JP7805763B2 - Manufacturing method and manufacturing device for vehicle interior components - Google Patents

Description

This invention relates to a manufacturing method and manufacturing apparatus for vehicle interior components having a base material and a skin material.

Vehicle interior components such as instrument panels and floor consoles are arranged inside the passenger compartment of an automobile. The texture of vehicle interior components is improved by covering the surface of a base material formed into a required shape with a skin material. To further improve the texture, stitching is sometimes provided on the skin material (see, for example, Patent Document 1). In Patent Document 1, the skin material and base material are positioned by fitting a bulge in the skin material where the stitching will be formed into a recess provided in the base material.

Patent No. 5813415

If the skin material shifts from the base material, the appearance of the stitching in vehicle interior components will deteriorate, so there is a need to position the skin material with greater precision.

The present invention was proposed in light of the above-mentioned problems associated with the prior art, and aims to provide a method and apparatus for manufacturing vehicle interior components with attractive stitching.

In order to overcome the above problems and achieve the intended object, the manufacturing method of the vehicle interior member according to the present invention comprises:
The skin material having the stitches is positioned by aligning the stitches with the indicator formed by the light irradiation and set in the skin material setting section;
The gist of the method is to bond the substrate set in the substrate setting section to the skin material.

In order to overcome the above problems and achieve the intended object, the manufacturing apparatus for a vehicle interior member according to the present invention comprises:
a skin material setting unit for setting the skin material;
a light emitting unit that forms an index for aligning stitches provided on the skin material;
a substrate setting unit for setting the substrate,
The skin material setting section and the base material setting section are configured to move forward and backward relative to each other.

According to the method for manufacturing a vehicle interior member of the present invention, a vehicle interior member having stitches with a good appearance can be obtained.
According to the manufacturing device for vehicle interior components of the present invention, vehicle interior components having stitches with good appearance can be obtained.

1 is a plan view showing a vehicle interior member according to an embodiment of the present invention; 1 is a cross-sectional view showing a vehicle interior member according to an embodiment of the present invention. 1A to 1C are explanatory diagrams showing a manufacturing process using the manufacturing apparatus of the embodiment. 1A to 1C are explanatory diagrams showing a manufacturing process using the manufacturing apparatus of the embodiment. 1A to 1C are explanatory diagrams showing a manufacturing process using the manufacturing apparatus of the embodiment. 1A to 1C are explanatory diagrams showing a manufacturing process using the manufacturing apparatus of the embodiment.

Next, a preferred embodiment of the manufacturing method and manufacturing apparatus for vehicle interior components according to the present invention will be described below with reference to the accompanying drawings.

As shown in Figures 1 and 2, the vehicle interior member 10 comprises a base material 12 and a skin material 14 placed on top of the base material 12. The vehicle interior member 10 is a multi-layered plate-like body in which the base material 12 and the skin material 14 are joined with an adhesive or the like and overlap in the thickness direction (front-to-back direction). While a simple shape is shown as an example of the vehicle interior member 10 in the embodiment, it may also have a three-dimensional shape with curved edges, curved in the front-to-back direction, or a combination of these.

As shown in Figures 1 and 2, the vehicle interior member 10 includes stitches 16. In the embodiment, the stitches 16 are composed of multiple seams formed by sewing the upholstery material 14 with thread. The stitches 16 appear on both the front and back surfaces of the upholstery material 14. The stitches 16 are provided along the edge of the vehicle interior member 10. In the embodiment, the stitches 16 are single stitches in which multiple seams are lined up along the longitudinal edge of the vehicle interior member 10 (sometimes referred to as the reference edge when specifically distinguished). The stitches 16 are also located near the reference edge. The vehicle interior member 10 in the embodiment has a design that simulates stitching with the stitches 16 to another vehicle interior member installed adjacent to the reference edge. Note that the stitches 16 may be formed by embossing the upholstery material 14 to simulate a seam. Even in this case, it is preferable to provide the back surface of the upholstery material 14 with an embossed shape or other shape that corresponds to the stitches 16.

