GB2142574A

GB2142574A - Laminated door panel

Info

Publication number: GB2142574A
Application number: GB08415839A
Authority: GB
Inventors: Muneharu Urai
Original assignee: Tachikawa Spring Co Ltd
Current assignee: Tachi S Co Ltd
Priority date: 1983-07-04
Filing date: 1984-06-21
Publication date: 1985-01-23
Also published as: FR2548584B1; IT1174236B; AU2985684A; IT8421747A0; GB8415839D0; FR2548584A1; CA1243927A; GB2142574B; DE3424637A1; AU547977B2

Abstract

A method for manufacturing a door panel comprises placing a surface layer material (1), a filler padding (2) made of polyurethane which has not been subjected to any previous treatment and a backing board (3), between ultrasonic machining horns (4) and ultrasonic machining horn rests (5), and applying ultrasonic vibration to desired portions (2a) of said laminate. <IMAGE>

Description

SPECIFICATION Door pad, and method for manufacturing the same by application of ultrasonic wave This invention relates to a door pad, and particularly to a door pad manufactured by welding normal polyurethane, which is not subjected to any treatment, under application of ultrasonic wave. The present invention relates also to a method for manufacturing a door pad by the ultrasonic welding of normal polyurethane not subjected to any previous treatment for welding, which could not be hitherto used in high frequency welding.

A door pad used as the inner covering of a vehicle door or the like (which will be hereinafter called a door pad merely), has been hitherto manufactured by utilization of a high frequency heating or any other suitable heating means. In Figure 1,there is shown a prior example of such a door pad. The prior door pad shown in Figure 1 has mainly been manufactured by putting a surface layer 1 and a backing board 3 one over the other, with a filler padding 1 interposed between them, compressing the surface layer 1, filler padding 2 and backing board 3 between high frequency electrode members (not shown) in contact with weld portions 2a and the other high frequency electrode members (also not shown) on the side of the opposite backing board 3, and supplying a high frequency current between both these electrode members to fuse the filler padding 2 so that the surface layer 1 and filler padding 2 are welded to the backing board 3 at the weld portions 2a.

In this case of the prior door pad, the bonding of the surface layer 1, filler padding 2 and backing board 3 has been achieved by the fusion of the filler padding 2 (except for normal polyurethane which will be described below), because the filler padding 2 is fused by heat produced therein upon the supply of a high frequency current, but the backing board 3 such as a hard board is not exothermically fused due to its selected material.

In the prior arts utilizing high frequency heating, normal polyurethane not subjected to any previous treatment, by way of example an impregnation with a welding filler substance for improving its weldability with a high frequency current, (which will be hereinafter shortened normal polyurethane merely) was not used inspite of its excellent physical properties (elasticity, durability, etc.) and its lower price, since it can not be fused because of its high melting point. Alternately, there have been hitherto used normal polyurethane treated so as to be capable of fusing at low temperatures, low melting point polyurethane and cushion materials with low melting points other than polyurethane. However, these materials have various defects, that is inferior physical properties and higher prices as compared with normal polyurethane.

In order to use normal polyurethane, with utilization of its excellent characteristics mentioned above, sometimes, a substance that can be fused by a high frequency current has been previously applied to the surface of the backing board 3 to be contacted with the filler padding 2. But, this prior art has been less effective, resulting in the manufacturing steps increased in number and the cost raised.

In view of the above, the present invention is intended to provide a door pad manufactured by using normal polyurethane not subjected to any previous treatment under application of ultrasonic wave. Furthermore, the present invention is intended to provide a method for manufacturing a door pad by the ultrasonic welding of normal polyurethane not subjected to any previous treatment for welding, which could not be hitherto used in high frequency welding.

According to one aspect of this invention, there is provided a door pad manufactured by ultrasonic welding, which comprises a laminate consisting of a surface layer material, a filler padding or polyurethane molding made of normal polyurethane which is not subjected to any treatment and a backing board, wherein desired portions of said laminate are fusion-bonded by heat produced therein by ultrasonic vibration.

According to another aspect of this invention, there is provided a method for manufacturing a door pad by the application of ultrasonic wave, which comprises the steps of putting a surface layer material, a filler padding or polyurethane molding made of normal polyurethane which is not subjected to any previous treatment and a backing board, in a laminated state, between ultrasonic machining horns and ultrasonic machining horn rests, and applying ultrasonic vibration to desired portions of said laminate by the ultrasonic machining horns, while a force is being imparted thereon, whereby the desired portions of the laminate are fusion-bonded by heat produced therein.

