HANDLE MANUFACTURING PROCESS

Abstract

Method for manufacturing a handle (W1, W4, W5, W6) with a handle section (R1, R4, R5, R6) that is grasped at the time of control and comprising a core material (3), a covering layer (10, 80) formed of urethane foam that covers an outer circumferential section of the core material (3), a sensor layer (13, 83) that covers an outer circumferential section of the covering layer (10, 80) and is configured to detect that the handle section (R1, R4, R5, R6) is grasped, and a protective layer (16, 86) that covers an outer circumferential section of the sensor layer (13, 83), comprising: a first step to form the sensor layer (13, 83) by applying a urethane-based lacquer coating containing a conductive material to a forming die (20, 90); and a second step to form the covering layer (10, 80) in an inner circumferential section of the sensor layer (13, 83) by closing the forming die (20, 90) onto which the urethane-based lacquer coating is applied, injecting a urethane material into a cavity (20a, 90a) of the forming die (20, 90) and curing the urethane material.

Description

[0001] The present invention relates to a method for manufacturing a handle in which a sensor layer capable of detecting a grip is provided on a handle section that is grasped by a user at the time of steering.

[0002] In the prior art of this type of handle, a sensor layer, capable of detecting a grip based on an increase in capacitance, is arranged on a handle section that is grasped at the time of control (JP 2019 - 202 446 A). The sensor layer uses a conductive material. Furthermore, the sensor layer is arranged on a skin material that is wrapped around one surface side of the handle section. The skin material consists of a base material layer, such as non-woven fabric or leather, an elastic body layer layered on top of the base material layer, and a coating layer on an outer surface side of the elastic body layer. The elastic body layer then contains a conductive material in urethane foam to form the sensor layer.

[0003] However, in the prior art handle, a skin material incorporating the sensor layer is formed by wrapping it around the surface of a covering layer made of urethane foam or the like, which is provided around a core material in the handle section. That is, in the prior art handle, it is necessary to apply an adhesive to the covering layer and to wrap the skin material around the outer surface of the covering section, which has a substantially elliptical cross-section of the handle section, without wrinkles. Therefore, in the prior art handle, manufacturing the handle section containing the sensor layer requires time and effort.

[0004] DE 10 2014 016 422 A1 discloses a steering wheel with a core material, a covering layer, a sensor layer and a protective layer.

[0005] Based on the prior art, the invention is based on the objective that the handle can be manufactured easily, even if the handle has the sensor layer for detecting the handle through the handle section.

[0006] The problem is solved according to the invention by a method according to claim 1. Further developments of the invention are specified in the dependent claims.

[0007] A handle according to the present disclosure is provided with a sensor layer capable of detecting a grip (a grasping / grasping) in a handle section that is to be grasped during steering. The handle section comprises a core material, a covering material formed from urethane foam arranged by die molds (injection molding) such that it covers a circumference of the core material, and a sensor layer. The sensor layer is formed from a mold coating material consisting of a urethane-based lacquer (paint) containing a conductive material and is arranged on a surface side of the covering layer during molding. Furthermore, the sensor layer is covered with a protective layer arranged on a surface side of the handle section.

[0008] The handle of the present disclosure is then provided with a sensor layer capable of detecting the handle in the handle section that is grasped at the time of control. The handle section comprises a core material, a covering layer formed from urethane foam arranged by die shapes such that it covers a circumference of the core material, and a sensor layer. The sensor layer is formed from a mold coating material consisting of a urethane-based lacquer containing a conductive material and is arranged on a surface side of the covering layer at the time of molding. Furthermore, the sensor layer is covered with a protective layer arranged on a surface side of the handle section.