As shown in FIG. 2, the substrate 12 is placed on the vehicle body side (back side) of the vehicle interior member 10. The substrate 12 forms the base of the vehicle interior member 10. The substrate 12 is formed from a hard resin molded product. For example, the substrate 12 can be formed from thermoplastic resins such as polypropylene (PP), polyethylene (PE), acrylonitrile butadiene styrene resin (ABS), and polycarbonate/acrylonitrile butadiene styrene resin (PC/ABS).

As shown in FIG. 2, the skin material 14 is disposed on the passenger compartment side (front side) of the vehicle interior member 10. The skin material 14 is the decorative surface of the vehicle interior member 10. The edges of the skin material 14 are folded back onto the back side of the base material 12. The skin material 14 can be a molded resin product that is softer than the base material 12. The skin material 14 may have a single-layer structure, or a multi-layer structure having a skin layer that forms the front side of the vehicle interior member 10 and a cushion layer provided on the back side of the skin layer. For example, the skin layer can be made of a flexible solid synthetic resin, and the cushion layer can be made of an elastic foam. The skin layer can be formed, for example, from a thermoplastic elastomer. Examples of thermoplastic elastomers that can be used include olefin-based elastomers (TPO), vinyl chloride-based elastomers, and styrene-based elastomers. Of these, olefin-based elastomers obtained by dispersing rubber such as ethylene-propylene rubber (EPDM, EPM) in olefin-based resins such as polypropylene (PP) are preferred. For the cushion layer, olefin-based materials such as polyethylene and polypropylene, or foamed polyurethane or styrene can be used, with polyethylene foam (PEF) being preferred.

In the embodiment, the base material 12 is formed flat at the position corresponding to the stitch 16, and does not have any recesses or other shapes for positioning the stitch 16. To align the base material 12 and the skin material 14, alignment shapes such as concave and convex shapes may be provided on the base material 12 or the skin material 14, but alignment shapes do not have to be provided as in the embodiment.

As shown in Figures 3 to 6, the manufacturing apparatus 20 for a vehicle interior member 10 according to the embodiment includes a substrate setting unit 22 for setting the substrate 12, and a skin setting unit 24 for setting the skin 14. The manufacturing apparatus 20 also includes a light irradiation unit 26 for forming an index 27 for aligning the stitches 16 on the skin 14. The substrate setting unit 22 and the skin setting unit 24 are configured to be movable back and forth relative to each other. In the embodiment, the substrate setting unit 22 is positioned above the skin setting unit 24, and the substrate setting unit 22 moves back and forth relative to the skin setting unit 24.

As shown in Figures 4 to 6, the substrate setting unit 22 holds the substrate 12 with its front surface facing downward (toward the skin material setting unit 24) and can move back and forth while maintaining this holding state. The substrate setting unit 22 holds the substrate 12 by engaging with an attachment portion (not shown) provided on the back surface of the substrate 12 to attach the vehicle interior component 10 to the vehicle body, or by adsorbing the substrate 12 using negative air suction pressure. The manufacturing apparatus 20 is equipped with a folding actuator 28 attached to the substrate setting unit 22 and operating the skin material folding unit 34 described below. The folding actuator 28 includes a cylinder 28a operated by air pressure or the like, and an actuator piece 28b moved back and forth by the cylinder 28a. The folding actuator 28 moves back and forth together with the substrate setting unit 22 as a whole. In the embodiment, the actuator piece 28b moves back and forth in the same vertical direction as the substrate setting unit 22.

As shown in Figure 3, the covering material setting unit 24 is equipped with a setting table 24a formed to fit the surface of the substrate 12. The setting table 24a is movable up and down, the same direction as the substrate setting unit 22. The setting table 24a is pushed down from the covering material setting position by the substrate setting unit 22. When the substrate setting unit 22 retreats upward, the setting table 24a returns to the covering material setting position by a biasing means such as a spring (not shown).