Brief description of the drawings The principle and construction of this invention will be clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which: Figure 1 is a schematic sectional view of a prior door pad.

Figures 2 to 5c are respectively schematic views showing embodiments of door pad according to this invention.

Figure 2 is a schematic sectional view of a door pad, wherein a method for manufacturing the same is illustrated.

Figure 3 is a schematic sectional view of a door pad in which the terminating ends of a surface layer are fixed on the back side of a backing board, enclosing the backing board.

Figure 4 is a schematic sectional view of a door pad having a filler padding partially different in thickness.

Figure 5a is a schematic sectional view of a door pad in which button-shaped portions are formed on and a welt-shaped member of separate body is welded to the surface of a surface layer.

Figure 5b is a perspection view of a welt-shaped member.

Figure 5c is a perspective view of a welt-shaped member in another contour.

Detailed description of preferred embodiments This invention will be described in detail with reference to embodiments of door pad and method for manufacturing the same shown in Figures 2 to 5c of the accompanying drawings, and prior arts other than the ones already mentioned above will be further described there for comparison.

Referring now to Figure 2, there is shown therein a door pad according to this invention. The door pad shown in Figure 2 is manufactured by utilization of the ultrasonic vibration-exothermic fusion process which is quite different from the prior arts, because normal polyurethane can not be exothermically fused by means of a dielectric loss caused by a high frequency current or another heating means, as mentioned in the above.

The door pad manufacturing method according to this invention comprises the steps of arranging ultrasonic machining horns 4 at weld portions 2a and ultrasonic machining horn rests Son the back side of a backing board 3 (such as a hard board), and causing the ultrasonic machining horns 4 to vibrate, while a surface layer 1, a filler padding 2 and the backing board 3 are being pressed and compressed, and transmitting the ultrasonic vibration to the surface layer 1, filler padding 2 and backing board 3 so that the filler padding 2 made of normal polyurethane is mainly fused through the vibration of each of these layers and the surface layer 1, filler padding 2 and backing board are bonded.In such a case that the surface of the backing board 3 to be contacted with the filler padding 2, to which vibration is applied, and/or the surface layer 1 are fusible due to their selected materials and the given conditions of vibration, the surface layer 1, filler padding 2 and backing board 3 will be bonded more strongly by heat produced with the ultrasonic vibration.

Figure 3 shows another embodiment of door pad according to this invention. In the door pad shown in Figure 5, the surface layer 1 is fixed on the back side of the backing board 3, with both its terminating ends la covering the circumference of the backing board 3.

In accordance this invention, all the circumferences of the terminating ends Ia of the surface layer 1 are welded on the backing board 3 by means of the ultrasonic machining horns 4A and the ultrasonic machining horn rests 5A wider in area, attached on the top side of the surface layer 1, although in the prior arts, the terminating ends 1 a have been hitherto fixed thereon by the driving of metal fasteners by a tacker or the adhesion with an adhesive. In this case of door pad shown in Figure 3, one of the surface of the backing board 3 in contact with the terminating ends la and the surfaces of the terminating ends 1 a in contact with the backing board 3, or both of these surfaces are welded and bonded.

Since the width and area of the ultrasonic machining horn rests 5A are larger than those of the ultrasonic machining horns 4A as shown in Figure 3, the dents forced by the ultrasonic machining horn rests 4A or ultrasonic machining horns 5A are not remaining on the top side of the surface layer 1. In addition, although not illustrated, the ultrasonic machining horns 4A and the ultrasonic machining horn rests 5A may be used in the state of several divided parts, not in one block.

With reference to Figure 4 showing a further embodiment of this invention, reference numeral 2A indicates a polyurethane molding or partially lamin ated filler padding. This filler padding 2A is partially different in thickness. When a high frequency current was caused to pass in order to partially weld a surface layer 1 at the weld portion 2b in the thick portion of a filler padding 2A in the prior high frequency heating process, it passed through all the region under the weld portion 2b, resulting in the fusion of all the region. In the prior process, namely, the fusion of only the surface layer 1 was impossible and the region under the weld portion 2b was often cut.

In the door pad manufacturing method according to this invention, the weld portion 2b is partially fused in the longitudinal direction by means of the ultrasonic machining horn 4.

Figures 5a, Sb and 5c show further embodiments according to this invention, in which button-shaped portions 2C are formed on and a welt-shaped member 6 of separate body is welded to the top surface of the surface layer 1.

