JPH0215376B2 - - Google Patents

Description

Detailed Description of the Invention The present invention provides door pads for vehicles such as automobiles by ultrasonic welding using ordinary urethane without any pretreatment for welding, which could not be done by conventional high-frequency welding. The present invention also relates to a method for manufacturing door pads for similar uses.

Conventionally, a door pad for lining a vehicle door (hereinafter simply referred to as a door pad) has been constructed by laminating a wadding 2 between a skin 1 and a substrate 3, as shown in FIG. Between a mold (not shown) and another high-frequency electrode mold (not shown) on the opposite side of the substrate 3, the skin 1, wading 2 and substrate 3 are compressed, and a high-sonic current is passed through.
The wadding 2 was melted, and the skin 1 and the wadding 2 were fused to the substrate 3 at the fused portion 2a.

When a high frequency current is applied, the substrate 3 does not undergo heat generation and melting due to the high frequency due to its material, and the wading 2 (except for ordinary urethane, which will be described next) melts because of the heat generated by the high frequency. By melting this wading, the skin 1, the wadding 2, and the substrate 3 were bonded together.

The above-mentioned high-frequency fusion is performed using ordinary urethane (hereinafter simply referred to as ordinary urethane) that does not require any pretreatment such as impregnation with a fusion agent to improve fusion.
However, despite its excellent physical properties (elasticity, durability, etc.) and low price, it cannot be realized because of its high melting point. Therefore, we have no choice but to use ordinary urethane treated to melt it at a low melting point, low-melting urethane, or cushion materials with a low melting point other than urethane, but these have inferior physical properties and are average in price. It had the disadvantage of being more expensive than urethane.

Furthermore, in order to take advantage of the advantages of ordinary urethane as described above, the wading 2 of the substrate 3 is
It was also possible to pre-coat the surface in contact with a material that could be melted by high-frequency current, but this was not very effective as it required a lot of man-hours and was expensive.

Further, a method using ultrasonic welding is also known, as shown in, for example, Japanese Patent Application Laid-Open No. 57-201621. However, this ultrasonic welding method is for bonding a skin such as an olefin-based elastomer sheet, an olefin-based foam sheet such as polypropylene, polyethylene, etc. to a hard core material made of a similar olefin-based polypropylene composite material, and is not normally used. There is no disclosure regarding urethane. Moreover, in this method, the intervening foam sheet is completely crushed to fuse the skin to the core material.

The object of the present invention is to provide a method of ultrasonic welding, rather than high frequency welding, of ordinary urethane which has the best physical properties and is low in cost as described above, and in particular to provide a method of ultrasonically welding thick ordinary urethane.

That is, the present invention laminates the skin, ordinary urethane wading or urethane mold, and a substrate without any pretreatment, places an ultrasonic tool horn thereon, and uses the ultrasonic tool horn to cut the required portions of the laminate while applying pressure. In the method of manufacturing a door pad using ultrasonic waves, which generates heat by applying ultrasonic vibrations to fuse and bond the parts, the ultrasonic tool horn is applied to the thick part of the wading or urethane mold from above the skin and close to the surface of the thick part. The skin is fused by applying pressure to such an extent that only the area is deformed and applying ultrasonic vibration to partially melt the area near the surface of the thick part of the wading or urethane mold in the longitudinal direction. This is the method for manufacturing door pads using ultrasonic waves.

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will now be described in detail with reference to embodiments illustrated in the accompanying drawings.

In FIG. 2, reference numeral 2A denotes a urethane mold or partially laminated wadding, which has different thicknesses in parts. That is, on the left side of FIG. 2, the urethane mold 2A is of normal thickness, and in this part, the skin 1 is
An ultrasonic tool horn (similar to 4 on the right) is pressed from above, and an ultrasonic tool horn holder (not shown) is pressed from below from below the substrate 3 (hardboard, etc.) to generate ultrasonic vibrations. Then, the urethane mold is melted and the skin 1 and the substrate 3 are welded together.

However, in the thick part on the right side, as shown by reference numeral 2b, an ultrasonic tool horn 4 is pressed from above the skin 1 to such an extent that only the area close to the surface of the urethane mold 2A is deformed, and ultrasonic vibration is applied to the urethane mold 2A. The skin 1 is adhered to the urethane mold 2A by partially melting only the area in the longitudinal direction. It is completely impossible to partially fuse the skin 1 at the thick welded portion 2b of the urethane mold 2A using high frequency.

