CN215436275U - 车辆内部部件 - Google Patents

车辆内部部件 Download PDF

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Publication number
CN215436275U
CN215436275U CN202120289437.7U CN202120289437U CN215436275U CN 215436275 U CN215436275 U CN 215436275U CN 202120289437 U CN202120289437 U CN 202120289437U CN 215436275 U CN215436275 U CN 215436275U
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CN
China
Prior art keywords
vehicle interior
decorative covering
component
stitch
hollow
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CN202120289437.7U
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English (en)
Inventor
马切伊·切尔卡斯
约瑟夫·马塞蒂
本杰明·奥特曼
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Faurecia Interior Systems Inc
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Faurecia Interior Systems Inc
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    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
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Abstract

一种车辆内部部件，其中，在部件基底中形成多个中空针脚接受孔，以容纳附接至部件基底的装饰性覆盖物中的缝合接缝。缝合接缝延伸通过装饰性覆盖物，以从中空针脚接受孔生成填充的针脚接受孔。缝合接缝可在模内纹理过程之后生成，在模内纹理过程中，部件基底和装饰性覆盖物层压在一起。

Description

车辆内部部件
技术领域
本申请大致涉及具有缝合接缝的车辆内部部件，更具体地，涉及在车辆内部部件中形成缝合接缝。
背景技术
车辆内部部件通常包括在部件基底上的装饰性覆盖物，在装饰性覆盖物中形成有一个或多个缝合接缝。在一些情况下，缝合可延伸穿过部件基底和装饰性覆盖物。例如，Kato等人的US 2019/0016242和 Wenzel等人的EP 3177761公开了车辆内部部件，其中缝合接缝延伸穿过部件基底和装饰性覆盖物二者。然而，在这些车辆内部部件中，部件基底中的孔在缝合过程中形成。在Kato等人的US 2019/0016242 中，缝纫针本身用于刺穿基底，以及在Wenzel等人的EP 3177761中，在插入线之前，用锥子穿透装饰性覆盖物和基底。这些方法会在缝合过程中产生阻力，可使在该过程中使用的各种部件过热，并且可能需要除了本文所述的方法和部件之外的额外的成形设备。
实用新型内容
制造内部车辆部件的示例性方法包括以下步骤：在部件基底中形成多个中空针脚接受孔；将装饰性覆盖物附接至具有多个中空针脚接受孔的部件基底；以及通过所述装饰性覆盖物和多个中空针脚接受孔中的至少一些进行缝合，以形成缝合接缝，缝合接缝延伸穿过装饰性覆盖物，并在中空针脚接受孔中的至少一些中生成填充的针脚接受孔。
在一些实施方式中，附接步骤包括在热覆盖过程中将装饰性覆盖物层压至部件基底上。
在一些实施方式中，热覆盖过程是模内纹理层压过程，模内纹理层压过程在装饰性覆盖物的外表面上赋予表面纹理。
在一些实施方式中，热覆盖过程是模内纹理层压过程，模内纹理层压过程在装饰性覆盖物中生成模内沟槽。
