JP6100853B2 - 圧縮成形と射出成形の併用により車両用トリム部品を製造するシステムおよび方法 - Google Patents
圧縮成形と射出成形の併用により車両用トリム部品を製造するシステムおよび方法 Download PDFInfo
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- JP6100853B2 JP6100853B2 JP2015185147A JP2015185147A JP6100853B2 JP 6100853 B2 JP6100853 B2 JP 6100853B2 JP 2015185147 A JP2015185147 A JP 2015185147A JP 2015185147 A JP2015185147 A JP 2015185147A JP 6100853 B2 JP6100853 B2 JP 6100853B2
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- 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
- B29C45/1418—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 inserts being deformed or preformed, e.g. by the injection pressure
-
- 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
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- 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
- B29C45/14336—Coating a portion of the article, e.g. the edge of the article
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3005—Body finishings
- B29L2031/3014—Door linings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3005—Body finishings
- B29L2031/302—Trim strips
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3005—Body finishings
- B29L2031/3041—Trim panels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/58—Upholstery or cushions, e.g. vehicle upholstery or interior padding
-
- 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
- Y10T428/19—Sheets or webs edge spliced or joined
- Y10T428/192—Sheets or webs coplanar
-
- 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
-
- 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
-
- 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
Description
本願は、2011年8月30日出願の米国仮出願第61/528,832号、「SYSTEM AND METHOD FOR MANUFACTURING A VEHICLE TRIM COMPONENT VIA CONCURRENT COMPRESSION FORMING AND INJECTION MOLDING(圧縮成形と射出成形の併用により車両用トリム部品を製造するシステムおよび方法)」による優先権と利益を主張し、その全体を本願にて参照することにより援用する。
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および/また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の型部材および第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および第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および第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 (25)
- 車両トリム部品の製造方法であって、
第1面、第2面、及び前記第1面から前記第2面まで延びる周囲面を含む繊維パネルを型の第1の表面に配置することと、
前記型の第1の表面と前記型の第2の表面との間で前記繊維パネルを圧縮することによって前記繊維パネルを、前記型の第1の表面の第1の輪郭と前記型の第2の表面の第2の輪郭に対応する形状を有する圧縮形成部品に形成することと、
前記圧縮形成部品が形成された後に前記型に樹脂を射出することによって前記繊維パネルの周囲面の少なくとも一部分のまわりに境界部を形成することと、
前記型の空洞部から前記車両トリム部品を除去することと
を含む車両トリム部品の製造方法。 - 前記車両トリム部品の補助的部品を形成するように前記圧縮形成部品と前記型の第2の表面との間に構造物を形成することを含む請求項1の車両トリム部品の製造方法。