Note that the end portion 1a of the skin 1 where the skin 1 covers the periphery of the substrate 3 and is fixed to the back side of the substrate 3 is conventionally
The bonding was conventionally done by hammering a metal stopper with a tacker tool or bonding with an adhesive, but in the present invention, the entire circumference of the end portion 1a of the skin 1 is fused to the substrate 3 using an ultrasonic tool horn.

3a, b, and c show the case where a button-shaped part 2c and a separate bead-shaped part 6 are fused to the upper surface of the skin 1.

FIG. 3b is a perspective view of the bead-shaped object 6. FIG.

Although not shown, the ball-shaped object 6 may have a shape that covers the ball core. Bead-shaped object 6A in Fig. 3c
3B is a variation of the bead-shaped object 6 shown in FIG. 3b, and shows a tape-like example in which both ends of the bead-shaped object 6 are not wrapped. Although not shown, the bead-shaped object 6 or 6A is fused to the skin 1 using an ultrasonic tool horn.

The button-shaped object 2c in FIG. 3a is obtained by melting the wading 2A partially and fusion-molding a part of the skin 1 into the button shape using an ultrasonic tool horn (not shown) for forming the button shape. It is something.

Figure 3b, epidermis 1 and bead-shaped object 6, Figure 3c
The skin 1 and the bead-shaped object 6A may be a combination of different materials, shapes, and colors. The skin 1 may be divided below the bead-shaped objects 6, 6A and then fused and fixed by the bead-shaped objects 6, 6A.

The above explanations are all based on embodiments in which the substrate 3 is a hard board, but the door pad, although not shown, is a molded product made of plastic injection molding or the like. Even when this is used in place of the substrate 3, ultrasonic welding is preferable to high-frequency welding, as described above. It is also possible to fuse the skin 1 and a plastic molded article by melting it.

According to the above-mentioned manufacturing method of the present invention, it becomes possible to use ordinary urethane or ordinary urethane mold, which has excellent physical properties and is inexpensive, as the wadding 2A, which could not be used conventionally.

By partially melting the surface side of the wading, mold or partially laminated wading, the skin can be molded and fused into a desired shape.

Although not shown, the parts for attaching to the vehicle door body were conventionally fixed to the board using screws or other methods (not shown), but these parts were fixed to the board by ultrasonic waves. It can be directly fused and fixed.

The above technology is not limited to door pads, but has the effect of being widely applicable to vehicle seats, vehicle interior parts, furniture, and the like.

[Brief explanation of drawings]

Fig. 1 is a sectional view of a door pad according to a conventional method, Fig. 2 and the following are related to the present invention, Fig. 2 is a sectional view showing an example of fusion of wading with partially different thicknesses, and Fig. 3a is a button-shaped part. , a cross-sectional view of a door pad showing a manufacturing method of molding or fusing a separate bead-shaped object onto the skin surface, FIG. 3b is a perspective view showing a bead-shaped object, and FIG. 3c is a different-shaped bead It is a perspective view showing a shaped object. 1...Skin, 1a...Terminal part, 2, 2A...Normal urethane wading or urethane mold,
2a, 2b... fusion part, 2c... button shaped part,
3... Board, 4... Ultrasonic tool horn, 6,6A
...A ball-shaped object.

Claims (1)

[Claims] 1. Laminate the skin, ordinary urethane wading or urethane mold, and substrate without any pretreatment, place an ultrasonic tool horn on top of the layer, and use the ultrasonic tool horn to remove the above laminate while applying pressure. In the method of manufacturing a door pad using ultrasonic waves, which generates heat by applying ultrasonic vibrations to the required parts and melts and bonds them, the ultrasonic tool horn is applied to the thick part of the wading or urethane mold from above the surface of the thick part. The skin is fused by applying pressure to such an extent that only the area close to the urethane mold is deformed and applying ultrasonic vibration to partially melt the area close to the surface of the thick part of the wading or urethane mold in the vertical direction. A method for manufacturing door pads using ultrasonic waves, which is characterized by: 2. A method for manufacturing a door pad according to claim 1, characterized in that a button-shaped portion is formed on the upper surface of the skin by a similar ultrasonic vibration process. 3. The manufacturing method according to claim 1 or 2, characterized in that a bead-shaped object is fused to the upper surface of the epidermis by similar ultrasonic vibration processing.
How to make door pads. 4. A method for manufacturing a door pad according to any one of claims 1 to 3, characterized in that the end portion of the skin is wrapped around the back side of the substrate and fused.