Method for manufacturing a patch and method for managing a patch

Abstract

Provided are a method for manufacturing a repair patch capable of achieving a repair without a sense of incongruity, and a method for managing a repair patch capable of easily finding the repair patch. A method for manufacturing a repair patch includes: a first step (S1) of installing a non-polar resin plate at a corresponding position of a virtual vehicle body corresponding to a repair portion where a coating film to be repaired is formed; a second step (S2) of passing the virtual vehicle body through a topcoat painting production line and forming a colored layer and a transparent layer on the non-polar resin plate respectively under the same conditions as the topcoat painting of an actual painted vehicle body; a third step (S3) of passing the virtual vehicle body through a painting drying production line and drying the non-polar resin plate having the colored layer formed thereon and the non-polar resin plate having the transparent layer formed thereon under the same conditions as the painting drying of the actual painted vehicle body; and a fourth step (S4) of removing the non-polar resin plate having the colored layer formed thereon and the non-polar resin plate having the transparent layer formed thereon from the virtual vehicle body and cutting them.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a repair patch for repairing a vehicle body coating film and a method for managing the repair patch. Background Art

[0002] As a method for manufacturing a repair patch for repairing a damaged part of a coating film, for example, there is a method described in Patent Document 1. In this Patent Document 1, the following method is disclosed: using a paint having the same composition as the damaged coating film, a base layer, a pattern layer, and a transparent layer are sequentially formed on a peelable surface, and after formation, drying is performed to manufacture a repair patch. Then, when repairing a damaged part of the coating film of the vehicle body, the manufactured repair patch is cut into an appropriate size and attached to the damaged part with an adhesive.

[0003] Prior Art Documents

[0004] Patent Document 1: Japanese Patent Laid-Open No. 10-220033 Summary of the Invention

[0005] However, even when using a paint having the same composition as the damaged coating film, the color tone of the manufactured repair patch varies depending on drying conditions and the like. Therefore, it is difficult to repair the damaged part without a sense of incongruity.

[0006] The present invention has been completed to solve such a technical problem, and an object thereof is to provide a method for manufacturing a repair patch and a method for managing the repair patch, which can achieve repair without a sense of incongruity.

[0007] The method for manufacturing a repair patch of the present invention is a method for manufacturing a repair patch for repairing a vehicle body coating film, characterized by including: a first step of detachably mounting a non-polar resin plate at a corresponding position of a virtual vehicle body corresponding to a repair part where a coating film to be repaired is formed; a second step of passing the virtual vehicle body through a topcoat (finish coat) painting production line, and forming a colored layer or a transparent layer, or the colored layer and the transparent layer on the non-polar resin plate under the same conditions as the topcoat painting of an actual painted vehicle body; and a third step of passing the virtual vehicle body through a painting drying production line, and drying the non-polar resin plate on which the colored layer or the transparent layer, or the colored layer and the transparent layer is formed under the same conditions as the painting drying of an actual painted vehicle body.

[0008] According to the method for manufacturing a repair patch of the present invention, by forming a colored layer or a transparent layer, or both a colored layer and a transparent layer on a non-polar resin plate under the same conditions as the topcoat painting and painting drying of an actually painted vehicle body and drying them, a repair patch with a color tone close to the painting color of the actually painted vehicle body can be manufactured. In addition, since the topcoat painting and painting drying are performed in a state where the non-polar resin plate is mounted at a corresponding position on a virtual vehicle body corresponding to a repair portion where a coating film to be repaired should be formed, color tone differences caused by different positions can be prevented, and a repair patch with a color tone substantially the same as the painting color of the actually painted vehicle body can be manufactured. Moreover, when performing repair using such a manufactured repair patch, a repair without a sense of incongruity can be achieved.

