CN110316102B - 具有对准特征部的装饰性覆盖材料 - Google Patents

具有对准特征部的装饰性覆盖材料 Download PDF

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CN110316102B
CN110316102B CN201910176123.3A CN201910176123A CN110316102B CN 110316102 B CN110316102 B CN 110316102B CN 201910176123 A CN201910176123 A CN 201910176123A CN 110316102 B CN110316102 B CN 110316102B
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sheet
decorative layer
decorative
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CN110316102A (zh
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尼古拉斯·纳塔尔
布拉德·库斯基
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Faurecia Interior Systems Inc
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Faurecia Interior Systems Inc
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24033—Structurally defined web or sheet [e.g., overall dimension, etc.] including stitching and discrete fastener[s], coating or bond
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24777—Edge feature

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Abstract

用于车辆内部面板的装饰性覆盖物由在接缝处接合在一起的两个材料片制成。所述材料片具有沿各自边缘的匹配的对准特征部，以在接合操作期间帮助视觉对准。所述对准特征部沿装饰层的边缘间隔开，并且切口沿附接的背衬层的相应边缘形成，使得当从背侧观察时，每个对准特征部通过切口中的一个切口是可见的。切口比对准特征部大并且在两个层被层压在一起之前形成，在层压期间有效地增加了可允许的公差。这种构造特别地可与皮革一起使用，其通常经历切割‑缝合操作并且与背衬层一起使用。

Description

具有对准特征部的装饰性覆盖材料
技术领域
本公开内容总体上涉及用于车辆内部的材料，并且特别地涉及在安装之前缝合或拼接在一起的装饰性覆盖材料。
背景技术
装饰性覆盖物在车辆内部中用于为车辆乘员提供期望的美观性，并且通常应用在车辆的不太引人注意的结构组件或功能组件上，从而有效地从视野中隐藏这些组件，同时为乘员提供舒适的感觉。装饰性覆盖物由许多不同类型的材料制成，例如纺织织物、皮革、人造皮革、基于聚合物的膜或它们的组合，并且可以包括各种纹理、形状、颜色、图案和其它美学特性中的任一种。
皮革通常被认为是高价材料，部分是由于在车辆组件制造环境中与皮革一起使用时产生的额外成本。例如，虽然许多制造过程可以并且已经自动化，但是诸如将分开的材料片缝合在一起的制造操作继续由人类操作者执行，所述人类操作者在视觉上监测操作并且不断地进行手动调整的能力没有被任何类型的成本有效的自动化复制。