As shown in FIG. 3 , the manufacturing apparatus 20 includes multiple light irradiators 26. The light irradiators 26 are installed around the setting table 24a of the upholstery material setting unit 24. The light irradiators 26 irradiate light toward a predetermined position on the setting table 24a to form an indicator 27 indicating the placement position of the stitch 16. The light irradiators 26 irradiate light in a line shape (in the present embodiment) or a dot shape. The multiple light irradiators 26 each irradiate light at a different position, forming the indicator 27 in the form of multiple divided lines. In the present embodiment, the light irradiator 26 includes a light source that irradiates a line-shaped laser beam. The light irradiator 26 includes a slit in front of the light source, allowing the length of the projected light line to be adjusted by shortening the distance between the light source and the slit or lengthening the length by increasing the distance between the light source and the slit. While red or green laser beams can be used, red is preferred from the perspective of making the indicator 27 easier to see.

The covering material setting unit 24 is equipped with a holding means 30 that holds a predetermined portion of the covering material 14 stacked on top of the setting table 24a. The holding means 30 holds the portion of the covering material 14 placed on the setting table 24a that is not adjacent to the stitches 16. The holding means 30 does not hold the portion of the covering material 14 that corresponds to the stitches 16. In this embodiment, the holding means 30 holds the covering material 14 by using a suction pump 30a to create negative pressure by sucking air from multiple suction holes 30b provided in the setting table 24a. In this embodiment, the holding means 30 can select the suction holes 30b from which to suck air. For example, in the setting table 24a, the row of suction holes 30b on the reference edge side is not used to suck air, and the row of suction holes 30b away from the reference edge is used to suck air, thereby holding the portion of the covering material 14 that is not adjacent to the stitches 16.

As shown in Figures 3 to 6, the manufacturing apparatus 20 is provided with positioning units 32 attached to the skin material setting unit 24, which position the skin material 14 placed on the setting table 24a. The positioning units 32 are arranged around the periphery of the setting table 24a. In this embodiment, multiple positioning units 32 are provided along the side of the setting table 24a where the reference edge is located. In addition, positioning units 32 are also provided on the side of the setting table 24a where the edge that intersects with the reference edge is located.

As shown in Figures 4 to 6, the manufacturing apparatus 20 is equipped with a skin material folding unit 34 attached to the skin material setting unit 24, which folds the end of the skin material 14 toward the back side of the substrate 12. The skin material folding unit 34 is movable between a retracted position where it is separated from the setting table 24a and an operating position where it overlaps the upper side of the setting table 24a. The skin material folding unit 34 moves from the retracted position to the operating position when the operating piece 28b of the folding operating unit 28 presses the operating piece 28a against the operating piece 34b. When the operating piece 28b of the folding operating unit 28 retracts from the operating piece 34a, the skin material folding unit 34 returns from the operating position to the retracted position by a biasing means such as a spring (not shown).

Next, a method for manufacturing a vehicle interior member 10 according to an embodiment using the manufacturing apparatus 20 described above will be described. A base material 12 is prepared, molded into a predetermined shape by a molding method such as injection molding. A skin material 14 is prepared, formed into a predetermined shape by a cutting process such as a Thomson die. The skin material 14 is then sewn at predetermined locations with a sewing machine to form stitches 16. The skin material 14 is formed to be larger than the base material 12.

The covering material 14 is placed on the setting table 24a at the covering material setting position (see Figures 3(a) and 4(a)). The back side of the covering material 14 faces upward. At this time, the edge of the covering material 14 that extends beyond the setting table 24a is abutted against the positioning members 32 around the setting table 24a to roughly align it (see Figures 3(b) and 4(b)). Next, the covering material 14 is moved on the setting table 24a to align it so that the stitches 16 overlap the indicators 27 formed by the light emitted from the light irradiation unit 26. At this time, the holding means 30 is not operating. Once the covering material 14 has been positioned by overlapping the stitches 16 with the indicators 27, the holding means 30 is operated to hold the portion of the covering material 14 that is not covered by the stitches 16 in the covering material setting unit 24. As a result, the skin 14 is held by the set table 24a on the side opposite the reference edge of the main body portion that overlaps the surface of the base material 12, restricting its movement. The end of the skin 14 that protrudes from the reference edge of the main body portion and the set table 24a remains free.