[0009] In the method for manufacturing a repair patch of the present invention, preferably, in the second step, when forming the colored layer, or both the colored layer and the transparent layer on the non-polar resin plate, the colored layer is formed in such a manner that its thickness varies. By forming the colored layer in such a manner that its thickness varies, gradation can be imparted to the color tone of the repair patch. As a result, by selecting a portion of the repair patch that matches the color tone of the coating film of the repair object and performing repair using the selected portion, it is possible to easily perform color adjustment of the coating film of the repair object and more easily achieve a repair without a sense of incongruity.

[0010] In addition, the management method of the repair patch of the present invention is characterized in that vehicle lot information and repair patch lot information are managed in association with each other, the vehicle lot information includes coating information applied to the vehicle body, and the repair patch lot information includes coating information of the repair patch for repairing the coating film of the vehicle body.

[0011] In the management method of the repair patch of the present invention, since the vehicle lot information and the repair patch lot information are managed in association with each other, it is possible to determine the vehicle lot information based on the vehicle having the coating film to be repaired, and then determine the repair patch lot information based on the vehicle lot information. As a result, it is possible to easily find the repair patch corresponding to the coating film to be repaired and easily perform color adjustment of the coating film of the repair object.

[0012] According to the present invention, a repair without a sense of incongruity can be achieved. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 is a flowchart showing the method for manufacturing a repair patch according to the first embodiment.

[0014] Figure 2A is a schematic diagram showing the method for manufacturing a repair patch according to the first embodiment.

[0015] Figure 2B is a schematic diagram showing the cutting of the repair patch according to the first embodiment.

[0016] Figure 2C It is a schematic diagram showing the peeling of the colored layer or the transparent layer from the non-polar resin plate.

[0017] Figure 2D It is a schematic diagram showing the attachment of the colored layer and the transparent layer to the repair area.

[0018] Figure 3 It is a cross-sectional view of a repair patch having a non-polar resin plate and a colored layer.

[0019] Figure 4 It is a cross-sectional view of a repair patch having a non-polar resin plate and a transparent layer.

[0020] Figure 5 It is a cross-sectional view showing the arrangement of the colored layer and the transparent layer when repairing the vehicle body coating film.

[0021] Figure 6 It is a cross-sectional view showing the production of the repair patch of the second embodiment.

[0022] Figure 7 It is a cross-sectional view showing the production of the repair patch of the third embodiment.

[0023] Figure 8 It is a cross-sectional view showing the production of the repair patch of the fourth embodiment.

[0024] Explanation of reference numerals

[0025] 1: Simulation vehicle body; 2: Vehicle body; 3: Topcoat painting production line; 4: Automatic painting machine; 5: Vehicle to be repaired; 10, 11, 12, 13, 14: Repair patches; 20: Non-polar resin plate; 30, 31, 34: Colored layers; 32: Color layer; 33: Color transparent layer; 40, 41: Transparent layers Detailed implementation manners

[0026] Hereinafter, a method for manufacturing a repair patch and a method for managing the repair patch of the present invention will be described with reference to the drawings. In the description of the drawings, the same reference numerals are given to the same elements, and the repeated description thereof is omitted.

[0027] [Regarding the method for manufacturing a repair patch]

[0028] First, a method for manufacturing a repair patch will be described.

[0029] [First embodiment]

[0030] Based on Figures 1 to 5 A first embodiment of the method for manufacturing a repair patch will be described. The method for manufacturing a repair patch of this embodiment is a method for manufacturing a repair patch for repairing a vehicle body coating film. As Figure 1As shown, the method for manufacturing the repair patch includes: a first step S1 of detachably mounting a non-polar resin plate at a corresponding position on the simulated body; a second step S2 of forming a colored layer and a transparent layer on the non-polar resin plate under the same conditions as the topcoat painting of the actually painted body; a third step S3 of drying the non-polar resin plate with the colored layer formed thereon and the non-polar resin plate with the transparent layer formed thereon under the same conditions as the painting drying of the actually painted body; and a fourth step S4 of removing the non-polar resin plate with the colored layer formed thereon and the non-polar resin plate with the transparent layer formed thereon from the simulated body and cutting them. Hereinafter, these steps will be described in detail.