[0009] In the handle described in this disclosure, the sensor layer is arranged at the same time as the cover layer is formed. Therefore, the handle can be manufactured more easily than in a case where the sheet material containing the sensor layer is wound separately around the cover layer. That is, the sensor layer is the mold coating layer (mold interior coating layer). Therefore, the mold coating material, which consists of the urethane-based lacquer containing the conductive material, is applied in advance to the die surface of the forming die when the cover layer is die-formed. Then, after coating, the cover layer containing the sensor layer can be formed simply by forming the cover layer.Furthermore, in the comparative example where the sensor layer is not the mold coating layer, the urethane-based lacquer forming the sensor layer, which is applied to the outer surface of the covering layer after molding and cured to form the sensor layer, can be exemplified. However, this comparative example requires a process of applying a primer to the outer surface of the covering layer after molding or a drying process after applying the urethane-based lacquer. On the other hand, the handle of the present disclosure can be easily manufactured, since the aforementioned primer application process and the aforementioned drying process are not required. Moreover, the sensor layer is the same type of urethane-based lacquer as the covering layer, which is formed from urethane foam.Therefore, the sensor layer and the covering layer can exhibit good mutual fusibility (adhesion), and it is unlikely that the sensor layer will be displaced relative to the covering layer. Furthermore, the sensor layer of the present disclosure is provided with the protective layer on its surface. Therefore, since the handle of the present disclosure is not directly exposed on the surface side of the handle section, handle detection of the handle section can be carried out with a good lifetime.

[0010] Therefore, the handle of the present disclosure can be easily manufactured, even if the handle section includes the sensor layer for detecting the handle.

[0011] The handle of the present disclosure can be formed from the skin layer, which is made of urethane foam, in which the protective layer is arranged by matrix forming. This handle is configured to have the first urethane layer as the covering layer on the core material side on the back surface side of the sensor layer, and the second urethane layer as the skin layer on the surface side of the sensor layer.

[0012] In this design, the skin layer, acting as a protective layer, is formed as the second urethane layer and can be made elastic. Therefore, it is possible to improve the feel when gripping this handle section. Furthermore, if a predetermined pigment is added to the urethane foam material of the second urethane layer, the skin layer can be formed in a predetermined color scheme, thus improving the design of the handle.

[0013] In this case, it is desirable that the second urethane layer has a higher density than that of the first urethane layer.

[0014] In such a configuration, if the density of the second urethane layer on the outer surface of the sensor layer is higher than the density of the first urethane layer on the inner circumferential side of the sensor layer, the dielectric constant of the second urethane layer is improved compared to that of the first urethane layer. Therefore, the parasitic capacitance generated between the sensor layer and the core material can be suppressed, and the sensitivity of the sensor layer's grip detection can be improved. Consequently, the grip detection accuracy of this handle can be enhanced.

[0015] Furthermore, in the handle where the first urethane layer and the second urethane layer are arranged with the sensor layer in between, a fitting section in which the first urethane layer and the second urethane layer are adapted to each other (attached) can be provided with the sensor layer in between, so that the displacement of the second urethane layer relative to the first urethane layer can be suppressed.

[0016] Furthermore, in the handle described in the present disclosure, the protective layer can be arranged as the upper coating layer formed from the urethane-based lacquer. In this handle, the urethane-based lacquer of the upper coating layer is used as the first mold coating material, and the mold coating material forming the sensor layer is used as the second mold coating material. Then, if the first mold coating material and the second mold coating material are applied sequentially to the die surface of the molding die of the covering layer, the sensor layer formed from the second mold coating material and the protective layer formed from the first mold coating material are arranged on the surface side of the covering layer at the time of molding.

[0017] In this configuration, if the first and second coating materials are sequentially applied to the die surface of the coating layer's forming die, the sensor layer and the top coating layer (which serves as the protective layer) can be formed simultaneously. Therefore, with this handle, it is possible to more easily form the handle section, which has a (long) service life for the sensor layer. Furthermore, the sensor layer is covered by the top coating layer and is located on the outer surface of the handle section. This improves the sensitivity of grip detection.

[0018] Furthermore, in the handle described in the present disclosure, the protective layer can be arranged as the skin material to be applied to the outer surface of the sensor layer. The covering layer, which is formed from urethane foam, is further comprised of the first urethane layer on the core material side, the second urethane layer on the rear surface of the sensor layer, and the shielding layer arranged between the first and second urethane layers. The shielding layer is further comprised of the first mold coating material, which is formed from the urethane-based lacquer containing the conductive material, and the sensor layer is formed from the second mold coating material.Then, if the first mold coating material is applied to the die surface of the mold for the first urethane layer, the shielding layer formed from the first mold coating material is positioned on the surface side of the first urethane layer during the molding process. Furthermore, if the second mold coating material is applied to the die surface of the mold for the second urethane layer, the sensor layer formed from the second mold coating material is positioned on the surface side of the second urethane layer during the molding process.

