CN101024478B - 车辆用内装物以及其制造方法 - Google Patents

车辆用内装物以及其制造方法 Download PDF

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CN101024478B
CN101024478B CN2007100788433A CN200710078843A CN101024478B CN 101024478 B CN101024478 B CN 101024478B CN 2007100788433 A CN2007100788433 A CN 2007100788433A CN 200710078843 A CN200710078843 A CN 200710078843A CN 101024478 B CN101024478 B CN 101024478B
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青山光晴
多田正男
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Toyota Boshoku Corp
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Abstract

本发明是一种在基体材料上接合罩部件的车辆用内装物的制造方法，具备：将通过缝制而缝合了多个表皮件的表皮材料与上述基体材料的表面形状一致地成形的工序；在与上述基体材料的表面形状一致地成形了上述表皮材料之后，在上述表皮材料的背面上粘贴软质材料形成上述罩部件的工序；以及将上述罩部件接合在上述基体材料上的工序。

Description

车辆用内装物以及其制造方法
技术领域
本发明涉及车辆用内装物以及其制造方法。
背景技术
作为涉及车辆用内装物的现有技术，具有在树脂制基体材料的表面上覆盖缝合了多个表皮材料的罩的车辆用内装物(例如，参照作为日本公开专利公报的特开2002-79852的第3-4页、图2)。该现有技术中的罩，如下：在使一对表皮材料的表面右侧彼此重合之后，以对齐该对表皮材料的端部的状态相互缝合，其后，将该对表皮材料相互向相反方向打开。因此，从上述罩的缝合部处于规定宽度的窝边部在上述盖的背面方向突出的状态。由此，在基体材料的表面上被覆了罩时，存在窝边部从基体材料的表面突出导致车辆用内装物的表面凸出这一不良情况。于是，在该现有技术的车辆用内装物中，在基体材料的表面形成用于存放上述窝边的凹部。由此，防止车辆用内装物的表面因罩的窝边而凸出。如此地，该现有技术中的车辆用内装物具有如下的优点：罩的窝边突出但表面不会凸出，表面平滑且外观美观。
但是，在该现有技术中的车辆用内装物中，由于必须在基体材料的表面形成用于存放罩的窝边的凹部，所以导致用于成形基体材料的成形模的形状复杂。为此，基体材料的制造成本变高，另外，根据情况，有时在基体材料成形时很难起模。
另一方面，作为上述现有技术以外的车辆用内装物，如下：在表皮材料的背面避开缝合部的窝边而接合垫子材料从而形成罩，将该罩粘贴在基体材料的表面上。在将该罩接合在基体材料上时，通过垫子材料的存在，从而窝边不会从基体材料的表面突出。由此，在基体材料的表面不必形成用于容纳窝边部的凹部也能够防止车辆用内装物表面的凸出，同时，能够将车辆用内装物的表面做得平坦，且使外观美观。
但是，在该现有技术中的车辆用内装物中，在表皮材料的背面接合了垫子材料之后，必须与基体材料的表面形状一致，且同时将表皮材料和垫子材料成形为规定形状。为此，因表皮材料和垫子材料的伸长量的差等，在垫子材料上发生应力，该应力成为原因，从而存在在表皮材料上发生褶皱等之类的问题。在表皮材料发生了褶皱时，导致车辆用内装物的表面外观明显降低。
发明内容
本发明基于上述情况而完成的，目的在于提供外观美观的车辆用内装物以及其制造方法。
本发明是一种在基体材料上接合罩部件的车辆用内装物的制造方法，具备：将通过缝制而缝合了多个表皮件的表皮材料与上述基体材料的表面形状一致地成形的工序；在与上述基体材料的表面形状一致地成形了上述表皮材料之后，在上述表皮材料的背面上粘贴软质材料形成上述罩部件的工序；以及将上述罩部件接合在上述基体材料上的工序。由此，由于与基体材料的表面形成一致地成形了表皮材料之后在其表皮材料的背面上粘贴软质材料，所以不会发生因表皮材料和软质材料的伸长量的差等引起的在软质材料上发生应力，从而在表皮材料上不会发生褶皱等。其结果，能够得到外观美观的车辆用内装物。
在本发明中，优选在与上述基体材料的表面形状一致地成形上述表皮材料的工序中，在模面上开口有通气孔的成形模上放置了上述表皮材料之后，通过上述通气孔，依次将上述表皮材料的一部分吸引向上述模面，从而成形上述表皮材料。这是因为，同时吸引了表皮材料整体的情况，通过施加在表皮材料整体上的吸引力，表皮材料被拉至通气孔的内侧。并且，在表皮材料被拉至通气孔的内侧的情况中，由于打开在翻转模上的表皮材料的面积缩小，所以导致软质材料对表皮材料背面的粘贴作业变难。