[0031] In the first step S1, the operator detachably mounts a non-polar resin plate at a corresponding position on the simulated body corresponding to the repair area where the repair coating film is to be formed. The part here, that is, the body part, refers to the part that constitutes the body and can be visually recognized on the appearance (in other words, can be visually recognized from the outside of the vehicle), including the front door, rear door, hood, roof, trunk lid, front fender, rear fender, front pillar, middle pillar, and rear pillar, etc. In the present embodiment, an example is given in which a damaged part (such as a scratch) is generated on the coating film of the front door and the damaged part is repaired. Therefore, the repair coating film is the coating film of the front door.

[0032] As Figure 2A shown, the simulated body 1 can be the same as the actually produced body 2 (in other words, the actually painted body 2), or can be different from the actually produced body 2 in other structures except for the above-mentioned body parts. That is, the simulated body 1 can be the same model of the same shape and size as the actually painted body 2 as a product, or can be such that the body parts such as the front door, rear door, hood, roof, trunk lid, front fender, rear fender, front pillar, middle pillar, and rear pillar have the same shape and size as the actually painted body 2 as a product, but the other parts are different from the actually painted body 2 as a product.

[0033] The non-polar resin plate 20 is thinly formed of a so-called difficult-to-bond resin that does not bond to the colored layer or transparent layer formed thereon. The non-polar resin is preferably at least one selected from polypropylene-based resins, polyolefin-based resins, polydiene-based resins, polystyrene-based resins, ethylene-vinyl acetate copolymers, styrene-based copolymer rubbers, styrene-based thermoplastic elastomers, and natural rubbers. By using the non-polar resin plate 20 in this way, the formed colored layer or transparent layer can be supported, and the formed colored layer or transparent layer can be easily separated (in other words, the formed colored layer or transparent layer can be easily peeled off from the non-polar resin plate 20).

[0034] As described above, since the repair coating film is the coating film of the front door, the operator detachably mounts the non-polar resin plate 20 on the front door of the simulated body 1 (refer toFigure 2A ). The installation work of the non-polar resin plate 20 is performed, for example, at a temporary stop of the vehicle body. In addition, in order to easily remove the non-polar resin plate 20 from the simulated vehicle body 1, the non-polar resin plate 20 is mounted on the simulated vehicle body 1, for example, using a metal wire or a clamp. In addition, in order to easily peel off the formed colored layer or transparent layer from the non-polar resin plate 20, unlike the usual resin buffer coating, no adhesive such as a primer is applied to the non-polar resin plate 20.

[0035] In the second step S2, the operator first passes the simulated vehicle body 1 equipped with the non-polar resin plate 20 through the topcoat painting line 3. At this time, for example, based on the production plan information for the day, the simulated vehicle body 1 can be introduced between the vehicle bodies 2 actually painted as products, or the simulated vehicle body 1 can be introduced after the last painted vehicle body of the day.

[0036] Next, a colored layer and a transparent layer are formed on the non-polar resin plate 20 under the same conditions as the topcoat coating of the actual painted vehicle body 2. That is, for the non-polar resin plate 20 mounted on the simulated vehicle body 1, a colored layer and a transparent layer are formed under the same conditions as the vehicle body 2 actually painted as a product. The same conditions here refer to the paint used, the equipment such as the automatic coating machine 4, the coating conditions, and the environment of the coating room are all the same.

[0037] In this embodiment, if Figure 3 and Figure 4 As shown, a coloring layer 30 and a transparent layer 40 are formed on the non-polar resin plates 20 prepared separately (more specifically, on the outer surface of the non-polar resin plates 20). Therefore, for example, a coloring layer 30 is formed on the non-polar resin plate 20 installed on the left front door of the simulated vehicle body 1, and a transparent layer 40 is formed on the non-polar resin plate 20 installed on the right front door. Therefore, when forming the coloring layer 30, the automatic coating machine 4 on the right side of the topcoat coating line 3 is stopped, and the non-polar resin plate 20 installed on the left front door is coated by the automatic coating machine 4 on the left side. When forming the transparent layer 40, the automatic coating machine 4 on the left side of the topcoat coating line 3 is stopped, and the non-polar resin plate 20 installed on the right front door is coated by the automatic coating machine 4 on the right side.