[0019] In this type of handle, the first mold coating layer, formed from the first mold coating material containing the conductive material, acts as a shielding layer on the core material side of the sensor layer. Therefore, this handle makes it possible to suppress the influence of parasitic capacitance on the core material side and improve the sensitivity of the handle detection in the sensor layer. Naturally, the protective layer covering the sensor layer on the surface side of the handle section is used as the skin material to be applied to the sensor layer. Thus, in this handle, the design of the handle section can be improved by the design of the skin material.

[0020] Furthermore, the handle can be formed from the skin material attached to the outer surface of the sensor layer. In such a handle, the handle section can consist of the core material, the covering layer (made of urethane foam formed by die molding to cover the circumference of the core material), the sensor layer, and the skin material as the protective layer for the sensor layer. Fig. Figure 1 is a schematic top view showing a handle according to a first embodiment of the present disclosure. Fig. Figure 2 is a sectional view of a handle section of the handle of the first embodiment and corresponds to section II-II of Fig. 1. Fig. Figure 3 is a top view to illustrate a manufacturing process of the handle of the first embodiment. Fig. Figure 4 is a view illustrating a manufacturing process of the handle of the first embodiment and shows a state after Fig. 3. Fig. Figure 5 is a schematic top view showing a handle of a modified example of the first embodiment. Fig. 6 is a sectional view of a handle section of the grip, which is located in Fig. 5 is shown, and corresponds to section VI-VI of Fig. 5. Fig. Figure 7 is a view to explain a manufacturing process of the handle, which is in Fig. 5 is shown. Fig. Figure 8 is a view illustrating a manufacturing process of the handle, which is in Fig. 5 is shown, and shows a state after Fig. 7. Fig. Figure 9 is a schematic top view showing a handle of a second embodiment. Fig. Figure 10 is a sectional view of a handle section of the handle of the second embodiment and corresponds to section XX of Fig. 9. Fig. Figure 11 is a view illustrating a manufacturing process of the handle of the second embodiment. Fig. Figure 12 is a schematic top view showing a handle of a third embodiment. Fig. Figure 13 is a sectional view of a handle section of the handle of the third embodiment and corresponds to section XIII-XIII of Fig. 12. Fig. Figure 14 is a view illustrating a manufacturing process of the handle of the third embodiment. Fig. Figure 15 is a view illustrating a manufacturing process of the handle of the third embodiment and shows a state after Fig. 14. Fig. Figure 16 is a schematic top view showing a handle of a fourth embodiment. Fig. Figure 17 is a sectional view of a handle section of the handle of the fourth embodiment and corresponds to section XVII-XVII of Fig. 16. Fig. Figure 18 is a top view to illustrate a manufacturing process of the handle of the fourth embodiment. Fig. Figure 19 is a schematic top view showing a handle of another modified example of the first embodiment. Fig. Figure 20 is a schematic sectional view showing a handle of another modified example of the first embodiment.

[0021] Preferred embodiments of the present disclosure are described below with reference to the accompanying drawings.

[0022] As in Fig. 1 and Fig. As shown in Figure 2, a handle (a steering wheel) W1 of a first embodiment has a substantially ring-shaped grip section (gripping section) R1, which is to be gripped when steering a vehicle (not shown), a projecting section (bulge / bead section) B in the center of the grip section R1, and a spoke section S (L, R, and B) for connecting the grip section R1 and the projecting section B. The spoke section S comprises the spoke sections SL and SR, which extend from the projecting section B on both a left and a right side, and the spoke section SB, which extends from the projecting section B on a rear side.Furthermore, the handle W1 has an airbag device 105, represented by a dashed line with two dots, arranged on an upper side of the projection section B, a handle main body H1 and a lower cover (not shown) covering a lower side of the projection section B.