Wang等人的中国实用新型CN 203715975公开了用于在其中将两种材料层压在一起的层压过程中使人造皮革材料的边缘与离型纸的边缘对准的自动化方法。每种材料以卷筒形式提供，并且层压过程是连续的过程。该过程使用视觉系统来监测边缘对准并且从一侧至另一侧移动卷筒材料以在连续过程期间校正任何未对准。不存在关于层压材料的边缘与不同材料的边缘对准的同时在接合操作中形成接缝的公开内容。
发明内容
根据各种实施方案，用于制造车辆内部面板的装饰性覆盖物的材料片包括装饰层、背衬层、多个对准特征部和多个切口。装饰层具有装饰侧、相对的背侧和沿材料片的周边延伸的边缘。背衬层附接至装饰层的背侧，并且具有沿装饰层的边缘延伸的相应边缘。对准特征部沿装饰层的边缘以沿边图案的形式间隔开。多个切口沿背衬层的相应边缘形成。每个切口被定位成使得当从背侧观察材料片时，每个对准特征部通过切口中的一个切口是可见的。当在接缝处与另一不同的材料片接合时，材料片形成装饰性覆盖物的一部分，所述另一不同的材料片具有沿所述不同的材料片的边缘以匹配沿边图案的形式间隔开的对准特征部。
在一些实施方案中，沿装饰层的边缘的每个对准特征部是凹口。
在一些实施方案中，每个切口的形状不同于通过所述切口可见的每个对准特征部的形状。
在一些实施方案中，每个切口的宽度大于通过所述切口可见的每个对准特征部的宽度。
在一些实施方案中，每个切口的宽度是通过所述切口可见的每个对准特征部的宽度的至少两倍。
在一些实施方案中，每个切口的宽度是通过所述切口可见的每个对准特征部的宽度的至少三倍且不超过五倍。
在一些实施方案中，每个切口的深度等于通过所述切口可见的每个对准特征部的深度。
在一些实施方案中，每个切口的投影面积是通过所述切口可见的每个对准特征部的投影面积的至少两倍。
在一些实施方案中，每个切口的投影面积是通过所述切口可见的每个对准特征部的投影面积的至少五倍且不超过十倍。
在一些实施方案中，装饰层是皮革。
在一些实施方案中，背衬层附接至装饰层的背侧。
在一些实施方案中，对准特征部和切口沿材料片的周边的曲线部分布置。
在一些实施方案中，车辆内部面板包括由在接缝处与不同的材料片接合的材料片形成的装饰性覆盖物，并且每个材料片在接缝的相对侧上。
在一些实施方案中，制造用于车辆内部面板的装饰性覆盖物的方法包括以下步骤：将材料片缝合至不同的材料片，并且在缝合步骤期间将装饰层的对准特征部与所述不同的材料片的对准特征部对准。
在一些实施方案中，在缝合步骤之前将背衬层附接至装饰层的背侧，并且沿装饰层的边缘形成对准特征部，并且在背衬层附接至装饰层的背侧之前沿背衬层的相应边缘形成切口。
在前述段落、权利要求和/或以下描述和附图中阐述的各个方面、实施方案、实例、特征和替换方案可以独立地采用或以其任意组合的形式采用。例如，结合一个实施方案所公开的特征在不存在特征不相容的情况下适用于所有实施方案。
附图说明
下文将结合附图描述一个或多个实施方案，其中相同的标号表示相同的元件，并且其中：
图1是包括具有缝合接缝的装饰性覆盖物的车辆内部面板的一部分的横截面视图；
图2是包括装饰层和背衬层并且可以用于形成图1的装饰性覆盖物的材料片的分解图；
图3是图2的材料片的一部分的放大视图，示出装饰层中的对准特征部和背衬层中的切口；
图4示出图3的材料片以及具有对准特征部的匹配图案的第二材料片；
图5是在接合操作期间图4的两个材料片的横截面视图；以及
图6是由图5的接合操作产生并且被示出为图1的车辆内部面板的一部分的装饰性覆盖物。
具体实施方式
以下描述的是材料构造，其对增强用于在接缝处将分开的材料片接合在一起的对准特征部的效用是有用的。分开的片具有沿待接合的边缘的匹配对准特征部，以在接合操作期间帮助视觉对准。当材料是多层材料时，对准特征部可以在具有形成于重叠层中的切口的一个层中形成，因此对准特征部通过切口是可见的。这种材料构造相对于具有穿过多层材料的所有层形成的对准特征部的构造提供了益处，并且以下描述为用于车辆内部面板的装饰性覆盖物的一部分。所公开的构造和技术也可以用于其它产品，例如家具装潢品或衣服。