在一些实施方式中，模内沟槽至少部分地沿着中空针脚接受孔中的至少一些的线跟随。
在一些实施方式中，将中空针脚接受孔模制、激光刻痕、或机器人铣削到部件基底中。
在一些实施方式中，中空针脚接受孔包括在部件基底的外表面上的闪光部。
在一些实施方式中，装饰性覆盖物中的中空针脚接受孔与部件基底的中空针脚接受孔中的至少一些对齐。
在一些实施方式中，装饰性覆盖物包括表层和泡沫层。
在一些实施方式中，缝合接缝是链式缝合，包括沿着装饰覆盖物的外表面的单线通过、在填充的针脚接受孔中的每个中的双线通过、以及沿着部件基底的内表面的双线通过。
在一些实施方式中，多个中空针脚接受孔中的每个中空针脚接受孔均具有孔横截面轮廓，以及其中孔横截面轮廓是椭圆形的。
本申请还提供了说明性的内部车辆部件，该内部车辆部件包括：具有外表面和内表面的装饰性覆盖物；部件基底，具有多个中空针脚接受孔、外表面和内表面，其中，装饰性覆盖物的内表面在所述多个中空针脚接受孔中的至少一些中空针脚接受孔的上方附接至部件基底的外表面；以及缝合接缝，延伸穿过装饰性覆盖物，以在中空针脚接受孔中的至少一些中生成填充的针脚接受孔。
在一些实施方式中，中空针脚接受孔具有孔横截面轮廓，并且孔横截面轮廓是椭圆形的。
在一些实施方式中，孔横截面轮廓的最长尺寸与缝合接缝的方向对齐。
在一些实施方式中，缝合接缝至少部分地与装饰性覆盖物中的模内沟槽对齐。
可设想的是，除了特征不相容的情况外，上述实施方式以及在附图或以下描述中描述的任何其它实施方式的任何数量的单独特征均可以以任何组合方式组合来限定本申请。
附图说明
下文将结合以下附图描述说明性实施方式，其中，相同的附图标记表示相同的部件，在附图中：
图1是装备有车辆内部部件的各种实施方式的车辆客舱内部的立体图；
图2是图1的车辆内部部件的局部视图，示出示例性的缝合接缝；
图3是在缝合过程中车辆内部部件的局部剖视图，其中接缝由在部件基底中预先形成的中空缝合接纳孔容纳；
图4示出根据一个实施方式的来自中空针脚接受孔的示例性孔横截面轮廓；
图5是根据一个实施方式的中空针脚接受孔的剖视图；
图6是示出形成车辆内部部件的示例性现有技术方法的流程图；
图7是示出根据一个实施方式的形成车辆内部部件的方法的流程图；以及
图8是示出根据另一实施方式的形成车辆内部部件的方法的流程图。
具体实施方式
本文描述了具有缝合接缝的车辆内部部件的实施方式以及制造这种车辆内部部件的方法。缝合接缝容纳于中空针脚接受孔中，所述中空针脚接受孔在缝合过程之前在部件基底中预先形成。有利地，在模内纹理层压过程中将装饰性覆盖物层压至部件基底之前，中空针脚接受孔模制到部件基底中或激光刻痕到基底中。这可消除对额外的热成形工具的需求，从而降低制造成本，减少占地空间，并改善循环时间。另外，与在缝合过程中形成孔的方法相比，当前方法可提供更高质量的车辆内部部件，因为用于刺穿部件基底的缝合过程的锥子、针等可生成不希望的形状的孔，并导致线中的碎片。
图1是根据本文所述的方法的示例性车辆内部部件的立体图，车辆内部部件可包括具有缝合接缝的装饰性覆盖物。仅举几个例子，仪表板组件10、座位组件12、控制台组件14和门板组件16均可包括布置在它们各自的部件基底上并附接至它们各自的部件基底上的装饰性覆盖物18。位于车辆22的内部车厢20内的其它车辆内部部件也可包括如本文所述的装饰覆盖物和缝合。下面的描述集中在仪表板组件10 上；然而，所述方法、结构、特征等也可应用于任何其它部件，诸如座椅组件12、控制台组件14、门板组件16、和/或在装饰性覆盖物中具有缝合接缝的任何其它车辆部件。
图2是位于图1的仪表板组件10中的两个缝合接缝24、26的放大示意图。本文所述的缝合接缝可为连接材料的分离部分的功能性缝合接缝，或在一些实施方式中，缝合接缝可为非功能性或装饰性缝合接缝，仅为各种车辆内部部件提供一定的美观性。缝合接缝24、26 沿着且大致跟随模内沟槽28的部分的路径定位。换言之，缝合接缝 24、26大致与形成在装饰性覆盖物18中的模内沟槽28对齐，或大致平行于该模内沟槽28(大致平行于该模内沟槽28可意味着在制造公差内平行于该模内沟槽28的至少部分)。在该实施方式中的装饰性覆盖物18包括最外表层30，最外表层30具有大致面向车辆22的内舱 20的外表面32。外表面32也可被称为A侧。除了形成在表层30的外表面32中的模内沟槽28之外，表层还可包括纹理图案34。模内沟槽28和/或纹理图案34可有利地在如下文进一步详述的模内纹理层压过程或另一热覆盖过程期间赋予到装饰性覆盖物18中。在其它实施方式中，可能不存在模内沟槽或纹理图案。