[0023] The main handle body H1 has a core material 3, made of a metallic material such as an aluminum alloy, which connects the handle section R1, the projection section B, and the spoke sections S. The core material 3 has a handle core material section 4 located in the handle section R, a projection core material section 5 located in the projection section B, and spoke core material sections 6 (L and R) and 7 located in the spoke sections S (L, R, and B). The spoke core material sections 6 (L and R) and 7 connect the handle core material section 4 and the projection core material section 5. The projection core material section 5 has a steel projection 5a that is coupled to a steering shaft of the vehicle. Furthermore, the spoke core material sections 6L and 6R are located on the left and right spoke sections SL and SR, respectively.The spoke core material section 7 is located on the rear side of the spoke section SB. The spoke core material section 7 branches to the left and right on a projecting core material section 5 side and is coupled to a grip core material section 4 side.

[0024] The projecting section B is provided with a grip detection circuit 100 on a section of the main handle body H1, which is covered by the airbag device 105. The grip detection circuit 100 is connected to a connecting wire (not shown) extending from a sensor layer 13, which will be described later. As the driver's hand approaches the sensor layer 13 to grasp the handle section R1, the capacitance of the sensor layer 13 increases. The grip detection circuit 100 detects this increase in capacitance and thus registers the driver's gripping action.

[0025] Then you show how in Fig. Figure 2 shows the handle section R1 comprising the handle core material section 4 of the core material 3, a covering layer 10 covering a circumference of the handle core material section 4, the sensor layer 13 arranged on a surface of the covering layer 10, and a protective layer 16 arranged on a surface side of the sensor layer 13. The covering layer 10 is formed by die forming and is made of urethane foam, as will be described later.

[0026] The sensor layer 13 is formed from a mold coating material 28, which consists of a urethane-based lacquer containing a conductive material (powder, such as conductive carbon or metal oxide) (see Fig. 3) The mold coating material 28 is applied to the die surfaces 21a and 22a of the forming die 20, which forms the covering layer 10. Then, at the time of subsequent forming of the covering layer 10, the sensor layer 13, which is formed from the mold coating material 28, is arranged on the surface side of the covering layer 10.

[0027] In the case of the first embodiment, the sensor layer 13 is formed from a urethane-based varnish containing (electrically) conductive carbon.

[0028] The protective layer 16 is arranged as a skin layer 17. In the case of the first embodiment, the skin layer 17 is formed from urethane foam and is arranged by die forming.

[0029] In the case of the first embodiment, the urethane foam has a first urethane layer 11 as the covering layer 10 on the handle core material section 4 side on the back surface side of the sensor layer 13 and a second urethane layer 18 as the skin layer 17 on the surface side of the sensor layer 13.

[0030] In the first embodiment, the sensor layer 13 is formed from a urethane-based lacquer containing conductive carbon, and the surface of the covering layer 10 is coated with a dark black color. On the other hand, the skin layer 17 is not black, and urethane foam containing a light beige pigment is used to enhance the design.

[0031] In the first embodiment, the thickness dimension St1 of the sensor layer 13 is defined, taking into account conductivity, lifetime, and haptics, as approximately 5 to 50 µm, preferably 20 µm, within a range of approximately 10 to 30 µm. The thickness dimension Ut1 of the second urethane layer 18 of the skin layer 17 is defined, taking into account the lifetime, haptics, and sensitivity of the sensor layer 13, as 2 mm within a range of approximately 1 to 3 mm.

[0032] Furthermore, in the first embodiment, where each of the first urethane layer 11 and the second urethane layer 18 is made of urethane foam, the density of the second urethane layer 18 is higher than the density of the first urethane layer 11. If the density of the second urethane layer 18 is high, its dielectric constant is high, and the sensitivity of the sensor layer 13 for grip detection can be improved. The density of the first urethane layer 11 is set to 0.3 g / cm³. 3 in a range of approximately 0.2 to 0.4 g / cm³ 3 specified, and the density of the second urethane layer 18 is set at 0.7 g / cm³ 3 within a range of approximately 0.5 to 0.9 g / cm³ 3 determined.

[0033] The manufacturing process of the handle main body H1 of the first embodiment comprises a mold coating agent application process, a first urethane layer forming process and a second urethane layer forming process.