[0038] The coloring layer 30 is also called a base layer and is a layer having a coloring pigment. The coloring layer 30 may be a single-layer structure or a multi-layer structure. On the other hand, the transparent layer 40 is a transparent layer without a coloring pigment and is used to improve the weather resistance and chemical resistance of the coloring layer 30 and to enhance the gloss and high-grade feeling of the coating film.

[0039] In the third process S3, the operator passes the simulated body 1 through the painting and drying production line, and dries the non-polar resin plate 20 having the colored layer 30 and the non-polar resin plate 20 having the transparent layer 40 under the same conditions as the painting and drying of the actual painted body 2. For example, the simulated body 1 after the topcoat painting is introduced into the heating and drying chamber, and the non-polar resin plate 20 having the colored layer 30 and the non-polar resin plate 20 having the transparent layer 40 are dried under the same conditions as the body 2 actually painted as a product. Furthermore, the same conditions here mean that all the equipment, drying temperature, and drying time in the heating and drying chamber are the same.

[0040] In the fourth process S4, the operator introduces the dried simulated body 1 into, for example, the temporary stop of the body, and removes the non-polar resin plate 20 having the colored layer 30 and the non-polar resin plate 20 having the transparent layer 40 from the simulated body 1, and cuts them into predetermined sizes respectively with a laser or the like (refer to Figure 2B ). Thus, the repair patches 10 having the non-polar resin plate 20 and the colored layer 30 (refer to Figure 3 ), and the repair patches 11 having the non-polar resin plate 20 and the transparent layer 40 (refer to Figure 4 ) are respectively produced.

[0041] According to the method for producing the repair patch of the present embodiment, by forming the colored layer 30 and the transparent layer 40 on the non-polar resin plate 20 respectively under the same conditions as the topcoat painting and painting drying of the actually painted body 2 and drying them, the repair patches 10, 11 having colors close to the painting color of the actually painted body 2 can be produced. In addition, since the topcoat painting and painting drying are performed in a state where the non-polar resin plate 20 is installed at the corresponding position of the simulated body 1 corresponding to the repair coating film repair part to be formed, the color difference caused by different configuration positions such as horizontal configuration or vertical configuration can be prevented, and the repair patches 10, 11 having colors substantially the same as the painting color of the actually painted body 2 can be produced. Therefore, if the coating film damaged part is repaired using the repair patches 10, 11 thus produced, a repair without a sense of incongruity can be achieved.

[0042] Furthermore, in the case of repairing the coating film damaged part of the front door using the produced repair patches 10, 11, as shown in Figure 2C and Figure 2D , first, the colored layer 30 is peeled off from the non-polar resin plate 20 of the repair patch 10, and the colored layer 30 is attached to the front door of the vehicle 5 to be repaired with an adhesive or the like. Then, the transparent layer 40 is peeled off from the non-polar resin plate 20 of the repair patch 11, and the transparent layer 40 is attached on the colored layer 30 with an adhesive or the like so as to cover the colored layer 30 attached to the front door.

[0043] Moreover, when the transparent layer 40 is attached on the colored layer 30, asFigure 5 As shown, it is preferable to prepare a transparent layer 40 with an area larger than that of the colored layer 30 attached to the front door 50, and attach it to the colored layer 30 and the front door 50 in such a way that the peripheral portion of the transparent layer 40 covers the colored layer 30 and is in direct contact with the front door 50. In addition, it is preferable to heat the peripheral portion of the transparent layer 40 in direct contact with the front door 50 to adapt it to the surroundings. In this way, at the peripheral portion of the repair area, only the transparent layer 40 remains, so the thickness becomes thinner compared to the case where the peripheral portion has both the colored layer 30 and the transparent layer 40. As a result, the peripheral portion of the repair area becomes less noticeable, achieving the effect of reducing the visual recognition of the repair area, and thus it is easier to achieve a repair without a sense of incongruity.

