JP6534181B2 - 自動車用内装部品 - Google Patents

自動車用内装部品 Download PDF

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Publication number
JP6534181B2
JP6534181B2 JP2018536657A JP2018536657A JP6534181B2 JP 6534181 B2 JP6534181 B2 JP 6534181B2 JP 2018536657 A JP2018536657 A JP 2018536657A JP 2018536657 A JP2018536657 A JP 2018536657A JP 6534181 B2 JP6534181 B2 JP 6534181B2
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Japan
Prior art keywords
laser beam
cutting
pet
film
stitch
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Expired - Fee Related
Application number
JP2018536657A
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English (en)
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JPWO2018042645A1 (ja
Inventor
広道 中川
広道 中川
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Kasai Kogyo Co Ltd
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Kasai Kogyo Co Ltd
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Publication of JPWO2018042645A1 publication Critical patent/JPWO2018042645A1/ja
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • 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
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/40—Applying molten plastics, e.g. hot melt
    • B29C65/405—Applying molten plastics, e.g. hot melt characterised by the composition of the applied molten plastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/30—Organic material
    • B23K2103/42—Plastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36—Removing material
    • B23K26/38—Removing material by boring or cutting
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1648—Laser beams characterised by the way of heating the interface radiating the edges of the parts to be joined
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • B29C65/62—Stitching
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/74—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area
    • B29C65/747—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using other than mechanical means
    • B29C65/7473—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using other than mechanical means using radiation, e.g. laser, for simultaneously welding and severing
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
    • B29C66/137—Beaded-edge joints or bead seals
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/22—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being in the form of recurring patterns
    • B29C66/221—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being in the form of recurring patterns being in the form of a sinusoidal wave