参照图3，装饰性覆盖物18包括多层结构36，其由提供各种结构、功能、美学和/或触觉质量的不同材料的多层组成。根据实施方式，多层结构36可包括表层或箔层30和泡沫层38。可有比图3所示更多的层，或可有更少的层。例如，可包括其它中间层，诸如间隔层和/或一个或多个粘合剂层。在又一实施方式中，装饰性覆盖物18仅包括位于部件基底40上方的单个表层或箔层30。另外，这些层的结构和/或组成可不同于本文所示和所述的，因为本文所述的多层结构36仅仅是一个实例。
表层30是装饰性覆盖物18的最外层，并且包括沿着外表面32 的可见外侧或A侧，其中相对的或内表面42朝向部件基底40抵靠泡沫层38。表层30的主要功能是为车辆内的乘客提供具有美学吸引力的弹性的、持久的暴露表面，美学吸引力包括所需的视觉特性，诸如颜色、形状和纹理。因而，表层30可包括在A侧或外表面32处可见的设计特征，诸如上面关于图2讨论的浮雕纹理图案或所需颜色的漆膜。表层30还可至少部分地为装饰性覆盖物18提供所需的类似家具内饰的触觉特性，诸如柔软的触感或光滑的感觉。在一些情况下，表层30由合成材料形成，所述合成材料配置成具有模仿其它更昂贵的材料的美学特性，所述其它更昂贵的材料为诸如皮革(例如，诸如热塑性烯烃(TPO)、聚氨酯(PUR)、聚氯乙烯(PVC)和/或聚丙烯(PP) 的薄塑料层)。在其它实施方式中，表层30是天然材料，诸如皮革。
可包括泡沫层38以为仪表板或车辆部件10提供所需的触觉特性。这种触觉特性可为缓冲的形式，当力施加于板10的外表面或A侧32 时，该缓冲压缩，以及当力被移除以使表层30返回到其原始位置时，该缓冲解压缩。泡沫层38具有面对表层30的外表面44和面对部件基底40的内表面46，并大致限定装饰性覆盖物18和多层结构36的内表面。一种合适的泡沫层材料是由包括多元醇和二异氰酸酯的液体前体材料形成的聚氨酯泡沫。其它泡沫材料(例如，聚烯烃基)也是可能的。泡沫层38还可提供隔音和/或具有不均匀的厚度，以便当表层 30和基底的相应轮廓彼此不同时，填充表层30与部件基底40之间的空间。泡沫层38的厚度可在1mm至10mm的范围内，并且其可单独设置，并与相邻的材料层粘附。在其它实施方式中，除了泡沫层38 之外或作为泡沫层38的替代物，使用织物或稀松布层。在其它实施方式中，不使用泡沫层，使得表层30的内表面42直接与部件基底40 相接(有时经由一个或多个粘合剂层等)。
部件基底40通常是多层组件的所示层中最刚硬的，从而在车辆 22内的所需位置为上覆的一个或多个装饰性覆盖层提供结构支承。部件基底40具有面向内机舱20并面向装饰覆盖物18的内表面46的外表面48。部件基底40具有内表面50，该内表面50可包括各种凸台、肋、凹槽等，这些凸台、肋、凹槽赋予结构益处和/或促进与车辆22 的其它部件的附接。有利的是，缝合接缝24位于远离任何这种特征的位置，从而为缝纫机缝合板52提供清晰的路径。在一些实施方式中，由于很难围绕弯曲部或角部操作缝纫机缝合板52，因而可设置铰链或活动铰链53，使得缝合接缝24可缝合穿过基底40，然后基底可移动到其安装位置，如图3示意性所示。厚度为1.6mm至4mm的玻璃纤维增强聚丙烯是合适的部件基底40的一个实例，但是可以以类似的方式使用各种其他类型的材料和材料组合和/或不同的厚度范围(例如，丙烯腈丁二烯苯乙烯(ABS)或聚碳酸酯ABS(PCABS))。部件基底 40有利地比表层30更厚和更硬。
为了增强制造过程并减少废料，除其它有益效果外，部件基底40 还包括多个预先形成的中空针脚接受孔54。如将在下面进一步详细描述的是，在将装饰性覆盖物18层压至部件基底40之前，在部件基底 40中形成中空针脚接受孔54，与在缝合过程本身期间形成孔的其它方法相比，这可提供处理益处。例如，在缝合过程中形成孔的其它过程中，在线56中可捕获碎屑。在缝合过程中形成孔的另一例子中，针 58、锥子或其它刺穿机构可过热，并且需要更频繁地更换。有利的是，中空针脚接受孔54激光刻痕或模制到部件基底40中。为了使制造过程流线化，在用装饰性覆盖物18进行模内纹理层压过程之前，在部件基底40中形成中空针脚接受孔54。
