JP7844280B2 - Vehicle-mounted structures - Google Patents

Description

This invention relates to a vehicle-mounted structure that is laid on a vehicle body panel.

Floor carpets are laid on vehicle body panels, such as floor panels, to smooth out unevenness in the body panels within the passenger compartment and to reduce noise. The floor carpets consist of cushioning material for raising the surface and reducing noise, as well as interior materials such as carpet.

For example, Patent Document 1 describes a floor carpet in which a cushioning material made of nonwoven fabric and an interior material for a vehicle are integrally constructed.

Japanese Patent Application Publication No. 07-223478

The floor carpet described in Patent Document 1 above is constructed by bonding together molded fiber products or urethane-based molded products that are molded to correspond to the unevenness of the vehicle body panel (floor panel) and the shape of the interior surface, and is then transported and laid on the floor panel. Therefore, because the floor carpet described in Patent Document 1 tends to increase in weight and size, laying it on the floor panel may be difficult due to constraints such as the upper limit of weight that workers can carry and the size of the opening in the vehicle body when loading it into the vehicle.

Furthermore, this type of bonded, integrated assembly presents challenges in terms of ease of separation and dismantling during vehicle dismantling or component breakdown, making recycling difficult.

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.

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.

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 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,
The upper layer and the lattice-shaped resin molded body, and the lattice-shaped resin molded body and the lower layer are not bonded together .

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.

Figure 1 is a perspective view showing one example of the configuration of a vehicle laying structure according to the first embodiment. Figure 2 is a side cross-sectional view of the vehicle-mounted structure shown in Figure 1. Figure 3 is a perspective view showing one example of the configuration of the resin molded body shown in Figure 2. 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 is a side cross-sectional view showing one example of the configuration of a vehicle-mounted structure according to the second embodiment.

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 the 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 the line A-A 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.

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 area of a vehicle, as shown in Figure 1. Figure 1 shows an example of the overall shape of the vehicle interior material 2, described later, provided by the vehicle installation structure of the present invention. The location where the vehicle installation structure can be installed is not limited to the passenger compartment floor area of the vehicle, but may also be the passenger compartment side wall, passenger compartment ceiling, deck floor, dashboard, engine hood, fender, etc.

As shown in Figure 2, the vehicle installation structure of the first embodiment comprises a vehicle interior material 2 and a raising member 3 provided in at least a portion of the space between the vehicle body panel 1 and the vehicle interior material 2. The vehicle interior material 2 and the raising member 3 are sized and shaped to correspond to the unevenness of the vehicle body panel 1 and the shape of the interior surface at the installation site of the vehicle installation structure. The vehicle interior material 2 is, for example, a carpet made of a fibrous molded product. A well-known vehicle floor mat or the like may be further installed on top of the vehicle interior material 2.

The raising member 3 comprises a buffer layer 4 consisting of an upper layer 41 and a lower layer 42, and a resin molded body 5 for raising the height and reducing noise inside the vehicle. The resin molded body 5 is provided in at least a portion of the space between the upper layer 41 and the lower layer 42. For example, the buffer layer 4 can be made of felt made of fibers. Since the vehicle interior material 2 can also function as a buffer layer 4 depending on its material and thickness, 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 is in contact with the vehicle body panel 1, vibration noise may be generated between 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 5 be covered by the lower layer 42 of the buffer layer 4.

As shown in Figure 3, the resin molded body 5 has a configuration comprising multiple vertical walls 51 arranged in a grid pattern parallel to the thickness direction of the raising member 3, and multiple horizontal walls 52 arranged in a grid pattern in directions perpendicular or intersecting the multiple vertical walls 51. By arranging the multiple vertical walls 51 parallel to the thickness direction of the raising member 3 in this way, the resin molded body 5 can efficiently receive loads from inside the vehicle, thereby improving the load-bearing capacity of the resin molded body 5. As shown in Figure 3, since the resin molded body 5 is a structure combining multiple hollow materials composed of multiple vertical walls 51 and multiple horizontal walls 52, it can be manufactured to be relatively lightweight.

If the outer surface of the resin molded body 5 is flat, stepping on the vehicle interior material 2 with one's foot can cause the resin molded body 5 to shift, worsening the feel underfoot and potentially preventing the desired sound insulation performance from being achieved. In this embodiment, since the resin molded body 5 is provided with multiple vertical walls 51 arranged in a grid pattern, the buffer layer 4 (both the upper layer 41 and the lower layer 42) fits into the grid of the vertical walls 51, preventing the resin molded body 5 from shifting when the vehicle interior material 2 is stepped on. Furthermore, this eliminates the need to fix the buffer layer 4 and the resin molded body 5 using adhesive, thus reducing the processing cost of the riser member 3.