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/303—Particular design of joint configurations the joint involving an anchoring effect
    • B29C66/3034—Particular design of joint configurations the joint involving an anchoring effect making use of additional elements, e.g. meshes
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/532—Joining single elements to the wall of tubular articles, hollow articles or bars
    • B29C66/5326—Joining single elements to the wall of tubular articles, hollow articles or bars said single elements being substantially flat
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B29C66/712—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined the composition of one of the parts to be joined being different from the composition of the other part
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7212—Fibre-reinforced materials characterised by the composition of the fibres
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/723—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/729—Textile or other fibrous material made from plastics
    • B29C66/7294—Non woven mats, e.g. felt
    • B29C66/72941—Non woven mats, e.g. felt coated
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/82—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps
    • B29C66/826—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps without using a separate pressure application tool, e.g. the own weight of the parts to be joined
    • B29C66/8266—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps without using a separate pressure application tool, e.g. the own weight of the parts to be joined using fluid pressure directly acting on the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/90—Measuring or controlling the joining process
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    • B29C66/929—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools characterized by specific pressure, force, mechanical power or displacement values or ranges
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    • B29C66/90—Measuring or controlling the joining process
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    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
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    • B29K2023/06—PE, i.e. polyethylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29K2077/00—Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
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Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
  • Laminated Bodies (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Plasma & Fusion (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Description

本発明は、樹脂芯材の表面に表皮材を接合してなる自動車用内装部品に関し、特に、自動車用内装部品全体としての部品点数や製造工数の削減、並びに、自動車用内装部品製造ラインの完全自動化に好適なものである。
従来、この種の自動車用内装部品としては、樹脂芯材の表面に表皮材を接合した構造のもの、例えばドアトリムが知られており、このような構造の自動車用内装部品は、表皮材側が意匠面として自動車室内側に配置されるようにして、当該自動車の車体パネルに取付けられる。
また、前記のような従来の自動車用内装部品では、その表皮材側が意匠面として自動車室内側に配置されるため、自動車室内側から見た見栄えの向上を図る等の観点から、表皮材にステッチが形成される場合もある（例えば、特許文献１を参照）。このステッチは表皮材を糸で縫うことによって表皮材に形成してある。
ところで、前記のようなステッチを備えた表皮材を用いて従来の自動車用内装部品、例えばドアトリムを製造する工程は、樹脂芯材の表面に表皮材を接合する工程と、接合された樹脂芯材と表皮材からなるドアトリム用素材の不要部分をカット切断する、いわゆるトリミング加工を行う工程とを含んでいる。
図３（ａ）は従来の自動車用内装部品の製造に用いられる表皮材（樹脂芯材に接合される前の状態）の平面図、同図（ｂ）は説明の便宜上同図（ａ）のステッチに沿って表皮材を切断した状態の断面図、同図（ｃ）は従来の自動車用内装部品の製造工程におけるトリミングにより表皮材とステッチを切断したときの切断面の模式図である。
従来の自動車内装部品の製造に用いられる表皮材３（ステッチ４を備えるもの）は、前述のトリミング加工により、図３（ｃ）のようにステッチ４を構成する糸４Ａ、４Ｂが途中で切断され、糸のほつれが生じ易くなるため、トリミング加工の後に、切断された糸４Ａ、４Ｂの端を図３（ａ）（ｂ）のようにテープＴで固定している。
図３（ａ）に示されたステッチ４は、ミシン装置での縫製によって形成されたものであり、同図（ｂ）のように上下の糸４Ａ、４Ｂ（上糸と下糸）が表皮材３の厚み方向中央付近で係合した形態になっている。このため、前述のテープＴでの固定作業では、トリミング加工によって同図（ｃ）のように切断された上下の糸４Ａ、４Ｂのうち、上側の糸４Ａを表皮材３の裏面側に手作業で引き込み、これらの糸４Ａ、４Ｂを表皮材３の裏面で一箇所にまとめてテープＴで固定している。
しかし、従来の自動車用内装部品では、前記の通り、トリミング加工によって切断された糸４Ａ、４Ｂの端をテープＴで固定するというテーピング方式を採用している。このため、自動車用内装部品の構成部材として当該テープＴが必要となる分、自動車用内装部品全体としての部品点数が多くならざるを得ない。また、前述した手作業での糸４Ａの引き込み作業や、当該テープＴによる固定作業が必要となる点で、自動車用内装部品全体としての製造工数も多くならざるを得ないし、この種の自動車用内装部品の製造ラインを完全自動化（フルオートメーション化）することもできないという問題点がある。
実用新案登録第３１８４８０７号公報
本発明は、前記問題点を解決するためになされたものであり、その目的は、自動車用内装部品全体としての部品点数や製造工数の削減、並びに、自動車用内装部品製造ラインの完全自動化に好適な自動車用内装部品とその製造方法を提供することである。
前記目的を達成するために、物の発明としての本発明は、樹脂芯材の表面に表皮材を接合してなる自動車用内装部品であって、前記表皮材を糸で縫うことによって前記表皮材に形成されたステッチを備え、前記樹脂芯材と前記表皮材と前記ステッチがレーザー光線で切断された状態になっていること、および、そのレーザー光線による切断面付近は、前記ステッチを構成する糸と前記表皮材を構成する素材とが前記レーザー光線の熱で溶融し混じり合って固化した状態の組織構造になっていることを特徴とする。
前記本発明（物の発明）において、前記組織構造は、下記《条件》を満たすことによって得られたものであることを特徴としてもよい。
また、製造方法の発明としての本発明は、樹脂芯材の表面に表皮材を接合してなる自動車用内装部品の製造方法であって、前記樹脂芯材と前記表皮材とこの表皮材に糸で縫うことによって形成されたステッチとをレーザー光線で切断する工程を含み、前記レーザー光線による切断面付近で、前記ステッチを構成する糸と前記表皮材を構成する素材とが前記レーザー光線の熱で溶融し混じり合って固化した状態の組織構造が得られることを特徴とする。
前記本発明（製造方法の発明）において、前記組織構造は、下記《条件》を満たすことによって得られたものであることを特徴としてもよい。
《条件》
前記樹脂芯材の構成：ＰＥＴ不織布とグラスファイバー強化ＰＰ樹脂シートとＰＡフィルムまたはＰＰフィルム、ＰＥＴフィルム、ＰＥフィルムを積層した構造。
前記表皮材の構成：ＰＥＴ不織布と、ウレタン層と、ＰＥＴ表皮またはウレタン表皮、ＰＶＣ表皮を積層した構造。
前記糸の構成：ＰＥＴまたはＰＡ
前記レーザー光線による切断速度：３０mm/min〜３００００mm/min
前記レーザー光線を射出するレーザカットノズルから前記レーザー光線による切断の対象物までの距離：０．５mm〜５mm
前記レーザー光線の出力：３００W〜２０００W
前記レーザー光線による切断で用いるアシストガスの圧力：０．１kgf〜４kgf
本発明では、前記構成の採用により、表皮材とステッチはレーザー光線で切断された状態になっており、かつ、そのレーザー光線による切断面付近は、ステッチを構成する糸と表皮材を構成する素材とがレーザー光線の熱で溶融し混じり合って固化した状態の組織構造になっている。このため、そのような組織構造によって、レーザー光線で切断された糸の先端は安定に固定されているから、レーザー光線による切断でトリミング加工を行った場合の後処理、例えば従来のような手作業での糸の引き込み作業や、テープによる固定作業は不要であり、それらを全面的に廃止できる点で、自動車用内装部品全体としての部品点数や製造工数の削減、並びに、自動車用内装部品製造ラインの完全自動化に好適な自動車用内装部品とその製造方法を提供し得る。