图3示意性地示出了穿过装饰性覆盖物18和中空针脚接受孔54 中的至少一些的缝合过程。缝合接缝24穿过装饰性覆盖物18和部件基底40形成。下面的讨论集中于缝合接缝24，但也可应用于位于车辆内部部件中的其它缝合接缝，诸如缝合接缝26。缝合接缝24的形成在多个中空针脚接受孔54中生成填充的针脚接受孔60。因此，填充的针脚接受孔60中具有穿过的线，而中空针脚接受孔54中不具有穿过的线。图3所示的缝合接缝24是链式缝合62，其具有沿着装饰性覆盖物18的外表面32的单线通过、在填充的针脚接受孔60中的每个中的双线通过、以及沿着部件基底40的内表面50的双线通过。在另一实施方式中，缝合接缝24可为锁定缝合或另一种类型的缝合。在有利的实施方式中，缝合接缝24在表层30或装饰性覆盖物18的外表面32上开始和结束。
在装饰性覆盖物18附接或定位在基底的外表面48之上之前，在部件基底40中形成中空针脚接受孔54。在一些实施方式中，中空针脚接受孔54也可形成在装饰性覆盖物18中，并且随后与覆盖物的中空针脚接受孔54对齐。中空针脚接受孔54有利地在基底最初被注射模制时模制到部件基底40中，或激光刻划到模制基底中。尽管部件基底40的注射模制是有利的，但是形成部件基底的其它方法当然也是可能的。模制孔或激光刻痕孔54优于在缝合过程中形成的其它孔，因为视觉扫描系统(例如，机器人和照相机)可帮助监视孔的放置和随后的缝合放置，从而提供更有效的处理和更紧密的公差。因而，可使用作为视觉扫描系统的部分的软件来监测中空针脚接受孔54的放置，该软件可在缝合过程中记录针58的放置，以便将装饰性覆盖物18的刺穿与对应于孔54的位置相对应。因而，由于中空缝线接受孔54的已知布置，缝线24的布置可进一步预先规划。在其它实施方式中，例如，中空针脚接受孔54通过铣削或机器人或手工钻孔形成。然而，在这些实施方式的任何一个中，在附接装饰性覆盖层18之前形成中空针脚接受孔54。这可允许进一步的过程效率、更低的成本和改进的产品，如下面进一步详述的。
在附接装饰性覆盖物18之前形成中空针脚接受孔54可允许孔结构的更大的自由度，因为在缝合过程中不用针58或锥子形成孔。如图 4的俯视图所示，在一个实施方式中，中空针脚接受孔54具有长圆形或椭圆形的孔横截面轮廓64。在缝合过程中在基底中形成孔的实施方式中，孔是圆形的，并且不具有图4所示的长圆形或椭圆形孔横截面轮廓64。在附接至装饰性覆盖物18之前，在部件基底40中的孔中进行激光刻痕或模制，可在孔横截面轮廓64中形成这种有利的形状。
图4示出了与孔横截面轮廓64相关的多个尺寸X1-4，并且一旦形成，最终可规定与缝合接缝24相关的多个尺寸。尺寸X1是针脚长度，并且也对应于缝合接缝方向。该缝合接缝方向X1与孔横截面轮廓64 的最长尺寸X2对齐。这可提供更理想的美学外观。给定孔横截面轮廓的椭圆形形状，尺寸X2是孔横截面轮廓64的最长尺寸，而尺寸X3是孔横截面轮廓的最短尺寸(X2可认为是椭圆形孔54的长度，X3可认为是椭圆形孔54的宽度)。优选地，尺寸X2比尺寸X3大1.25至2 倍。尺寸X4表示孔之间的间隔。在特别有利的实施方式中，X1是5mm, X2是2mm,X4是1.5mm，以及X4是3mm。其它尺寸当然也是可能的，并且将取决于部件10和缝合接缝24的所需质量。
图5示出了中空针脚接受孔54的另一实施方式。在该实施方式中，存在闪光部(flashing)或闪光盖(flashover)57，其可覆盖基底40 的外表面48上的孔54。该闪光孔54导致在闪光部57处留下少量、薄量的材料，其中该孔未模制或以其它方式形成为一直穿过外表面48 和内表面50之间的基底40的厚度。孔54的侧壁59仍然构成外表面 48与内表面50之间的基底40的大部分厚度(例如，厚度的95-99％)，这仍然可导致干净的缝合过程。
图6至图8的流程图示出了各种制造方法，其中图6示出了形成缝合接缝的现有技术方法，以及图7和图8示出了可形成本文所述的中空针脚接受孔54、缝合接缝24和车辆内部部件10-16的制造方法(可选的步骤以虚线示出；例如，对于其中基材是ABS和/或PC的实施方式，与PP相反，可不需要火焰处理步骤)。图6示出了根据热覆盖或模内纹理层压过程形成基底以及装饰性覆盖物。对于图6的现有技术实施方式，在缝合过程之前，在基底中不形成中空针脚接受孔54。通常，如图6所示，在装饰性覆盖物与基底层压之前，在装饰性覆盖物中进行缝合。因此，使用热成形工具将基底和装饰性覆盖物压结合。