图1是示例性车辆内部面板10的一部分的横截面视图，其包括位于基板14上的装饰性覆盖物12。车辆内部面板的非限制性实例包括仪表板、门板、控制台盖、立柱盖、方向盘板或座椅板，仅举几例。装饰性覆盖物12具有装饰侧16，当安装在车辆中时，装饰侧16在视觉上面对车辆的乘客舱的内部。下面的基板14可以是提供面板10的整体形状和轮廓的结构组件和/或功能组件。在示例性仪表板中，基板14可以由厚度为2mm至4mm的填充的热塑性材料(例如玻璃填充的聚丙烯合金)形成。较小和/或较少的结构面板可以包括由未填充的热塑性塑料(例如TPO或ABS)模制的基板。在装饰性覆盖物12提供座椅表面的情况下，基板14可以是或可以包括泡沫垫。
装饰性覆盖物12由在缝合接缝20处接合在一起的两个单独提供的材料片18、18’形成。在图1的实例中，接缝20是具有位于设置在基板14中的凹陷中的材料片18、18’的边沿(margin)或自由边缘22的平缝，以使在接缝的可见侧处的任何外观凸起最小化。在其它非限制性实例中，省略基板凹陷并且在与基板14组装之前将自由边缘22修整为较短的，每一自由边缘在其相应的材料片的下方回折并且缝合至该相应的材料片以形成法式接缝，或者两个自由边缘在相同方向上在一个材料片下方折叠并且缝合以形成甲板接缝。虽然本文所示的示例性接缝通过缝合形成并且包括延伸穿过接合的材料片的缝合线，但是所公开的材料构造也可用于在其它类型的接合操作(诸如热密封、超声边缘焊接或粘合剂接合)中形成接缝期间的片对准。
示例性材料片18是多层材料，包括装饰层24和背衬层26。装饰层24具有装饰侧28和相对朝向的背侧30，并且装饰侧28提供组装的覆盖物12的装饰侧16的一部分。例如，背衬层26经由层压和/或粘合层而附接至装饰层24的背侧30。装饰层24和背衬层26中的每一个本身可以包括多个层。在特定的实例中，装饰层24是皮革或人造皮革。背衬层26可以是间隔织物或泡沫层，并且通常在装饰层24与基板14之间提供弹性缓冲作用，以在被车辆乘员触摸时提供更加豪华的感觉。装饰层24也可以是基于聚合物的膜层。所公开的配置可以特别适用于皮革装饰层，部分地是因为可商购获得的聚合物装饰层通常包括预层压的背衬层。
图2是示例性材料片18的分解图，并且图3是材料片的一部分的放大等距视图。材料片18示为具有面朝下的装饰侧28，并且具有外周边P，两个层24、26在外周边P内配合。装饰层24具有沿材料片18的周边P延伸的边缘32，并且沿装饰层的边缘以沿边图案的形式设置对准特征部34。沿边图案由在沿装饰层24的平面中的边缘32测量的独立的每一对相邻的对准特征部34之间的特定且有序的中心至中心间距(X1、X2…Xn)限定。背衬层26具有沿装饰层24的边缘32延伸的相应边缘36，并且切口38沿背衬层的边缘设置。切口38被定位成使得当从背侧观察材料片18时，每个对准特征部34通过切口中的一个切口是可见的，如图3所示。
在所示的实例中，每个对准特征部34为穿过装饰层24的厚度所形成的V形凹口的形式。切口38是U形的并且以与对准特征部34大体相同的沿边图案布置，使得单个对准特征部通过切口中的每个切口是可见的。还可能地，超过一个的对准特征部34通过单个切口38是可见的，例如其中对准特征部沿弯曲边缘相对紧密地间隔开。对准特征部34和切口38的示例形状是非限制性的。切口38通常大于对准特征部34和/或具有与对准特征部34不同的形状，以促进对准特征部的可见性。例如，每个切口38的宽度(W)、深度(D)和/或投影面积可以大于相应的对准特征部34的宽度(W)、深度(D)和/或投影面积。在一些实施方案中，形成对准特征部34，并且没有材料从装饰层24的边缘32被去除。例如，每个对准特征部34可以是沿装饰层24的边缘32形成并且通过切口38中的一个切口可见的狭缝或可见标记的形式。
