in the welding process. When the method shown in Fig. 9 is adopted, the first resin member 20 and the second resin member 21 are integrally molded in advance as shown in Fig. 8. Specifically, an original member having the same outer shape and size as the first resin member 20 is cut out from a single sheet-like resin member (not shown; made of the same material and thickness as the first and second resin members 20 and 21). Then, the inner part of the cut-out original member is hollowed out into a predetermined shape to complete the integrally molded first and second resin members 21.

The integrally molded first and second resin members 21 are in a state where the end of the first resin member 20 on the side wall 10x side and the end of the second resin member 21 on the base 10x-1 side of the storage section side portion 20x are connected. Therefore, perforations 23 are formed at the boundary between the end on the side wall 10x side and the end on the base 10x-1 side. The perforations 23 are composed of multiple fine slits. Note that the method of integrally molding the first and second resin members 21 is not limited to the above example.

In the placement process, as shown by reference numeral 901 in FIG. 9, the first resin member 20 can be placed in the first desired area of the sheet 1x, and the second resin member 21 can be placed in the second desired area 1x-2 of the sheet 1x, approximately simultaneously. This eliminates the need to individually position and place the first and second resin members 20 and 21, and facilitates the manufacturing process of the door hole seal 1.

In the manufacturing process, the first and second resin members 20 and 21 are pressed against each other by the tips of the first to third heating members 51x to 51z, and the first resin member 20 and the second resin member 21 are separated at the perforation 23. Then, when the formation of the side wall 10x and the top wall 10y is complete, as shown by reference numeral 902 in FIG. 9, the first resin member 20 is disposed on the peripheral region of the base 10x-1 of the side wall 10x on the first surface 1x-1. The second resin member 21 is disposed on the second surface 10z-1 of the connection portion 10z-1.

In this way, by forming perforations 23 in the integrally molded first and second resin members 20 and 21, the manufacturing process of the door hole seal 1 can be simplified while these resin members can be positioned and welded at the desired positions on the sheet 1x and the storage section 10.

9, in order to facilitate positioning of the first resin member 20 on the sheet 1x and to facilitate rising near the base of the side wall 10x, a support base 52y is provided surrounding the periphery of the lower die 52x. In addition, in the process of pressing the first and second resin members 20 and 21 with the respective tips of the first to third heating members 51x to 51z, it is preferable to start the welding process at least immediately before the end of the manufacturing process in order to prevent these resin members from being welded to unintended locations.

[Additional Notes]
The present invention is not limited to the above-described embodiment and modifications, and various modifications are possible within the scope of the claims. Embodiments obtained by appropriately combining the technical means disclosed in the different embodiments and modifications are also included in the technical scope of the present invention.

1 Door hole seal 1x Sheet 1x-1 First surface 1x-2 Second desired area (fourth surface)
10 Storage section 10x Side wall 10x-1 Base 10x-2 Third surface 10y Top wall 10z Connection section 10z-1 Second surface 20 First resin member 20x Storage section side portion (portion on the storage section side)
21, 21-1: second resin member; 21x, 21x-1: side wall portion; 21z: second spaced portion (spaced portion)
100 Front door (vehicle door)
101 Door inner panel 101x Door hole 102x Side 102y Tip

Claims (1)

It is attached to the inner door panel of the vehicle door,
A sheet is provided to cover the door inner panel from the inside of the vehicle,
a part of the seat is configured as a storage section for storing a protrusion protruding toward the vehicle interior through a door hole formed in the door inner panel,
The storage portion has a side wall extending from a first surface of the seat on the vehicle interior side toward the vehicle interior side and surrounding a side surface of the protrusion, and a top wall covering a tip end of the protrusion from the vehicle interior side,
creating the storage section by deforming a portion of the sheet to form the side walls and the top wall;
a bonding step of bonding a second resin member to a second surface of a connection portion between the side wall and the top wall on an interior side of the vehicle;
a placing step of placing the second resin member on a fourth surface of the portion of the seat facing the vehicle interior side and corresponding to the second surface,
In the placing step, the second resin member is placed on the fourth surface so that a separated portion is formed in the second resin member that is separated from the fourth surface.

Images