在本发明中，优选上述表皮材料以如下的方式形成：使一对的上述表皮件中的表面右侧彼此重合并以其端部对齐的状态相互缝合之后，将一对上述表皮件相互向相反方向打开；在一对上述表皮件端部的重合部上粘贴带部件。由此，增大表皮件端部的重合部的刚性成为可能，能够防止表皮件的缝合部扭弯或者表皮件的缝合部会打开的情况。
附图说明
图1是实施方式的车辆用内装物的剖视图。
图2是用在图1所示的车辆用内装物的制造中所使用的成形机的外观图。
图3是表示切下表皮材料的表皮件工序的剖视图。
图4是表示在构成表皮材料的一对表皮件上实施缝合工序的剖视图。
图5是表示使一对表皮件缝合之后将一对表皮件相互向相反方向打开状态的剖视图。
图6是表示在表皮件的重合部粘贴了热熔带状态的剖视图。
图7是表示在翻转模上放置了表皮材料状态的剖视图。
图8是表示成形表皮材料工序的剖视图。
图9是表示在表皮材料上涂敷粘结剂工序的剖视图。
图10是表示在表皮材料上配置垫子材料工序的剖视图。
图11是表示在表皮材料的背面上粘贴垫子材料工序的剖视图。图中：
1-车辆用内装物；2-基体材料；3-罩部件；4-垫子材料；5-表皮材料；6-成形机；51、52-表皮件；56-热熔带；63-翻转模；63a-模面；63b-通气孔；63c-小件存放箱(glove box)上部；63d-中心组(center cluster)上部；63e-仪表罩(meter hood)部
具体实施方式
根据图1至图11说明本发明的实施方式。
如图1所示，本实施方式的车辆用内装物1由基体材料2以及与基体材料2的表面接合的罩部件3构成。
基体材料2是车辆的仪表板(instrument panel)。基体材料2是由聚丙稀等的树脂一体成形的。基体材料2安装在车辆前席(驾驶席)的前方。
罩部件3由表皮材料5以及粘贴在表皮材料5背面的垫子材料4构成。
表皮材料5是将多个表皮件51、52通过缝制进而缝合而构成的。多个表皮件51、52用牛皮等的兽皮(皮革)构成。多个表皮件51、52通过缝线53而缝合。
表皮材料5与基体材料2的表面形状一致地立体成形。在表皮材料5的外表面上形成多个缝合线54。另外，在表皮材料5的缝合线54的侧方以从两侧夹持该缝合线54的方式施加一对装饰用缝合线55(双层缝合线)。
在表皮材料5的背面上粘贴有具备适度的柔软性的垫子材料4。通过该垫子材料4与基体材料2接合，进而车辆用内装物1构成适当的触感。垫子材料4并不限于此，还能够使用在相对的一对纺织品之间介入装有树脂制的环形材料。垫子材料4具有适当弹性。垫子材料4对应于本发明的“软质材料”。
在表皮件51、52端部的重合部粘贴有热熔带56。通过粘贴该热熔带56，可加强表皮件51端部的重合部。另外，表皮件51、52端部的重合部作为用于相互缝合表皮件51、52的窝边部。热熔带56对应于本发明的“带部件”。
如图1所示，垫子材料4避开表皮件51、52端部的重合部而粘贴在表皮材料5的背面上。由此，处于表皮材料5距基体材料2的表面远离相当于垫子材料4厚度的量的状态。其结果，表皮件51、52端部的重合部不会从基体材料2的表面突出，所以在表皮材料5的表面不会发生凸起。
接下来，参照图2以及图7的同时说明用于成形表皮材料5的成形机6。
成形机6具备：附带滚动轮的可移动的支承台61；设置在支承台61上的真空箱62；以及设置在真空箱62上的翻转模63。翻转模63是用于成形表皮材料5的成形模。
真空箱62由木材等形成为箱形(参照图7)。在真空箱62的内部形成有空腔62a。在真空箱62的侧面形成有与空腔62a连通的多个真空吸附口62b。在真空吸附口62b上通过未图示的切换阀连接有真空泵。由此，会使空腔62a内部成为真空状态。另外，在真空箱62的侧面上设有多个温度调节用的出入口62c(参照图2)。连接到该出入口62c的管路通过真空箱62的内部，再与翻转模63内部连通，该管路被用于成形时的翻转模63的温度调节。
翻转模63由环氧树脂形成。翻转模63是用于与基体材料2的表面形状一致地成形表皮材料5的成形模。翻转模63具有使被覆在基体材料2上状态中的表皮材料5的外表面形状翻转的形状。
如图7所示，在翻转模63上形成有多个细小的通气孔63b。通气孔63b使翻转模63在垂直方向上贯通。作为翻转模63的上面的模面63a和位于翻转模63下方的真空箱62的空腔62a通过通气孔63b而连通。由此，在真空箱62的空腔62a内成为了真空状态时，放置在翻转模63上的表皮材料5会被吸引向模面63a。
另外，如图2所示，翻转模63被划分为小件存放箱上部63c、中心组上部63d以及仪表罩部63e这三个部分。另一方面，真空箱62的空腔62a与这些部分相对应也被划分为三个室。在真空吸附口62b上通过上述切换阀连接有真空泵。通过该真空泵以及切换阀，可使真空箱62内的三个室分别成为真空状态。