如图3所示，每个切口38可以具有比每个相应的可见对准特征部34的宽度(W)更大的宽度(W)。在一个实施方案中，每个切口38的宽度是每个相应的对准特征部34的宽度的至少两倍。在另一个实施方案中，每个切口38的宽度是每个相应的对准特征部34的宽度的三倍至五倍。例如，每个切口38可以具有约10mm的宽度，并且每个对准特征部具有2mm至3mm的宽度。
此外，每个切口38可以具有比通过相应的切口可见的每个对准特征部34的投影面积更大的投影面积。在一个实施方案中，每个切口38的投影面积是每个相应的对准特征部34的投影面积的至少两倍。在另一个实施方案中，每个切口38的投影面积是每个相应的对准特征部34的投影面积的五倍至十倍。例如，每个切口38可以具有约20mm2至约30mm2的投影面积，并且每个对准特征部可以具有约2mm2至约4.5mm2的投影面积。在一个非限制性实例中，每个对准特征34是具有2mm或3mm的宽度(W)和深度(D)的对称V形凹口，并且相应的切口38具有10mm的宽度(W)和与对准特征部相同的深度(D)。
在两个单独形成的层24、26的层压期间，背衬层26中的尺寸过大的切口38的益处是较大的加工窗口。换而言之，如果背衬层26中的切口38以与装饰层24中的对准特征部34相同的沿边图案、形状和尺寸制成，则在层压期间需要两个层的完美对准和配准(registration)—即，在没有完美对准的情况下，背衬层26将使每个对准特征部34的至少一部分观察不清，在使用另一材料片的后续接合过程中使对准特征部的效用失效。所公开的切口38的作用在图3中是明显的，其中不是所有的对准特征部34都完美地居中在相应的切口38中。如果图3的切口38以与具有所示切口间距的对准特征部34相同的形状和尺寸形成，则将至少部分地阻挡一些对准特征部34而观察不到。更糟糕地，缝合操作者将倾向于在缝合或其它接合操作期间使用不适当定位的切口作为对准特征部，导致在完成的装饰性覆盖物中的未对准的装饰层。
相对于在已经层压的材料片中形成对准特征部，在将各层层压在一起以形成材料片18之前在装饰层24中提供对准特征部34和单独地在背衬层26中提供尺寸过大的切口38还提供了一些益处。特别地，至少一个切割步骤可以连同切割工具的成本一起被消除。制造所公开的材料片18的方法包括以下步骤：将装饰层24和对准特征部34从装饰材料片中模切成期望的外部形状，将背衬层26和切口38从背衬材料片模切成相同的外部形状，然后将这两个层层压在一起以形成具有通过切口38可见的对准特征部34的材料片18。该方法仅需要两个模切步骤，并且因此仅需要两个切割模具。在切割对准特征部穿过两个层之前首先将层24、26层压在一起的过程需要至少三个切割操作和相应的模具。在此类过程中，装饰材料和背衬材料中的每一个必须首先被单独地粗糙切割成比期望的最终形状稍大的形状，然后被层压在一起，随后在第三精密模切步骤形成穿过层压材料的对准特征部。
图4至图6示出在形成装饰性覆盖物12的各个阶段中的图2和图3的材料片18。图4是在第二材料片18’的一部分上对准的图2和图3的材料片18的一部分的等距视图。在本实例中，两个材料片18、18’以大体相同的方式构造，具有以匹配的沿边图案形式沿每个装饰层24的边缘的对准特征部34和在每个背衬层26中的尺寸过大的切口38。切口38仅需要在材料片18、18’中的一个中是尺寸过大的—即，无论哪个材料片都具有在接合过程期间可见的背侧。