- 前記繊維パネル内に前記繊維パネルの材料によって囲まれる間隙を形成することと、
前記圧縮形成部品の形成後に前記間隙に樹脂を射出することと
を含む請求項1の車両トリム部品の製造方法。 - 前記繊維パネルは複数の繊維及び熱可塑性樹脂を含む請求項1の車両トリム部品の製造方法。
- 前記繊維パネルは前記熱可塑性樹脂を少なくとも部分的に溶解する温度に加熱され、
前記繊維パネルは加熱された後に前記型に配置され、
前記繊維パネルが前記型の中で冷却されて前記熱可塑性樹脂が凝固することによって前記繊維パネルが前記圧縮形成部品に形成される請求項4の車両トリム部品の製造方法。 - 前記繊維パネルは複数の繊維及び熱硬化性樹脂を含む請求項1の車両トリム部品の製造方法。
- 前記型が前記熱硬化性樹脂を硬化するべく加熱されることによって前記繊維パネルが前記圧縮形成部品に形成される請求項6の車両トリム部品の製造方法。
- 前記圧縮形成部品の形状は前記繊維パネルのオリジナル形状とは異なる請求項1の車両トリム部品の製造方法。
- 繊維パネルを型の第1の表面に配置することは、
カバーストックを前記型の第1の表面に位置決めすることと、
前記繊維パネルを前記カバーストックに配置することと
を含む請求項1の車両トリム部品の製造方法。 - 前記カバーストックは前記繊維パネルに結合する請求項9の車両トリム部品の製造方法。
- 前記カバーストックは(a)織布、(b)不織布、(c)アップリケ、(d)ビニル、(e)発泡体、(f)フォイル、(g)皮革の内の少なくとも一つからなる請求項10の車両トリム部品の製造方法。
- 車両室内のためのトリム部品であって、
複数の繊維、及び前記繊維を結合するべく構成された第1樹脂を含む繊維パネルと、
第2樹脂を含む構造物と
を含み、
前記繊維パネルは、第1面、第2面及び周囲面を含み、
前記繊維パネルの周囲面は、前記繊維パネルの第1面から前記繊維パネルの第2面まで延び、
前記構造物は、前記繊維パネルの周囲面の少なくとも一部のまわりに形成された境界部を与えるトリム部品。 - 前記繊維パネルの周囲面は、前記構造物の境界部が形成されたエッジを含む請求項12のトリム部品。
- 前記構造物は、前記繊維パネルの少なくとも一つのエッジにおいて少なくとも一つのばらつきに適応するべく構成される請求項12のトリム部品。
- 前記車両室内の(a)ドアフレーム、(b)計器パネル又は(c)支持構造物の少なくとも一つと前記トリム部品との連結を促進するべく構成された(a)補助的部品、(b)リブ又は(c)コネクタの少なくとも一つをさらに含む請求項12のトリム部品。
- (a)前記繊維パネルを支持するべく、又は(b)前記繊維パネルの厚さ低減を促進することによって前記トリム部品の重量を低減するべく構成されたリブをさらに含む請求項12のトリム部品。
- 前記繊維パネルと前記構造物との界面を横切るように延びて前記界面の強度を向上させるべく構成されたリブをさらに含む請求項12のトリム部品。
- 前記第2樹脂から形成された前記構造物の境界部は、前記境界部において前記繊維パネルの周囲面まわりに寸法精度を与えるべく構成される請求項12のトリム部品。
- 車両室内のためのトリム部品であって、
複数の繊維、及び前記繊維を結合するべく構成された樹脂を含む繊維パネルと、
樹脂を含む構造物と
を含み、
前記繊維パネルは、第1面、第2面、及び前記繊維パネルの第1面から前記繊維パネルの第2面まで延びて前記繊維パネルの中に間隙を画定する内部表面を含み、
前記構造物の樹脂は、前記繊維パネルの間隙において前記繊維パネルを補強するべく構成されるトリム部品。 - 前記繊維パネルと前記構造物とは、連続する構造物を与えるべく構成される請求項19のトリム部品。
- 前記構造物は、前記繊維パネルの内部表面に沿って延びる低強度ゾーンを与えるべく構成される請求項19のトリム部品。
- 前記低強度ゾーンは、前記構造物が前記繊維パネルから分離されてエアバッグを展開させることを促進するべく構成される請求項21のトリム部品。
- 前記繊維パネルの間隙は、前記繊維パネルの裂け目を含み、
前記構造物は、連続する表面を形成するべく前記間隙を埋めるように構成される請求項19のトリム部品。 - 前記繊維パネルは第1曲率の第1曲面を含み、
前記構造物は、前記第1曲率とは異なる第2曲率の第2曲面を含み、
前記第1曲面と前記第2曲面とは連続するように構成される請求項19のトリム部品。 - 前記樹脂を含む構造物が、前記構造物を前記繊維パネルに形成するべく前記間隙の中に形成されて前記繊維パネルの第1面の少なくとも一部に沿って、かつ、前記繊維パネルの第2面の少なくとも一部に沿って延びる請求項19のトリム部品。
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WO2016077773A1 (en) * | 2014-11-14 | 2016-05-19 | Yangfeng Us Automotive Interior Systems I Llc | Vehicle trim component having cover and method for such manufacturing vehicle trim component via compression forming and injection molding |
WO2013142773A1 (en) * | 2012-03-23 | 2013-09-26 | Cutting Dynamics, Inc. | Composite structural component |
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