Adhesive is applied to the front surface of the substrate 12 and to the area on the back surface of the substrate 12 where the folded-over skin material 14 will overlap. The substrate 12 is then set in the substrate setting unit 22 with the front surface facing downwards. The substrate setting unit 22 holds the back surface of the substrate 12. At this time, the front surface of the substrate 12 is exposed, and the area on the back surface of the substrate 12 where the folded-over skin material 14 will overlap is also exposed. Note that either the substrate 12 or the skin material 14 can be set in the manufacturing apparatus 20 first.

The substrate setting unit 22, on which the substrate 12 has been set, is lowered, and the front surface of the substrate 12 is pressed against the back surface of the skin material 14 set in the skin material setting unit 24 (see Figure 5(a)). As the substrate setting unit 22 is further lowered, the setting table 24a is lowered (see Figure 5(b)). As the setting table 24a is lowered, the end of the skin material 14 that protrudes from the substrate 12 rises up (see Figure 5(b)).

The cylinder 28a of the folding actuator 28, which is descending along with the substrate setting unit 22, is actuated to lower the operating piece 28b (see Figure 6(a)). The operating piece 28b contacts the operating support piece 34a, and the skin folding unit 34 moves from the retracted position toward the operating position, guided by the sloped surfaces at the tips of the operating piece 28b and the operating support piece 34a. This causes the end of the skin 14 to fold back onto the back surface of the substrate 12 (see Figure 6(a)).

The cylinder 28a of the folding actuator 28 is actuated to raise the operating piece 28b. As the operating piece 28b moves away from the operating receiving piece 34a, the skin folding portion 34 returns from the operating position to the retracted position. The holding means 30 releases the skin 14. As the substrate setting section 22 is raised, the vehicle interior component 10 rises along with the substrate setting section 22 (see Figure 6(b)). The vehicle interior component 10 is then removed from the substrate setting section 22. This results in a vehicle interior component 10 in which the substrate 12 and the skin 14 are joined together.

The covering material 14 is positioned by aligning the stitching 16 with the indicator 27 formed by light irradiation, and then set in the covering material setting section 24. The substrate 12 set in the substrate setting section 22 and the covering material 14 are then joined. This allows the stitching 16 to be precisely positioned in the vehicle interior member 10. When the stitching 16 extends along the reference edge of the vehicle interior member 10, as in the embodiment, the stitching 16 can be precisely positioned to align with the reference edge, improving the appearance of the vehicle interior member 10. Furthermore, since the covering material 14 can be positioned before the substrate 12 and the covering material 14 are overlapped, fine adjustments to the position of the covering material 14 can be easily made. Furthermore, even if adhesive is applied to the substrate 12 or the covering material 14, this does not affect the positioning of the covering material 14. If the covering material 14 is aligned while overlapping the substrate 12, pre-application of adhesive would make it difficult to shift and adjust the covering material 14.

If the entire covering material 14 is held by the covering material setting unit 24, depending on the shape of the substrate 12, it may be difficult to align the covering material 14 to the shape of the substrate 12 when the substrate 12 and the covering material 14 are overlapped, which may result in wrinkles or misalignment of the stitches 16. Furthermore, if the stitches 16 of the covering material 14 are aligned with the index 27 and then held by the covering material setting unit 24, the stitches 16 may be misaligned from the index 27, causing visual confusion for the worker. In particular, if the substrate 12 has a curved shape, the above-mentioned problems, such as wrinkles or misalignment of the stitches 16, are more likely to occur when the covering material 14 is aligned to the shape of the substrate 12. As described above, after positioning the covering material 14, the portions of the covering material 14 that are not aligned with the stitches 16 are held by the covering material setting unit 24. This makes it easier to align the skin material 14 with the base material 12 when the base material 12 and the skin material 14 are overlapped and joined together. This allows the stitches 16 to be positioned accurately in the vehicle interior member 10, improving the appearance of the vehicle interior member 10. In this case, when positioning the skin material 14 in the skin material setting section 24, it is sufficient to form the indicators 27 in advance, taking into account deformation of the skin material 14 when bonding.