[0034] First, in the mold coating agent application process, as shown in (A) and (B) of Fig. Figure 3 shows a mold 20 used to form (cast) the first urethane layer 11 as the covering layer 10. The mold 20 has sub-matrices 21 and 22. The mold coating agent 28, which forms the sensor layer 13, is then applied to the matrix surfaces 21a and 22a of the sub-matrices 21 and 22 by means of a spray gun 27. Before applying the mold coating agent 28, a mold solvent is applied to the matrix surfaces 21a and 22a.

[0035] Then, as the first urethane layer formation process, as in (C) and (D) of Fig. As shown in Figure 3, the forming die 20, which is formed from the partial dies 21 and 22, is closed, and the urethane material for forming the first urethane layer 11 is injected into the cavity 20a. If the injected urethane material cures, an intermediate product 15, in which the first urethane layer 11 is formed, can then be produced. The produced intermediate product 15 is removed by opening the forming die 20.

[0036] Then, in the second urethane layer forming process, as in (A) and (B) of Fig. As shown in Figure 4, a forming die 24 is used to form the second urethane layer 18. The forming die 24 has sub-diees 25 and 26. First, the forming die 24 is opened, the intermediate forming product 15 is inserted, and the forming die 24 is closed. Then, as shown in Figures (B) and (C), Fig. As shown in Figure 4, the urethane material for forming the second urethane layer 18 is injected into the cavity 24a. Afterwards, if the injected urethane material cures, the second urethane layer 18 can be formed. Before forming, a molding solvent is applied to the die surfaces 25a and 26a of the partial dies 25 and 26. After forming the second urethane layer 18, if the forming die 24 is opened and emptied, a molded product (formed product) equipped with the handle section R1, i.e., the main handle body H1, can be obtained.

[0037] In the handle main body H1, which is manufactured in this way, a projection 5a of the projection section B is tightened / attached to the control shaft of the vehicle, while a lower cover (not shown) is attached to the underside of the projection section B. Furthermore, if the airbag device 105 is attached to the upper side of the projection section B of the handle main body H1, the handle W1 can be assembled and mounted on the vehicle. When the airbag device 105 is attached, the sensor layer 13 and the handle detection circuit 100, which are capable of detecting the driver's grip, are connected by a predetermined connecting wire.

[0038] With the handle W1, which is mounted on the vehicle, when the driver's hand approaches the sensor layer 13 of the handle section R1 to grasp the handle section R1, the predetermined handle detection circuit 100 detects that the capacity has increased, and the handle detection circuit 100 can detect the driver's handle.

[0039] Then, in the handle W1 of the first embodiment, the sensor layer 13 is arranged at the same time as the covering layer 10 is formed. That is, it is not necessary to separately wrap a sheet material provided with the sensor layer around the covering layer 10. Consequently, the handle W1 of the first embodiment can be easily manufactured, even if the handle section R1, which includes the sensor layer 13, is provided. In other words, the sensor layer 13 is a mold coating layer 14 (mold lining coating layer). Therefore, the mold coating agent 28, which consists of a urethane-based lacquer containing a conductive material, is applied in advance to the die surfaces 21a and 22a of the forming die 20 when the covering layer 10 is die-formed.After the mold coating material 28 is applied, the cover layer 10, which is provided with the sensor layer 13, can be formed simply by molding the cover layer 10. In a comparative example where the sensor layer 13 is not used as the mold coating layer 14, a urethane-based lacquer forming the sensor layer, applied to an outer surface of the cover layer after molding, can be specified. However, this comparative example requires the process of applying a primer to the outer surface of the cover layer after molding or the drying process after applying the urethane-based lacquer.In comparison to this example, the first embodiment can be manufactured more easily because the aforementioned priming and drying processes are not required. Furthermore, in the first embodiment, the sensor layer 13 is a urethane-based coating of the same type as the covering layer 10, which is made of urethane foam. Therefore, the mutual fusibility (adhesion) between the covering layer 10 and the sensor layer 13 is also good, and displacement of the sensor layer 13 is unlikely. Additionally, the sensor layer 13 of the handle W1 in the first embodiment is provided with a protective layer 16 on its surface. Therefore, in the first embodiment, since the sensor layer 13 is not directly exposed on the surface side of the handle section R1, handle detection can be performed with a good lifetime.

[0040] Therefore, the handle W1 of the first embodiment can be easily manufactured, even if the handle section R1 has the sensor layer 13 for detecting the handle.