图5是用示意性示出的缝合针40在缝合操作中接合在一起的两个材料片18、18’的横截面视图。两个片面对面地放置在一起，并且它们的装饰侧28彼此面对，并且针迹线42形成在期望的接缝位置处。可以通过工作台或其它固定装置(以虚线示出)从与可见侧或缝合针侧相对的侧面支撑材料片，所述工作台或其它固定装置可以包括引导件44，材料的边缘可以沿着引导件44移动以保持期望的边沿长度(M)和接缝位置。图5的横截面是通过每个材料片的对准特征部34和切口38截取的，在该实例中，所述对准特征部34和切口38具有相等的深度。图5示出对准特征部34和切口38的深度的可能的实际限制：它们应当小于期望的边沿长度(M)。在一个实施方案中，边沿长度约为对准特征部和/或切口的深度的两倍。例如，对准特征部和切口的深度可以为2mm至3mm，并且边沿长度可以为4mm至6mm。
图5还间接地示出限制切口38的宽度的益处。虽然较大的切口宽度在层压过程期间提供了与装饰层的较大的对准公差，但是如果切口形成太宽，则在缝合操作期间分层的片18、18’的引导可能受到不利影响，因为装饰层24的较大的沿边跨度在底部上不受支撑并且在顶部不受约束。
在接合操作之后，两个材料片18、18’的相对的装饰表面被分开并且变平以形成装饰性覆盖物12，如图6所示，其中相应的材料片18、18’位于接缝20的相对的侧面上。所示的覆盖物12可以布置在基板14上并且附接至基板14，以获得图1的车辆内部面板10。在一些实施方案中，每个边沿22的至少一部分在组装至基板之前被修整掉。在一些情况下，此类修整步骤从完成的装饰性覆盖物12中完全去除对准特征部和切口。例如，接合的材料片18、18’可以具有沿与针迹线42平行的修整线修整的边沿，并且该边沿与接合材料的边缘间隔大于对准特征部的深度并且小于边沿长度(M)的距离。此类修整可以在分开相对的装饰表面并且将接合的片整平成装饰性覆盖物12之前执行。在一些实施方案中，同时执行修整和接合。例如，当缝合操作沿着针迹线行进时，修整工具(例如，刀)可以在材料供给方向上定位在缝合针的下游，以从边沿修整多余的材料。
虽然在图4和图5中接合的材料片18、18’的各自边缘是直边缘，但应注意，接缝20可以沿具有弯曲边缘的材料片和/或具有不同轮廓边缘的材料片形成。实际上，在其中接缝20沿轮廓装饰侧16定位的车辆内部面板的实施方案中，被接合以形成装饰性覆盖物12的材料片的各自边缘的轮廓通常彼此不同，使得在接合期间用于适当对准边缘的对准特征部34的可见性变得甚至更重要。
应理解，前述内容是对本发明的一个或多个优选示例性实施方案的描述。本发明不限于本文所公开的特定实施方案，而是仅由权利要求限定。此外，前述描述中含有的陈述涉及特定实施方案，并且不应被解释为对本发明的范围或对权利要求书中使用的术语的定义的限制，除非术语或短语在上文明确定义。各种其它实施方案和对所公开的实施方案的各种改变和调整对于本领域技术人员将变得显而易见。所有这样的其它实施方案、改变和调整旨在落入所附的权利要求的范围内。
如在本说明书和权利要求中所用的，术语“例如(for example/for instance/such as)”和“如(like)”以及动词“包含(comprising)”、“具有(having)”、“包括(including)”以及它们的其它动词形式，当与一个或多个组件或其它项目的列表结合使用时，各自被解释为是开放式的，意味着该列表不被认为排除其它的、附加的组件或项目。其它术语应使用其最广泛的合理含义来解释，除非它们在需要不同解释的上下文中使用。

Claims (23)

1.用于制造车辆内部面板的装饰性覆盖物的材料片，所述材料片包括：
装饰层，其具有装饰侧、相对的背侧和沿所述材料片的周边延伸的边缘；
背衬层，其附接至所述装饰层的背侧，并且具有沿所述装饰层的边缘延伸的相应边缘；
多个对准特征部，其沿所述装饰层的边缘以沿边图案的形式间隔开；以及
多个切口，其沿所述背衬层的相应边缘形成，每个切口被定位成使得当从所述背侧观察所述材料片时，每个对准特征部通过所述切口中的一个切口是可见的，
其中当在接缝处与另一不同的材料片接合时，所述材料片形成所述装饰性覆盖物的一部分，所述另一不同的材料片具有沿所述不同的材料片的边缘以匹配沿边图案的形式间隔开的对准特征部，以及