[0044] Furthermore, it is not necessary to produce the repair patch 11 having the non-polar resin plate 20 and the transparent layer 40. For example, when the transparent layer is formed by spraying at the repair work site, it is sufficient to produce only the repair patch 10 having the non-polar resin plate 20 and the colored layer 30.

[0045] [Second Embodiment]

[0046] Next, based on Figure 6 the manufacturing method of the repair patch of the second embodiment will be described. The manufacturing method of the repair patch of this embodiment is different from the first embodiment in that the colored layer 31 having a two-layer structure is formed. Hereinafter, only the differences will be described.

[0047] As Figure 6 shown, the colored layer 31 of this embodiment has a colored layer 32 formed on the non-polar resin plate 20 and a colored transparent layer 33 formed on the colored layer 32. Therefore, in the second process, when forming the colored layer 31 on the non-polar resin plate 20 under the same conditions as the topcoat painting of the actual painted vehicle body 2, first the colored layer 32 is formed on the non-polar resin plate 20, and then the colored transparent layer 33 is further formed on the formed colored layer 32. Thus, the repair patch 12 having the non-polar resin plate 20, the colored layer 32, and the colored transparent layer 33 is produced.

[0048] According to the manufacturing method of the repair patch of this embodiment, in addition to being able to obtain the same effects as the above-described first embodiment, since the colored layer 31 has a two-layer structure (i.e., the colored layer 32 and the colored transparent layer 33), the variation of the colored layer can be increased, making it easier to adjust the color tone.

[0049] Then, when using the produced repair patch 12 to repair the damaged coating portion of the front door, the colored layer 31 having the colored layer 32 and the colored transparent layer 33 is peeled off from the non-polar resin plate 20 together, attached to the front door of the vehicle 5 to be repaired, and then the transparent layer 40 is attached thereto.

[0050] [Third Embodiment]

[0051] Next, based on Figure 7 A method for manufacturing a repair patch according to the third embodiment will be described. The method for manufacturing a repair patch according to this embodiment is different from the first embodiment in that the colored layer 30 and the transparent layer 40 are formed on the same non-polar resin plate 20. Hereinafter, only the differences will be described.

[0052] That is, in the second step S2, under the same conditions as the topcoat painting of the actual painted vehicle body 2, first, the colored layer 30 is formed on the non-polar resin plate 20. Then, the transparent layer 40 is further formed on the formed colored layer 30. Thus, the repair patch 13 having the non-polar resin plate 20, the colored layer 30, and the transparent layer 40 is manufactured.

[0053] According to the method for manufacturing a repair patch according to this embodiment, in addition to being able to obtain the same effects as those of the above-described first embodiment, since the colored layer 30 and the transparent layer 40 are formed on the same non-polar resin plate 20, when using the manufactured repair patch 13 to repair the damaged part of the coating film, the colored layer 30 and the transparent layer 40 are peeled off from the non-polar resin plate 20 together and attached to the front door of the vehicle 5 to be repaired. In this way, compared with the first embodiment in which the colored layer 30 and the transparent layer 40 are separately formed on different non-polar resin plates 20, the repair operation time can be shortened.

[0054] [Fourth Embodiment]

[0055] Next, based on Figure 8 A method for manufacturing a repair patch according to the fourth embodiment will be described. The method for manufacturing a repair patch according to this embodiment is different from the first embodiment in that the colored layer 34 and the transparent layer 41 are formed on the same non-polar resin plate 20 and the colored layer 34 is formed in such a manner that its thickness varies. Hereinafter, only the differences will be described.