図１（ａ）は本発明を適用した自動車用内装部品の製造に用いられる表皮材（樹脂芯材に接合される前の状態）の平面図、同図（ｂ）は説明の便宜上同図（ａ）のステッチに沿って表皮材を切断したときの切断面の模式図、同図（ｃ）は自動車用内装部品の製造工程において同図（ａ）のカットラインに沿ってレーザー光線で表皮材とステッチを切断したときの切断面の模式図。 樹脂芯材と表皮材を接合する前の分解断面図。 図３（ａ）は従来の自動車用内装部品の製造に用いられる表皮材（樹脂芯材に接合される前の状態）の平面図、同図（ｂ）は説明の便宜上同図（ａ）のステッチに沿って表皮材を切断した状態の断面図、同図（ｃ）は従来の自動車用内装部品の製造工程における刃物でのトリミングにより同図（ａ）のカットラインに沿って表皮材とステッチを切断したときの切断面の模式図。
以下、本発明を実施するための最良の形態について、添付した図面を参照しながら詳細に説明する。
図１（ａ）は本発明を適用した自動車用内装部品の製造に用いられる表皮材（樹脂芯材に接合される前の状態）の平面図、同図（ｂ）は説明の便宜上同図（ａ）のステッチに沿って表皮材を切断したときの切断面の模式図、同図（ｃ）は自動車用内装部品の製造工程において同図（ａ）のカットラインに沿ってレーザー光線で表皮材とステッチを切断したときの切断面の模式図である。
図１（ｃ）を参照すると、本実施形態の自動車用内装部品１は、樹脂芯材２の表面に表皮材３が接合された構造になっている。
図２を参照すると、前記接合前の樹脂芯材２は、ベース基材２Ａ（具体的にはグラスファイバー強化ＰＰ樹脂シート）の表面側に溶着用フィルム２Ｂ（具体的にはＰＡフィルムまたはＰＰフィルム、ＰＥＴフィルム、ＰＥフィルム）を貼付し、かつ、同ベース基材２Ａの裏面に接合面形成部材２Ｃ（具体的にはＰＥＴ不織布）を貼付した構造になっている。つまり、この樹脂芯材２は、ＰＥＴ不織布とグラスファイバー強化ＰＰ樹脂シートとＰＡフィルムまたはＰＰフィルム、ＰＥＴフィルム、ＰＥフィルムを積層した構造になっている。
前記接合前の表皮材３は、クッション材３Ａ（具体的にはウレタン層）の表面に加飾部材３Ｂ（具体的にはＰＥＴ表皮またはウレタン表皮、ＰＶＣ表皮）を貼付し、かつ、同クッション材３Ａの裏面に接合面形成部材３Ｃ（具体的にはＰＥＴ不織布）を貼付した構造になっている。つまり、この表皮材３は、ＰＥＴ不織布と、ウレタン層と、ＰＥＴ表皮またはウレタン表皮、ＰＶＣ表皮を積層した構造になっている。
そして、前記のような表皮材３のＰＥＴ不織布３Ｃと樹脂芯材２の溶着用フィルム２Ｂとを接触させる形で表皮材３と樹脂芯材２を重ね、それらを所定の圧力と温度で加圧および加熱すること、この加圧と加熱によって樹脂芯材２の溶着用フィルム２Ｂが溶融し表皮材３のＰＥＴ不織布３Ｃの網目に入り込んで固化することにより、樹脂芯材２と表皮材３は接合された状態になる。
また、本実施形態の自動車用内装部品１は、図１（ｃ）に示したように表皮材３を糸４Ａ、４Ｂで縫うことによって表皮材３に形成されたステッチ４を備えている。そして、樹脂芯材２と表皮材３とステッチ４はカットラインＣに沿ってレーザー光線で切断された状態（具体的には図１（ｃ）に示された表皮材３の右端を参照）になっており、また、そのレーザー光線による切断面ＣＳ付近は、ステッチ４を構成する糸４Ａ、４Ｂと表皮材３を構成する素材（前述の熱可塑性樹脂）とがレーザー光線の熱で溶融し混じり合って固化した状態の組織構造ＳＴになっている。
前記組織構造ＳＴは、下記《条件》を満たすことによって得られた。
《条件》
前記樹脂芯材の構成：ＰＥＴ不織布とグラスファイバー強化ＰＰ樹脂シートとＰＡフィルムまたはＰＰフィルム、ＰＥＴフィルム、ＰＥフィルムを積層した構造。
前記表皮材の構成：ＰＥＴ不織布と、ウレタン層と、ＰＥＴ表皮またはウレタン表皮、ＰＶＣ表皮を積層した構造。
前記糸の構成：ＰＥＴまたはＰＡ
前記レーザー光線による切断速度：３０mm/min〜３００００mm/min
前記レーザー光線を射出するレーザカットノズルから前記レーザー光線による切断の対象物までの距離：０．５mm〜５mm
前記レーザー光線の出力：３００W〜２０００W
前記レーザー光線による切断で用いるアシストガスの圧力：０．１kgf〜４kgf
レーザー光線の出力の下限値を前記のように３００Wとしたのは、前記のようなレーザー光線による切断速度や、表皮材の厚さ、糸の太さの設定条件下において、その出力の下限値を下回ると、ステッチ４の部分で樹脂芯材２と表皮材３と糸４Ａ、４Ｂとを全部一緒に切断することが困難となり、切断不良が発生し易くなるためである。
また、レーザー光線の出力の上限値を前記のように２０００Wとしたのは、前記のようなレーザー光線による切断速度や、表皮材の厚さ、糸の太さの設定条件下において、その出力の上限値を超えると、焦げが発生する等の不具合が生じ易くなるためである。
レーザー光線による切断速度の下限値を前記のように３０mm/minとしたのは、前記のようなレーザー光線の出力や、表皮材の厚さ、糸の太さの設定条件下において、その切断速度の下限値を下回ると、焦げが発生する等の不具合が生じ易くなるためである。
また、レーザー光線による切断速度の上限値を前記のように３００００mm/minとしたのは、前記のようなレーザー光線の出力や、表皮材の厚さ、糸の太さの設定条件下において、その切断速度の上限値を超えると、ステッチ４の部分で樹脂芯材２と表皮材３と糸４Ａ、４Ｂとを全部一緒に切断することが困難となり、切断不良が発生し易くなるためである。
