JP2017128123A - 車両トリム部品とその製造方法 - Google Patents
車両トリム部品とその製造方法 Download PDFInfo
- Publication number
- JP2017128123A JP2017128123A JP2017031956A JP2017031956A JP2017128123A JP 2017128123 A JP2017128123 A JP 2017128123A JP 2017031956 A JP2017031956 A JP 2017031956A JP 2017031956 A JP2017031956 A JP 2017031956A JP 2017128123 A JP2017128123 A JP 2017128123A
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- JP
- Japan
- Prior art keywords
- fiber panel
- mold
- resin
- fiber
- panel
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
- B29C45/14786—Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
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- Y10T428/24331—Composite web or sheet including nonapertured component
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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.]
- Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
- Y10T428/24322—Composite web or sheet
- Y10T428/24331—Composite web or sheet including nonapertured component
- Y10T428/24339—Keyed
-
- 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.]
- Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
- Y10T428/2481—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including layer of mechanically interengaged strands, strand-portions or strand-like strips
Abstract
【解決手段】型空洞部40の第1の表面38と第2の表面42との間で繊維パネル44を圧縮して、繊維パネル44を所望の形状に成形し、さらに、型空洞部40に樹脂を射出して、繊維パネル44に隣接する第1の表面38と第2の表面42との間の少なくとも1つの空隙を埋める車両用トリム部品の製造方法。
【選択図】図3
Description
本願は、その全体が本願に参照として組み入れられる2011年8月30日出願の「SYSTEM AND METHOD FOR MANUFACTURING A VEHICLE TRIM COMPONENT VIA CONCURRENT COMPRESSION FORMING AND INJECTION MOLDING」との名称の米国仮出願第61/528,832号の優先権及び利益を主張する。
型組立体には、繊維パネルを受け入れるように構成された第1の型部材と、繊維パネルを貫通して第1の型部材に繊維パネルを固定するように構成された複数のピンとを備えるものがある。ピンは、繊維パネルを所望の位置及び/又は向きに保持することにより、第2の型部材が第1の型部材に対して繊維パネルを圧縮し、所望形状の部品を形成することができる。残念ながら、これらピンは繊維パネルに不規則な空隙を残すので、質感がでこぼこの部品が形成されてしまう。また、第2の型部材は、第1の型部材から延伸するピンを収容するように構成された窪みを備えてもよい。第2の型部材に窪みを形成することにより、型組立体のコストや複雑性が増してしまう。
型組立体には、互いに合わせられて繊維パネルを所望の形状に圧縮するように構成された第1の型部材及び第2の型部材を備えるものがある。また、このような型組立体は、第1及び第2の型部材が互いに合わせられて繊維パネルを所望の寸法にトリミングする際に、繊維パネルを貫通するように構成されたトリムブレードを備えてもよい。残念ながら、型内トリムブレードを用いて繊維パネルを成形すると、パネルのエッジが弱くなり、寿命が短くなってしまう。