[0056] That is, in the second step S2, under the same conditions as the topcoat painting of the actual painted vehicle body 2, first, the colored layer 34 is formed on the non-polar resin plate 20. At this time, for example, in the longitudinal direction of the non-polar resin plate 20 along the front-rear direction of the vehicle body, the colored layer 34 is formed in such a manner that the thickness gradually decreases from the central portion to both end portions. Then, the transparent layer 41 is further formed on the formed colored layer 34. Furthermore, when forming the transparent layer 41, the thickness of the transparent layer 41 can also be adjusted so that the total thickness of the colored layer 34 and the transparent layer 41 is substantially the same in the longitudinal direction of the non-polar resin plate 20. Thus, the repair patch 14 having the non-polar resin plate 20, the colored layer 34, and the transparent layer 41 is manufactured.

[0057] According to the method for manufacturing a patch according to this embodiment, in addition to obtaining the same effects as those of the above-described first embodiment, since the colored layer 34 and the transparent layer 41 are formed on the non-polar resin plate 20, when using the manufactured patch 14 to repair the coating film of the vehicle body, the colored layer 34 and the transparent layer 41 can be peeled off from the non-polar resin plate 20 together and attached to the front door of the vehicle 5 to be repaired. In this way, compared with the first embodiment in which the colored layer 30 and the transparent layer 40 are respectively formed on different non-polar resin plates 20, the time for repair work can be shortened.

[0058] Furthermore, since the thickness of the formed colored layer 34 gradually decreases from the central portion to the both end portions, gradation can be imparted to the hue of the manufactured patch 14. As a result, by selecting a portion of the patch 14 that matches the hue of the coating film of the object to be repaired and performing repair on the selected portion, it is possible to easily perform color adjustment of the coating film of the object to be repaired. That is, it is possible to select the gradation of the patch 14 that is closest to the hue of the coating film of the object to be repaired and use the selected portion to repair the damaged portion of the coating film, so that it is easier to achieve a repair without a sense of incongruity.

[0059] [Method for managing patches]

[0060] Next, a method for managing patches will be described. In the method for managing the patches 10, 11, 12, 13, 14 according to the embodiment, the vehicle lot information and the patch lot information are associated and managed. The vehicle lot information includes the coating information applied to the vehicle body 2, and the patch lot information includes the coating information of the patch used to repair the coating film of the vehicle body 2. The coating information here includes information such as the lot number of the coating and the date and time of use. In this embodiment, for example, an information processing device equipped with a computer or the like is used to associate and manage the vehicle and the patch having the same lot number of the coating and the date and time of use.

[0061] In this way, since the vehicle lot information and the patch lot information are associated and managed, it is possible to determine the vehicle lot information based on the vehicle having the coating film to be repaired, and to determine the patch lot information based on the determined vehicle lot information. As a result, it is possible to easily find the patches 10, 11, 12, 13, 14 corresponding to the coating film to be repaired, and it is easy to perform color adjustment of the coating film of the object to be repaired.

[0062] The embodiments of the present invention have been described in detail above, but the present invention is not limited to the above embodiments, and various design changes can be made without departing from the spirit of the present invention described in the scope of the patent claim.

Claims

1. A method for manufacturing a repair patch, which is a method for manufacturing a repair patch for repairing a vehicle body coating film, characterized in that, Comprising: A first step of detachably mounting a non-polar resin plate at a corresponding position of a virtual body corresponding to a repair portion where a coating film to be repaired is formed; A second step of passing the virtual body through a topcoat painting production line and forming a colored layer or a transparent layer, or the colored layer and the transparent layer, on the non-polar resin plate under the same conditions as the topcoat painting of an actual painted body; And A third step of passing the virtual body through a painting drying production line and drying the non-polar resin plate on which the colored layer or the transparent layer, or the colored layer and the transparent layer, is formed under the same conditions as the painting drying of an actual painted body.

2. The method for manufacturing a repair patch according to claim 1, wherein in the second step, when forming the colored layer, or the colored layer and the transparent layer, on the non-polar resin plate, the colored layer is formed in such a manner that its thickness varies.

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