The resin molded body 5 shown in Figure 3 illustrates an example configuration in which multiple vertical walls 51 form multiple rectangles when viewed from above, and these rectangles are arranged without gaps. The shapes formed by the vertical walls 51 are not limited to rectangles; any polygon such as triangles or hexagons may be used. A structure in which multiple vertical walls 51 form multiple hexagons when viewed from above, and these rectangles are arranged without gaps (a so-called honeycomb structure), can increase the load-bearing capacity of the resin molded body 5 more than a structure in which multiple rectangles are formed by vertical walls 51 of the same size and thickness. In addition, because hexagons have better resin fluidity than rectangles, material defects are less likely to occur during the molding of the resin molded body 5. On the other hand, rectangles are advantageous in terms of cost because the processing cost of the mold is lower than that of hexagons, etc. Note that the area of each polygon formed by the vertical walls 51 and the length of one side may be changed as appropriate 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. If the length of one side of the polygon exceeds 100 mm, the heel will get caught in the grid (polygon) of the resin molded body 5 beneath the vehicle interior material 2 when stepped on, resulting in poor comfort. On the other hand, if the length of one side of the polygon is 5 mm or less, the amount of resin constituting the resin molded body 5 increases, thus increasing the weight of the resin molded body 5. Therefore, setting the length of one side of the polygon to 10 to 50 mm provides a resin molded body 5 with a good balance between comfort and weight. If the vehicle installation structure is located outside the vehicle's passenger compartment floor, it will not be stepped on, so the length of one side of the polygon may exceed 100 mm.

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. Furthermore, as shown in Figure 2, the resin molded body 5 may have parts that consist only of horizontal walls 52. Alternatively, the resin molded body 5 may have 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 further improved. The resin molded body 5 can be manufactured using a well-known resin molding method with plastics or resins such as polypropylene (PP), olefin elastomer (TPO), or polyvinyl chloride resin (PVC).

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 cabin. The openings 53 may be provided in all the side walls 52 within the multiple polygons formed by the vertical walls 51, or in some of the side walls 52 within the multiple polygons formed by the vertical walls 51. Furthermore, 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 quadrilateral, 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.

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 and sound absorption performance can be obtained. When installing a vehicle-mounted structure in areas where sound insulation and sound absorption performance are not required, the side walls 52 may be omitted to reduce the weight of the resin molded body 5.

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. 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 a good treading feel.

The resin molded body 5 may be divided into multiple sections 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 sections 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, since the vehicle interior material 2 shown in Figure 1 has a convex portion 21 in the center in the left-right direction, the buffer layer 4 and the resin molded body 5 may be divided into two sections 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 sections 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; they may also be divided into three or more parts and laid on the vehicle body panel 1.

In this configuration, the installation procedure for 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 installation procedure for the vehicle-mounted structure of the present invention.

When laying the vehicle-mounted 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 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.

Next, as shown in Figure 4(b), the resin molded body 5 is placed on the lower layer 42 of the buffer layer 4, sandwiching the lower layer 42 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 conform to the irregularities and shape of the vehicle body panel 1.

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.

Finally, as shown in Figure 4(d), the vehicle interior material 2 is mounted 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.

According to the vehicle laying structure of the first embodiment, the upper layer 41 and lower layer 42 of the buffer layer 4 are either 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 has a certain plate thickness and basis weight, it can be molded using relatively inexpensive existing press molding equipment, thus suppressing cost increases.

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 other means. 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.

Furthermore, the upper layer 41 and lower layer 42 of the buffer layer 4 are made of soft, 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. Also, the vehicle laying structure of this embodiment, compared to conventional molded products (fiber-based or urethane-based), uses a lightweight resin molded body 5 to achieve the required strength in the longitudinal (thickness) direction and the feel underfoot, thus contributing to the weight reduction of the vehicle.

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 one example of the configuration of a vehicle-mounted structure according to the second embodiment.

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 to 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, and therefore their explanation is omitted.

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, lightweight fibers such as felt, it can be easily laid on the vehicle body panel 1 even in large sizes, and the rails 6 can then be attached to the vehicle body panel 1 from above. In the second embodiment, the buffer layer 4 (lower layer 42) with small holes (small opening ratio) for attaching the rails 6 to the vehicle body panel 1 can be placed between the rails 6 and the vehicle body panel 1. Therefore, noise and vibration leaking from outside the vehicle into the vehicle interior through the vehicle body panel 1 are reduced by the buffer layer 4. This improves the vehicle's NV (Noise and Vibration) performance.

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 covering the upper surface of the rail 6 and the resin molded body 5 may be integrated. In a configuration where 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 integrated by connecting it at the lower surface of the rail 6.

According to the second embodiment of the vehicle-mounted structure, in addition to the same effects as the vehicle-mounted structure of the first embodiment, members 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.

1. Vehicle body panel 2. Vehicle interior material 3. Raising member 4. Cushioning layer 5. Resin molded body 6. Rail 21. Convex portion 41. Upper layer 42. Lower layer 51. Vertical wall 52. Horizontal wall 53. Opening 54. Engaging portion 61. Rail cover

Claims (5)

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 . 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. 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. The vehicle laying structure according to claim 3 , wherein at least a portion of the grid has a horizontal wall. The vehicle laying structure according to claim 4 , wherein an opening is provided in at least a portion of the side wall.