[0041] In the handle W1 of the first embodiment, the protective layer 16 is arranged as the skin layer 17, which is formed from urethane foam and is arranged by die forming. That is, the handle W1 of the first embodiment has the first urethane layer 11 and the second urethane layer 18. The first urethane layer 11 is the covering layer 10 on the back surface side of the sensor layer 13 on the handle core material section 4 side of the core material 3. The second urethane layer 18 is the skin layer 17 on the surface side of the sensor layer 13.

[0042] Therefore, in the first embodiment of the handle W1, the skin layer 17 is designed as the protective layer 16, which is the second urethane layer 18, and can be elastic, thus improving the feel when gripping the handle section R1. Furthermore, a predetermined pigment (in the present embodiment, a beige pigment) is added to the urethane foam material of the second urethane layer 18. Therefore, in the first embodiment of the handle W1, the skin layer 17 can be designed in a predetermined color scheme, and the design of the handle W1 can be improved.

[0043] Furthermore, in the first embodiment, the second urethane layer 18 has a higher density than that of the first urethane layer 11.

[0044] Therefore, in the first embodiment, since the dielectric constant of the second urethane layer 18 can be improved compared to the first urethane layer 11, the increase in parasitic capacitance generated between the sensor layer 13 and the handle core material section 4 can be suppressed, and the sensitivity of a handle detection by the sensor layer 13 can be improved. Consequently, the accuracy of a handle detection can be improved in the first embodiment.

[0045] In a case where the first urethane layer 11 and the second urethane layer 18 are arranged with the sensor layer 13 in between, the handle W1A, which is in Fig. 5 to Fig. The handle W1A, as shown in Figure 6, has fitting sections 12 and 19 in which the first urethane layer 11A and the second urethane layer 18A, with the sensor layer 13 in between, are aligned (attached) to each other. In this handle W1A, the fitting sections 12 and 19 can suppress the displacement of the second urethane layer 18A relative to the first urethane layer 11A.

[0046] The handle W1A differs from the handle W1 of the first embodiment in that the handle section R1A of the handle main body H1A is provided with fitting sections 12 and 19. Therefore, other configurations of this handle W1A are the same as those of the handle W1, and the same parts and components as those of the first embodiment are designated by the same reference numerals, and their description is omitted where necessary.

[0047] The fitting section 12, formed in the first urethane layer 11A, has a convex section 12a that is rounded and raised so that they are separated from each other, and a concave section 12b that is relatively concave with the convex section 12a around the convex section 12a. The fitting section 19, formed on the second urethane layer 18A, has a contour in which the fitting section 12 of the first urethane layer 11A is inserted (fitted) with the sensor layer 13 in between. That is, the fitting section 19 has a concave section 19a that fits the convex section 12a of the fitting section 12 of the first urethane layer 11A, and a convex section 19b that fits the concave section 12b of the fitting section 12.

[0048] The first urethane layer 11A and the second urethane layer 18A are the same urethane layers 11 and 18 as in the first embodiment. The overhang height dimension h1 of the convex section 12a, which sandwiches around the sensor layer 13, from a neutral point of the unevenness is approximately 0.5 mm, and the concavity depth dimension d1 of the concave section 12b is approximately 0.5 mm.

[0049] As in the first embodiment, the manufacturing process of the handle main body H1A comprises a mold coating agent application process, a first urethane layer forming process, and a second urethane layer forming process. In the mold coating agent application process, as in (A) and (B) of Fig. As shown in Figure 7, a forming die 20A is used to form the first urethane layer 11A as the covering layer 10A. First, the urethane-based lacquer, which forms the sensor layer 13, is applied to the die surfaces 21a and 22a of the sub-diees 21 and 22 of the forming die 20A by means of the spray gun 27. Prior to applying the forming coating 28, a mold solvent is applied to the die surfaces 21a and 22a.

[0050] In this forming die 20A, the concave and convex sections 21b and 22b on the die surfaces 21a and 22a of the sub-diees 21 and 22 are formed to create the fitting section 12.