再有，在翻转模63的模面63a上形成有在表皮材料5的成形时所使用的未图示的定位线。
其次，基于图3至图11说明有关本实施方式的车辆用内装物1的制造方法。
最初，切下牛皮等的皮革的周围，作成规定形状的多个表皮件51、52(参照图3)。
其次，使一对表皮件51、52的表面右侧彼此相互重合之后，以对齐它们端部的状态缝合(in-stitch)。由此，缝合一对表皮件51、52彼此。与此同时，使用划线机构7(例如，划线针)，在表皮材料5的背面划上作为粘贴垫子材料4时的定位线的划线(参照图4)。
缝合后的一对表皮件51、52相互向相反方向打开(参照图5)。其后，在形成于一对表皮件51、52背面(图5中的下面)的重合部上粘贴热熔带56。该重合部为窝边部。热熔带56配置在一对表皮件51、52的规定部位上之后，通过加热发挥粘性。
通过以从两侧夹持缝合线54的方式在表皮件51、52的各自的表面上施加一对装饰用缝合线(双层缝合线)，从而完成表皮材料(参照图6)。
通过缝合多个表皮件51、52所完成的表皮材料5放置在翻转模65的上面。此时，表皮材料5以覆盖图2所示的模面63a整体且其表面(图6中的上面)与模面63a抵接的方式放置在翻转模65的上面。
在将表皮材料5放置在翻转模65上时，使缝合线54与形成于模面63a上的定位线一致。由此，能够将表皮材料5准确定位在翻转模65上。
在翻转模65上放置了表皮材料5之后，通过操作真空泵以及切换阀，而使在真空箱62内被划分的三个室内依次成为真空状态。在真空箱62内被划分的三个室中，首先使小件存放箱上部63c下方的室内成为真空状态。其次，使中心组上部63d下方的室内成为真空状态。最后，使仪表罩部63e下方的室内成为真空状态。这样一来，能够依次将表皮材料5的各部分吸引向模面63a。
首先，通过在小件存放箱上部63c的模面63a上吸引表皮材料5，从而能够仅将表皮材料5的一部分成形为规定的立体形状(参照图8)。
其次，通过在中心组上部63d下方的模面63a上吸引表皮材料5，从而能够仅将表皮材料5的一部分成形为规定的立体形状。
最后，通过在仪表罩部63e的模面63a上吸引表皮材料5，从而能够仅将表皮材料5的一部分成形为规定的立体形状。
在成形了表皮材料5之后，在仍然维持真空箱62内部为真空状态下，将预先涂敷有粘结剂的垫子材料4粘贴在表皮材料5的背面上。或者，通过向表皮材料5的背面喷射粘结剂进行涂敷之后，将垫子材料4粘贴在表皮材料5的背面上。这样一来，能够将垫子材料4粘贴在表皮材料5的背面上(参照图9、图10)。此时，通过使垫子材料4外周的轮廓与形成于表皮材料5背面的划线一致，从而能够便于进行垫子材料4对表皮材料5的定位。
通过由翻转模63成形表皮材料5之后，在表皮材料5背面上粘贴垫子材料4，从而完成罩部件3。该罩部件3通过专用的接合装置等接合在基体材料2的表面上。
如此地，根据本实施方式，能够依次将表皮材料5的一部分吸引向模面63a。由此，能够在每部分中形成表皮材料5，同时，能够在每部分中将垫子材料4粘贴在表皮材料5的背面上。
根据本实施方式，与基体材料2的表面形状一致地成形了表皮材料5之后，在表皮材料5的背面上粘贴垫子材料4。因此，不会发生因表皮材料5和垫子材料4的伸长量的差等引起的在垫子材料4上产生应力的情况，且在表皮材料5的表面也不会发生褶皱，从而能够制造外观美观的车辆用内装物1。
表皮材料5放置在翻转模63的上面。依次仅将放置在翻转模63上的表皮材料5的其中一部分吸引向模面63a。因此，表皮材料5不会被拉到通气孔63b的内侧，放置在翻转模63上的表皮材料5的面积也不会缩小，垫子材料4对表皮材料5的粘贴作业也不会困难。
与此相对，同时吸引了表皮材料5整体的情况，通过施加在表皮材料5整体上的吸引力，表皮材料5被拉至通气孔63b的内侧。由此，由于放置在翻转模63上的表皮材料5的面积缩小，所以导致垫子材料4对表皮材料5背面的粘贴作业变难。
表皮材料5以如下方式形成：使多个表皮件中的一对相邻的表皮件的表面彼此重合并以其端部对齐的状态相互缝合之后，将一对表皮件51、52相互向相反方向打开。在一对表皮件51、52端部的重合部粘贴热熔带56。这样一来，增大一对表皮件51、52端部的重合部的刚性成为可能。另外，能够防止一对表皮件51、52的缝合部扭弯。此外，能够防止一对表皮件51、52的缝合部裂开。
(其它实施方式)
本发明不限于根据上述陈述以及附图说明的实施方式，例如，如下的实施方式涵盖在本发明的技术范围内，再有，在下述以外的在不脱离权利要求的范围内能够实施各种变更。
(1)表皮材料不限于牛皮，例如还可以是合成皮革。
(2)作为粘贴在表皮材料背面上的软质材料还可以使用发泡聚氨酯或海绵等的垫子材料。
(3)本发明还能够适用于仪表板以外的车辆用内装物中。例如，本发明也能够适用于车辆用的门装饰。
(4)表皮材料的各部位用什么样的顺序成形都可以。