As mentioned above, the indicator 27 is formed as a line divided into multiple segments. In this way, even if the stitch 16 is curved, the upholstery material 14 can be positioned based on the multiple divided indicators 27.

(Example of change)
The present invention is not limited to the above-mentioned items, and may be, for example, as follows: Note that the present invention is not limited to the specific descriptions of the examples and the following modified examples.
(1) The means for joining the base material and the skin material is not limited to adhesives such as hot melt, but may be ultrasonic welding or other means.
(2) Examples of vehicle interior components include instrument panels, floor consoles, door trims, pillar garnishes, and other components that are installed in the passenger compartment of a vehicle.
(3) The skin material setting section is not limited to holding only the portion of the skin material that is separated from the stitches. Depending on the shape of the base material, the skin material setting section may hold the entire skin material, or the range of the skin material that is held by the skin material setting section may be changed.

10 Vehicle interior member, 12 Base material, 14 Upholstery material, 16 Stitch, 22 Base material setting unit,
24 Covering material setting unit, 26 Light irradiation unit, 27 Index, 30 Holding means

Claims (6)

The skin material having the stitches is positioned by aligning the stitches with an index formed by irradiating the back side of the skin material with light, and is set in the skin material setting section;
A method for manufacturing a vehicle interior member, comprising joining a substrate set in a substrate setting section and the skin material. The skin material having the stitches is positioned by aligning the stitches with the indicator formed by the light irradiation and set in the skin material setting section;
The skin material setting unit and the substrate setting unit are moved relative to each other to bond the substrate set in the substrate setting unit to the skin material;
A method for manufacturing a vehicle interior member , which satisfies at least one of the following (1) to (3) :
(1) The skin material is set on a set table formed to match the surface shape of the base material in the skin material setting section.
(2) When the base material and the skin material are joined, the end of the skin material is folded back onto the back surface of the base material by operating a skin material folding unit with a folding operating unit attached to the base material setting unit.
(3) The substrate setting unit is moved toward the skin setting unit, and the skin setting unit is pushed by the substrate setting unit and moves together with the substrate setting unit. The skin material having the stitches is positioned by aligning the stitches with the indicator formed by the light irradiation and set in the skin material setting section;
A method for manufacturing a vehicle interior member, which includes joining a substrate set in a substrate setting unit and the skin material,
a skin setting section for setting the skin in position, the skin being positioned so that only the portion of the skin that is not in contact with the stitching is held by suction; a skin material setting unit for setting the skin material;
a light irradiation unit that forms an index for aligning stitches on the cover material set in the cover material setting unit;
a substrate setting unit for setting the substrate,
The skin material setting section and the base material setting section are configured to move forward and backward relative to each other,
A manufacturing device for a vehicle interior member, characterized in that it satisfies at least one of the following (1) to (3) :
(1) The skin material setting unit has a setting table formed to match the surface shape of the base material, and the light irradiating unit forms the indicator on the skin material set on the setting table.
(2) The apparatus further includes a folding operation unit attached to the substrate setting unit, and a skin folding unit that is operated by the folding operation unit and folds the end of the skin material onto the back surface of the substrate.
(3) The substrate setting unit moves back and forth relative to the skin setting unit, and the skin setting unit, which is pushed by the substrate setting unit, moves together with the substrate setting unit. a skin material setting unit for setting the skin material;
a light irradiation unit that forms an index for aligning stitches on the cover material set in the cover material setting unit;
a substrate setting unit for setting the substrate;
a holding means provided in the upholstery setting section and capable of holding a portion of the upholstery material that has come off the stitches ,
The skin material setting section and the base material setting section are configured to move forward and backward relative to each other.
1. A manufacturing apparatus for a vehicle interior member. The vehicle interior component manufacturing device according to claim 4 or 5, comprising a plurality of light irradiation units capable of irradiating light in a line shape.