表皮材３にステッチ４を形成する方法として、本実施形態の自動車用内装部品１ではミシン装置による縫製を採用したので、表皮材３に形成されたステッチ４は、上下の糸４Ａ、４Ｂ（上糸と下糸）が表皮材３の厚み方向中央付近で係合した形態になっているが、このような形態のステッチ４に限定されることはない。
樹脂芯材２を構成する素材は、表皮材３との接合に適した素材であればよく、そのように適した素材の中から必要に応じて適宜選択することができる。この一方、表皮材３を構成する素材やステッチ４を構成する糸４Ａ、４Ｂの素材については、前述のレーザー光線による切断によって組織構造ＳＴが得られるものに限定される。
前記のような構造からなる本実施形態の自動車用内装部品１は、下記《工程１》と《工程２》によって製造することができる。
《工程１》
工程１は、表皮材３と樹脂芯材２とを接合する工程である。この接合は、樹脂芯材２と表皮材３を重ねて接触させた状態で、それらを加圧および加熱することにより、樹脂芯材２の表面と表皮材３の裏面とを溶着させるというものである。
《工程２》
工程２は、前記工程１で接合した樹脂芯材２と表皮材３からなるドアトリム用素材の不要部分をカット切断する、いわゆるトリミング加工を行う工程であり、その切断ではレーザー光線が用いられる。
図１（ａ）および（ｂ）を参照すると、レーザー光線による切断のカットラインＣ上には前述のステッチ４が存在する。つまり、工程２では、樹脂芯材２と表皮材３とステッチ４をレーザー光線で切断することになる。
前記のような樹脂芯材２と表皮材３とステッチ４のレーザー光線による切断では、前述の《条件》が満たされるように設定される。これにより、レーザー光線による切断面ＣＳ付近では、ステッチ４を構成する糸４Ａ、４Ｂと表皮材３を構成する素材（前述の熱可塑性樹脂）とがレーザー光線の熱で溶融し混じり合って固化した状態の組織構造ＳＴが得られる。
以上説明した本実施形態の自動車用内装部品１とその製造方法にあっては、表皮材３とステッチ４はレーザー光線で切断された状態になっており、かつ、そのレーザー光線による切断面ＣＳ付近は、ステッチ４を構成する糸４Ａ、４と表皮材３を構成する素材とがレーザー光線の熱で溶融し混じり合って固化した状態の組織構造ＳＴになっている。このため、そのような組織構造ＳＴによって、レーザー光線で切断された糸４Ａ、４Ｂの先端は安定に固定されているから、レーザー光線による切断でトリミング加工を行った場合の後処理、例えば従来のような手作業での糸の引き込み作業や、テープによる固定作業は不要であり、それらを全面的に廃止できる点で、自動車用内装部品全体としての部品点数や製造工数の削減、並びに、自動車用内装部品製造ラインの完全自動化に好適である。
本発明は、以上説明した実施形態に限定されるものではなく、本発明の技術的思想内で当分野において通常の知識を有する者により多くの変形が可能である。
１ 自動車用内装部品
２ 樹脂芯材
３ 表皮材
４ ステッチ
４Ａ、４Ｂ 糸
Ｃ カットライン
ＣＳ レーザー光線による切断面
ＳＴ 組織構造
Ｔ 不織布テープ

Claims (4)

  1. 樹脂芯材の表面に表皮材を接合してなる自動車用内装部品であって、
    前記表皮材を糸で縫うことによって前記表皮材に形成されたステッチを備え、
    前記樹脂芯材と前記表皮材と前記ステッチがレーザー光線で切断された状態になっていること、および、そのレーザー光線による切断面付近は、前記ステッチを構成する糸と前記表皮材を構成する素材とが前記レーザー光線の熱で溶融し混じり合って固化した状態の組織構造になっていること
    を特徴とする自動車用内装部品。
  2. 前記組織構造は、下記《条件》を満たすことによって得られたものであること
    を特徴とする請求項１に記載の自動車用内装部品。
    《条件》
    前記樹脂芯材の構成：ＰＥＴ不織布とグラスファイバー強化ＰＰ樹脂シートとＰＡフィルムまたはＰＰフィルム、ＰＥＴフィルム、ＰＥフィルムを積層した構造。
    前記表皮材の構成：ＰＥＴ不織布と、ウレタン層と、ＰＥＴ表皮またはウレタン表皮、ＰＶＣ表皮を積層した構造。
    前記糸の構成：ＰＥＴまたはＰＡ
    前記レーザー光線による切断速度：３０mm/min〜３００００mm/min
    前記レーザー光線を射出するレーザカットノズルから前記レーザー光線による切断の対象物までの距離：０．５mm〜５mm
    前記レーザー光線の出力：３００W〜２０００W
    前記レーザー光線による切断で用いるアシストガスの圧力：０．１kgf〜４kgf
  3. 樹脂芯材の表面に表皮材を接合してなる自動車用内装部品の製造方法であって、
    前記樹脂芯材と前記表皮材とこの表皮材に糸で縫うことによって形成されたステッチとをレーザー光線で切断する工程を含み、
    前記レーザー光線による切断面付近で、前記ステッチを構成する糸と前記表皮材を構成する素材とが前記レーザー光線の熱で溶融し混じり合って固化した状態の組織構造が得られること
    を特徴とする自動車用内装部品における表皮材の製造方法。
  4. 前記組織構造は、下記《条件》を満たすことによって得られたものであること
    を特徴とする請求項３に記載の自動車用内装部品の製造方法。
    《条件》
    前記樹脂芯材の構成：ＰＥＴ不織布と、グラスファイバー強化ＰＰ樹脂シートと、ＰＡフィルムまたはＰＰフィルム、ＰＥＴフィルム、ＰＥフィルムを積層した構造。
    前記表皮材の構成：ＰＥＴ不織布と、ウレタン層と、ＰＥＴ表皮またはウレタン表皮、ＰＶＣ表皮を積層した構造。
    前記糸の構成：ＰＥＴまたはＰＡ
    前記レーザー光線による切断速度：３０mm/min〜３００００mm/min
    前記レーザー光線を射出するレーザカットノズルから前記レーザー光線による切断の対象物までの距離：０．５mm〜５mm
    前記レーザー光線の出力：３００W〜２０００W
    前記レーザー光線による切断で用いるアシストガスの圧力：０．１kgf〜４kgf
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