Claims (7)

1.一种车辆用内装物的制造方法，该车辆用内装物在基体材料上接合有罩部件，其特征在于，
具备：通过缝制而缝合了多个表皮件形成表皮材料的工序；
在上述多个表皮件被缝合后，通过配置在真空箱上的成形模，与上述基体材料的表面形状一致地成形上述表皮材料的工序；
在与上述基体材料的表面形状一致地成形了上述表皮材料之后，在上述表皮材料的背面上避开上述多个表皮件的端部的重合部粘贴软质材料形成上述罩部件的工序；以及
将上述罩部件接合在上述基体材料上的工序；
在与上述基体材料的表面形状一致地成形上述表皮材料的工序中，在保持上述真空箱为真空状态下，仅将表皮材料的一部分朝向上述成形模的模面吸引并成形为规定的立体形状，并且，在形成上述罩部件的工序中，在仍然维持真空箱内部为真空状态下，将上述软质材料粘贴在上述表皮材料的上述一部分的背面上，由此，在构成该表皮材料的各部分中依次成形上述表皮材料的同时，在上述各部分中依次将软质材料粘贴在上述表皮材料的背面上。
2.根据权利要求1所述的车辆用内装物的制造方法，其特征在于，
在与上述基体材料的表面形状一致地成形上述表皮材料的工序中，在上述模面上开有通气孔的上述成形模上放置了上述表皮材料之后，通过上述通气孔，依次将上述表皮材料的一部分向上述模面吸引，从而成形上述表皮材料。
3.根据权利要求1所述的车辆用内装物的制造方法，其特征在于，
上述表皮材料以如下的方式形成：使一对上述表皮件的表面右侧彼此重合并以其端部对齐的状态相互缝合之后，将一对上述表皮件相互向相反方向打开；
在一对上述表皮件端部的重合部上粘贴带部件，
处于上述表皮材料距上述基体材料的表面远离相当于上述软质材料厚度的量的状态。
4.根据权利要求2所述的车辆用内装物的制造方法，其特征在于，
上述表皮材料以如下的方式形成：使一对上述表皮件的表面右侧彼此重合并以其端部对齐的状态相互缝合之后，将一对上述表皮件相互向相反方向打开；
在一对上述表皮件端部的重合部上粘贴带部件，
处于上述表皮材料距上述基体材料的表面远离相当于上述软质材料厚度的量的状态。
5.根据权利要求2所述的车辆用内装物的制造方法，其特征在于，
上述表皮材料以如下的方式形成：使一对上述表皮件的表面右侧彼此重合并以其端部对齐的状态相互缝合之后，将一对上述表皮件相互向相反方向打开，
在一对上述表皮件端部的重合部上粘贴带部件。
6.根据权利要求1所述的车辆用内装物的制造方法，其特征在于，
上述表皮材料以如下的方式形成：使一对上述表皮件的表面右侧彼此重合并以其端部对齐的状态相互缝合之后，将一对上述表皮件相互向相反方向打开，
在一对上述表皮件端部的重合部上粘贴带部件。
7.一种车辆用内装物，其特征在于，通过如权利要求1所述的车辆用内装物的制造方法而制造。
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CN101024478A (zh) 2007-08-29
EP1820625B1 (en) 2009-07-22
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JP4766322B2 (ja) 2011-09-07
EP1820625A1 (en) 2007-08-22

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