其中所述装饰层是皮革。
2.如权利要求1所述的材料片，其中沿所述装饰层的边缘的每个对准特征部是凹口。
3.如权利要求1所述的材料片，其中每个切口的形状不同于通过所述切口可见的每个对准特征部的形状。
4.如权利要求1所述的材料片，其中每个切口的宽度大于通过所述切口可见的每个对准特征部的宽度。
5.如权利要求1所述的材料片，其中每个切口的宽度是通过所述切口可见的每个对准特征部的宽度的至少两倍。
6.如权利要求1所述的材料片，其中每个切口的宽度是通过所述切口可见的每个对准特征部的宽度的至少三倍且不超过五倍。
7.如权利要求1所述的材料片，其中每个切口的深度等于通过所述切口可见的每个对准特征部的深度。
8.如权利要求1所述的材料片，其中每个切口的投影面积是通过所述切口可见的每个对准特征部的投影面积的至少两倍。
9.如权利要求1所述的材料片，其中每个切口的投影面积是通过所述切口可见的每个对准特征部的投影面积的至少五倍且不超过十倍。
10.如权利要求1所述的材料片，其中所述背衬层经由层压或粘合层而附接至所述装饰层的背侧。
11.如权利要求1所述的材料片，其中所述对准特征部和所述切口沿所述材料片的周边的曲线部分布置。
12.如权利要求1所述的材料片，其中所述装饰层是人造皮革。
13.车辆内部面板，包括由在接缝处与不同的材料片接合的第一材料片形成的装饰性覆盖物，并且每个材料片在所述接缝的相对侧上，所述第一材料片包括：
装饰层，其具有装饰侧、相对的背侧和沿所述第一材料片的周边延伸的边缘；
背衬层，其附接至所述装饰层的背侧，并且具有沿所述装饰层的边缘延伸的相应边缘；
多个对准特征部，其沿所述装饰层的边缘以沿边图案的形式间隔开；以及
多个切口，其沿所述背衬层的相应边缘形成，每个切口被定位成使得当从所述背侧观察所述第一材料片时，每个对准特征部通过所述切口中的一个切口是可见的，
其中不同的材料片具有沿所述不同的材料片的边缘以匹配沿边图案的形式间隔开的对准特征部。
14.如权利要求13所述的车辆内部面板，其中所述装饰层是皮革。
15.如权利要求13所述的车辆内部面板，其中所述装饰层是人造皮革。
16.制造车辆内部面板的装饰性覆盖物的方法，所述方法包括步骤：
将第一材料片在接缝处接合至不同的材料片；以及
使所述第一材料片的对准特征部在接合步骤期间与所述不同的材料片的对准特征部对准，其中所述第一材料片包括：
装饰层，其具有装饰侧、相对的背侧和沿所述第一材料片的周边延伸的边缘，其中所述第一材料片的对准特征部沿所述装饰层的边缘以沿边图案的形式间隔开；
背衬层，其附接至所述装饰层的背侧，并且具有沿所述装饰层的边缘延伸的相应边缘；以及
多个切口，其沿所述背衬层的相应边缘形成，每个切口被定位成使得当从所述背侧观察所述第一材料片时，每个对准特征部通过所述切口中的一个切口是可见的，
其中不同的材料片的对准特征部沿所述不同的材料片的边缘以匹配沿边图案的形式间隔开。
17.如权利要求16所述的方法，其中所述背衬层在所述接合步骤之前附接至所述装饰层的背侧，以及
其中沿所述装饰层的边缘形成所述第一材料片的对准特征部，并且在所述背衬层附接至所述装饰层的背侧之前沿所述背衬层的相应边缘形成所述切口。
18.如权利要求16所述的方法，其中所述接合的步骤包括缝合。
19.如权利要求16所述的方法，还包括步骤：沿与所述装饰层的边缘、所述背衬层的边缘和所述不同的材料片的边缘间隔开的修整线修整掉接合的材料片的至少一部分边沿。
20.如权利要求19所述的方法，其中所述修整步骤包括去除接合的材料片的对准特征部。
21.如权利要求16所述的方法，其中所述装饰层是皮革。
22.如权利要求16所述的方法，其中所述装饰层是人造皮革。
23.如权利要求16所述的方法，其中沿所述装饰层的边缘的每个对准特征部是凹口。
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