The button-shaped portion 2C shown in Figure 5a is formed by partially fusing the filler padding 2A by use of a button-like shape-imparting ultrasonic machining horn (not shown) so that a portion of the surface layer 1 is made to be in the shape of a button.

Figure 5b is a perspective view of a welt-shaped member 6. Although not illustrated, the welt-shaped member 6 may have a welt core covered therewith.

Figure 5c shows another welt-shaped member 6A which is different in contour from the welt-shaped member 6 shown in Figure 5b, and this welt-shaped member 6A is in the form of a tap in that both the side ends of the welt-shaped member 6 are not folded inward. The welt-shaped member 6 or 6A is welded to the surface layer 2 by use of an ultrasonic machining horn (not shown).

The surface layer 1 and the welt-shaped member 6 shown in Figure 5b or the surface layer 1 and the welt-shaped member 6A shown in Figure 5c may be made of different materials or in distinct contours, and further may have various colors and patterns in combination. In addition, a surface layer 1 which is divided under the welt-shaped member 6 or 6A may be used, and these divided portions will be welded and fixed by the welt-shaped member 6 or 6A.

The embodiments, in all of which a hard board is used as the backing board 3, has been described in the above. Further, although not illustrated, a plastic molding or the like made by the injection or any other suitable molding of a plastic can be also used as the backing board 3. Also in the case that such a plastic molding is used as the backing board 3 instead of said hard board, it is capable to weld the surface layer 1 and the same plastic molding as the backing board 3, for example by partially fusing the filler padding 2 or 2A in the longitudinal direction or fusing the whole thereof when required, through the ultrasonic welding process rather than the prior high frequency heating process, as already mentioned in the above.

By the door pad manufacturing method according to this invention, it can be realized to use normal polyurethane excellent in physical properties and cheap in price, which could not be hitherto used, as the filler padding or polyurethane molding.

According to this invention, the surface layer of a door pad can be formed into desired shapes such as a button-like shape by partially fusing the top surface side of the filler padding or the polyurethane molding or partially laminated filler padding.

Furthermore, although not illustrated, according to this invention, portions for attaching the backing board 3 onto the body of a vehicle door can be directly welded on the backing board 3 itself, but these portions have been hitherto fixed on the backing board 3 by screws or other means.

The above-mentioned technique is not to be limited to a door pad, but it can be widely applied to vehicle seats, other interior parts for vehicles, furnitures or the likes.

While the invention has been shown and described with respect to the particular embodiments of door pad, it will be understood that various modification may be effected without departing from the spirit and scope of the concepts of this invention.

Claims

1. A door pad manufactured by ultrasonic welding, which comprises a laminate consisting of a surface layer material, a filler padding or polyurethane molding made of normal polyurethane which is not subjected to any treatment and a backing board, wherein desired portions of said laminate are fusion-bonded by heat produced therein by ultrasonic vibration.

2. A door pad, as set forth in Claim 1, in which the filler padding or polyurethane molding is partially fused in the longitudinal direction between weld portions and the backing board to weld the surface layer to the filler padding.

3. A door pad, as set forth in Claim 1, in which button-shaped portions are formed on or weltshaped members are welded to the surface layer.

4. A door pad, as set forth in Claim 1, in which the terminating ends of the surface layer are welded on the back side of the backing board, enclosing the backing board.

5. A method for manufacturing a door pad by the application of ultrasonic wave, which comprises the steps of putting a surface layer material, a filler padding or polyurethane molding made of normal polyurethane which is not subjected to any previous treatment and a backing board, in a laminated state, between ultrasonic machining horns and ultrasonic machining horn rests, and applying ultrasonic vibration to desired portions of said laminate by the ultrasonic machining horns, while a force is being imparted thereon, whereby the desired portions of the laminate are fusion-bonded by heat produced therein.

6. A method, as set forth in Claim 5, in which said filler padding or polyurethane molding is fused partially in the longitudinal direction between weld portions and the surface layer, thereby to weld the surface layer thereto.

7. A method, as set forth in Claim 5, in which button-shaped portions are formed on the top surface of the surface layer or welt-shaped members are welded on the surface layer.

8. A method, as set forth in Claim 5, in which the terminating ends of the surface layer are welded on the back side of said backing board, enclosing the backing board.

9. A door pad as set forth in Claim 1, and substantially as hereinbefore described with reference to, and as shown in any one of the embodiments illustrated in the accompanying drawings.

10. A method as set forth in Claim 5, and substantially as hereinbefore described with reference to, and as shown in any one of the embodiments illustrated in the accompanying drawings.