然而，在图7和图8所示的实施方式中，不需要额外的热成形工具，这可降低资金费用，降低必需的操作人员的人数，打开占地面积，降低成本，并改善循环时间。图7示出了一个实施方式，其中在所形成的部件基底40中激光刻痕中空针脚接受孔54。图8示出了一个实施方式，其中中空针脚接受孔54模制到部件基底40中。在图7和图 8的两个实施方式中，使用粘合剂将装饰性覆盖物18附接至具有中空针脚接受孔54的部件基底40，然后对多层部件进行模内纹理层压或其它热成形过程。如图2所示，通过设置纹理图案34和/或模内沟槽28，模内纹理层压过程赋予装饰性覆盖物18和/或表层30所需形状的三维形状。在模内纹理层压过程之后，缝合接缝24通过装饰性覆盖物 18和部件基底40二者缝合到车辆内部部件10中。
与在缝合过程中使用针或锥子刺穿基底的方法相比，图7和图8 的方法可防止碎屑与线干涉，以及防止刺穿部件过热。另外，通过在热覆盖或模内纹理层压过程之后施加缝合接缝24，以及将装饰性覆盖物18附接至部件基底40，消除了对用于将基底和装饰性覆盖物压接的单独热成形工具的需求，如图6所示。因而，降低了资本支出，并获得了效率。另外，与图6的方法相比，图7和图8的方法中的步骤的总数减少。另外，利用图7和图8的方法，可不需要手动折边，这可进一步提高效率，减少报废。
应当理解的是，上述内容是对本实用新型的一个或多个实施方式的描述。本实用新型不限于本文所公开的一个或多个特定实施方式，而是仅由所附权利要求书限定。另外，包含在上述描述中的陈述涉及特定实施方式，并且不应被解释为对本实用新型的范围或对权利要求书中使用的术语的定义的限制，除非上面明确地限定了术语或短语。对于本领域的技术人员来说，对所公开的实施方式的各种其它实施方式和各种改变和修改将是显而易见的。所有这些其它实施方式、变化和修改都在所附权利要求的范围内。
如本说明书和权利要求书中所使用的是，术语“例如(e.g.)”、“例如(forexample)”、“例如(for instance)”、“诸如”和“如”以及动词“包括”、“具有”、“包含”和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，各自解释为开放式的。这意味着该列表不应被认为排除其他的、附加的组件或项目。除非在需要不同解释的上下文中使用其它术语，否则其它术语将使用其最广泛的合理含义来解释。

Claims (10)

1.一种车辆内部部件，包括：
装饰性覆盖物，具有外表面和内表面；
部件基底，具有多个中空针脚接受孔、外表面和内表面，其中，所述装饰性覆盖物的内表面在所述多个中空针脚接受孔中的至少一些中空针脚接受孔的上方附接至所述部件基底的外表面；以及
缝合接缝，延伸通过所述装饰性覆盖物，以在所述多个中空针脚接受孔中的至少一些中生成填充的针脚接受孔。
2.如权利要求1所述的车辆内部部件，其中，所述多个中空针脚接受孔具有孔横截面轮廓，以及其中，所述孔横截面轮廓是椭圆形的。
3.如权利要求2所述的车辆内部部件，其中，所述孔横截面轮廓的最长尺寸与所述缝合接缝的方向对齐。
4.如权利要求1所述的车辆内部部件，其中，所述缝合接缝至少部分地与所述装饰性覆盖物中的模内沟槽对齐。
5.如权利要求4所述的车辆内部部件，其中，所述模内沟槽至少部分地沿着所述多个中空针脚接受孔中的至少一些的线跟随。
6.如权利要求1所述的车辆内部部件，其中，将所述多个中空针脚接受孔模制、激光刻痕、或机器人钻至所述部件基底。
7.如权利要求1所述的车辆内部部件，其中，所述多个中空针脚接受孔中的至少一些包括在所述部件基底的外表面上的闪光部。
8.如权利要求1所述的车辆内部部件，还包括在所述装饰性覆盖物中的中空针脚接受孔，所述装饰性覆盖物中的中空针脚接受孔与所述部件基底的所述中空针脚接受孔中的至少一些孔对齐。
9.如权利要求1所述的车辆内部部件，其中，所述装饰性覆盖物包括表层和泡沫层。
10.如权利要求1所述的车辆内部部件，其中，所述缝合接缝是链式缝合，所述链式缝合包括：沿着所述装饰性覆盖物的外表面的单线通过；在所述填充的针脚接受孔中的每个中的双线通过；以及沿着所述部件基底的内表面的双线通过。
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