型組立体には、互に合わせられて繊維パネルを所望の形状に圧縮するように構成された第1の型部材と第2の型部材とを備えるものがある。例えば、第2の型部材は、繊維パネルを移動させて、第1の型部材に接触させてもよい。第1の型部材に対して第2の型部材がさらに移動すると、この動きが繊維パネルを所望の形状に圧縮する。また、第1の型部材にトリムブレードが取り付けられてもよく、第1及び第2の型部材が繊維パネルを圧縮するときに繊維パネルを所望の寸法にトリミングするように構成されてもよい。残念ながら、第2の型部材が繊維パネルを移動させて第1の型部材に接触させると、トリムブレードが繊維パネルの一部を引き裂いてしまい、繊維パネルの強度が低下したり、外観/質感が望ましくない車両用トリム部品が形成されたりする場合がある。また、繊維パネルがトリムブレードに引っかかっている間、第2の型部材が第1の型部材側に移動し続けると、繊維パネル内の張力が大きくなる場合がある。繊維パネルがトリムブレードから解放されると、解放された張力によって、繊維パネルが型組立体内で移動し、所望の位置/方向からずれてしまうことがある。
Claims (35)
- 繊維パネルを型空洞部の第1の表面に配置し、
型空洞部の第1の表面と第2の表面との間で繊維パネルを圧縮して、繊維パネルを所望の形状に成形し、
型空洞部に樹脂を射出して、繊維パネルに隣接する第1の表面と第2の表面との間の少なくとも1つの空隙を埋めること
を特徴とする車両用トリム部品の製造方法。 - 繊維パネルを型空洞部の第1の表面に配置する前に、繊維パネルの少なくとも1つのエッジを所望の寸法にトリミングすることを特徴とする請求項1に記載の方法。
- 繊維パネルを型空洞部の第1の表面に配置する前に、繊維パネルを加熱することを特徴とする請求項1に記載の方法。
- 前記繊維パネルは、複数の構造用繊維と、熱可塑性樹脂とにより構成され、繊維パネルの加熱において、熱可塑性樹脂を液化させるのに十分な温度に繊維パネルを加熱することを特徴とする請求項3に記載の方法。
- 前記繊維パネルは、複数の構造用繊維と、熱硬化性樹脂とにより構成され、繊維パネルの加熱において、熱硬化性樹脂を硬化させるのに十分な温度に繊維パネルを加熱することを特徴とする請求項3に記載の方法。
- 型空洞部に樹脂を射出し、繊維パネルと第2の表面の間の少なくとも1つの二次空隙を埋めて、車両用トリム部品の補助部品を形成することを特徴とする請求項1に記載の方法。
- 前記少なくとも1つの空隙は、繊維パネルと樹脂部品との重ね継ぎ部を形成するような形状とされることを特徴とする請求項1に記載の方法。
- 車両用トリム部品を型空洞部から取り外し、
車両用トリム部品にカバーストックを配置して、装飾面を形成すること
を特徴とする請求項1に記載の方法。 - 前記少なくとも1つの空隙は、繊維パネルの周囲の少なくとも一部に延在することを特徴とする請求項1に記載の方法。
- 前記少なくとも1つの空隙は繊維パネル内の間隙に対応し、前記間隙は繊維パネルの材料により封止されることを特徴とする請求項1に記載の方法。
- 繊維パネルを型空洞部の第1の表面に配置し、
型空洞部の第1の表面と第2の表面との間で繊維パネルを圧縮して、繊維パネルを所望の形状に成形し、
型空洞部に樹脂を射出して、繊維パネルに隣接する第1の表面と第2の表面との間の少なくとも1つの空隙を埋めること
を特徴とするプロセスにより作成される車両用トリム部品。 - 前記プロセスは、車両用トリム部品を型空洞部から取り外し、
車両用トリム部品にカバーストックを配置して、装飾面を形成すること
を特徴とする請求項11に記載の車両用トリム部品。 - 前記プロセスは、繊維パネルを型空洞部の第1の表面に配置する前に、繊維パネルの少なくとも1つのエッジを所望の寸法にトリミングすることを特徴とする請求項11に記載の車両用トリム部品。
- 前記プロセスは、繊維パネルを型空洞部の第1の表面に配置する前に、繊維パネルを加熱することを特徴とする請求項11に記載の車両用トリム部品。
- 前記プロセスは、型空洞部に樹脂を射出し、繊維パネルと第2の表面の間の少なくとも1つの二次空隙を埋めて、車両用トリム部品の補助部品を形成することを特徴とする請求項11に記載の車両用トリム部品。
- 繊維パネルを受け入れるように構成された第1の表面と、
第1の表面と第2の表面との間で繊維パネルを圧縮して、繊維パネルを所望の形状に成形するように構成された第2の表面と、
繊維パネルに隣接する第1の表面と第2の表面との間の空隙に樹脂を射出するように構成された少なくとも1つの流体通路と
を備えることを特徴とする車両用トリム部品を製造するための型空洞部。 - 前記少なくとも1つの空隙は、繊維パネルの周囲の少なくとも一部に延在することを特徴とする請求項16に記載の型空洞部。
- 前記少なくとも1つの空隙は繊維パネル内の間隙に対応し、前記間隙は繊維パネルの材料により封止されることを特徴とする請求項16に記載の型空洞部。
- 繊維パネルと第2の表面の間の二次空隙に樹脂を射出して、車両用トリム部品の補助部品を形成するように構成された少なくとも1つの二次流体通路を備えることを特徴とする請求項16に記載の型空洞部。
- 前記型空洞部は、繊維パネルを冷却して、繊維パネル内の熱可塑性樹脂、熱硬化性樹脂、あるいは、それらの組み合わせの硬化を容易にするように構成されることを特徴とする請求項16に記載の型空洞部。
- 繊維パネルを受け入れるように構成された第1の型部材と、
繊維パネルを貫通して第1の型部材に繊維パネルを固定するように構成された複数の保持ピンを有する後退可能なピン組立体と、
第1の型部材の第1の表面と第2の型部材の第2の表面との間で繊維パネルを圧縮して、繊維パネルを所望の形状に成形するように構成された第2の型部材とを備え、
前記後退可能なピン組立体は、第1の表面と第2の表面との間で繊維パネルを圧縮する前又は圧縮中に、繊維パネルから複数の保持ピンを引き抜くように構成されること
を特徴とする車両用トリム部品を製造するための型組立体。 - 前記後退可能なピン組立体は、複数のリターンピンと第2の型部材との接触を介して、複数の保持ピンを繊維パネルから後退移動させるように構成された複数のリターンピンを備えることを特徴とする請求項21に記載の型組立体。
- 前記複数の保持ピンと複数のリターンピンは、接続プレートによって互いに連結されることを特徴とする請求項22に記載の型組立体。
- 前記後退可能なピン組立体は、複数の保持ピンを延伸させて、繊維パネルに対する保持ピンの貫通を容易にするように構成されたアクチュエータを備えることを特徴とする請求項21に記載の型組立体。
- 前記複数の保持ピンのうちの1つにより形成される繊維パネル内の空隙に樹脂を射出するように構成された流体通路を備えることを特徴とする請求項21に記載の型組立体。
- 繊維パネルを受け入れるように構成された第1の型部材と、
第1の型部材の第1の表面と第2の型部材の第2の表面との間で繊維パネルを圧縮して、繊維パネルを所望の形状に成形するように構成された第2の型部材と、
繊維パネルの屈曲エッジの先端に樹脂が広がるように、屈曲エッジの隣接内表面に樹脂を射出するように構成された流体通路と
を備えることを特徴とする車両用トリム部品を製造するための型組立体。 - 前記型組立体において空隙を有し、前記空隙は、屈曲エッジの隣接内表面に近接して配置され、前記空隙は流体通路から樹脂を受け入れるように構成されることを特徴とする請求項26に記載の型組立体。
- 前記空隙は、繊維パネルの周囲に延在することを特徴とする請求項27に記載の型組立体。
- 前記空隙は、繊維パネルの屈曲エッジを支持する樹脂特徴部を形成するように構成されることを特徴とする請求項27に記載の型組立体。
- 繊維パネルが第1及び第2の表面の間で圧縮されるときに繊維パネルを所望の寸法にトリミングするように構成されたトリムブレードを備えることを特徴とする請求項26に記載の型組立体。
- 互いに合わせられて繊維パネルを所望の形状に圧縮するように構成された第1の型部材及び第2の型部材と、
第1及び第2の型部材が互いに合わせられて繊維パネルを所望の寸法にトリミングする際に、繊維パネルを貫通するように構成されたトリムブレードと、
第2の型部材に連結される浮遊コア組立体であって、トリムブレードが繊維パネルを貫通する前に第1の型部材の表面に対して繊維パネルを付勢するように構成された浮遊コア組立体と
を備えることを特徴とする車両用トリム部品を製造するための型組立体。 - 前記浮遊コア組立体は、第2の型部材に移動可能に連結されたコアを備え、前記コアは、延伸位置にあるときに第1の型部材の表面に対して繊維パネルを付勢するように構成され、前記コアは、コアと繊維パネルと第1の型部材の表面との接触より、後退位置に移動するように構成されることを特徴とする請求項31に記載の型組立体。
- 前記コアを延伸位置に付勢するように構成された付勢部材を備えることを特徴とする請求項32に記載の型組立体。
- 前記付勢部材はバネにより構成されることを特徴とする請求項33に記載の型組立体。
- 前記トリムブレードは第1の型部材に連結され、第2の型部材の支持表面が、トリムブレードに対して繊維パネルを移動させるように構成されることを特徴とする請求項31に記載の型組立体。
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