[0051] In the first urethane layer forming process, as shown in (C) and (D) of Fig. As shown in Figure 7, the forming die 20A, which is formed from the partial dies 21 and 22, is closed. The urethane material for forming the first urethane layer 11A is injected and cured in the cavity 20a, and the intermediate product 15A, obtained by forming the first urethane layer 11A, is produced. Then the forming die 20A is opened, and the intermediate product 15A is removed. In the subsequent second urethane layer forming process, as shown in Figures (A) and (B), the urethane material is further formed. Fig. As shown in Figure 8, the forming die 24, which is formed from the partial dies 25 and 26, is used to form the second urethane layer 18A. First, the forming die 24 is opened, the intermediate forming product 15A is inserted, the forming die 24 is pulled / closed, and is then, as shown in Figures (B) and (C), Fig. As shown in Figure 8, the urethane material forming the second urethane layer 18A is injected into the cavity 24a and cured, thus forming the second urethane layer 18A. Before forming, a molding solvent is applied to the die surfaces 25a and 26a of the partial dies 25 and 26. After forming the second urethane layer 18A, if the die is opened and emptied, the molded product, which is provided with the handle section R1A, i.e., the main handle body H1A, can be obtained.

[0052] In the handle body H1A manufactured in this way, as in the first embodiment, the projection 5a of the projection section B is tightened to the control shaft of the vehicle, while the lower cover (not shown) is attached to the lower side of the projection section B, and the airbag device 105 is attached to the upper side of the projection section B. As a result, the handle W1A can be assembled and mounted on the vehicle. Once the airbag device 105 is attached, the sensor layer 13 and the handle detection circuit 100, which are capable of detecting the driver's grip, are connected by a predetermined connecting wire.

[0053] In the case of the handle W1A, which is mounted on the vehicle, the predetermined handle detection circuit 100, as in the first embodiment, detects that the capacitance has increased when the driver's hand approaches the sensor layer 13 of the handle section R1 to grasp the handle section R1A. Therefore, the handle W1A can detect the driver's grip and achieve the same operation and effect as the first embodiment. Furthermore, in the handle W1A, the first urethane layer 11A and the second urethane layer 18A have the fitting sections 12 and 19, which fit together with the sensor layer 13 between them. Therefore, in the handle W1A, the deviation of the second urethane layer 18A with respect to the first urethane layer 11A is suppressed. That is, at the time of grasping the handle section R1A, the second urethane layer 18A, which is the skin layer 17A as the protective layer 16A, does not deviate with respect to the first urethane layer 11A.As a result, with the W1A handle, it is possible to improve the feel of the R1A handle section during steering when it is gripped.

[0054] In the example shown, the fitting sections 12 and 19 are formed by providing a large number of point-like convex sections 12a and 19b. However, if the deviation of the second urethane layer 18A with respect to the first urethane layer 11A is suppressed, the unevenness of the fitting sections 12 and 19 can be formed from various shapes, such as a triangular pyramid, a columnar shape, and a ridge, along a circumferential direction of the grip section R1A in an area where the release from the forming die 20A is not hindered.

[0055] Next, a handle W2 of a second embodiment, which is in Fig. 9, Fig. 10 to Fig. Figure 11 shows and describes the following. In the handle W2 of the second embodiment, the core material 3, the airbag device 105, the lower cover (not shown), and the like are the same as those of the first embodiment. The handle W2 differs from the first embodiment in that the structure covering the core material 3 of the handle section R2, i.e., the handle core material section 4, differs from that of the first embodiment.

[0056] In the second embodiment, as in the first embodiment, the handle section R2 comprises the handle core material section 4 of the core material 3, the covering layer 30, which is formed from urethane foam and arranged by die forming to cover the circumference of the handle core material section 4, and the sensor layer 33. As in the first embodiment, the sensor layer 33 is formed from a mold coating material 48, which is formed from the urethane-based lacquer containing a conductive material (conductive carbon) (see Fig. 11) The mold coating agent 48 is applied to the die surfaces 41a and 42a of the forming die 40 (see Fig. 11) is applied for forming the covering layer 30 and is arranged on the surface side of the covering layer 30 at the time of forming the covering layer 30. Furthermore, the sensor layer 33 is covered with the protective layer 36, which is arranged on the surface side.

[0057] In the second embodiment, the protective layer 36 is arranged as an upper coating layer 37, which is formed from a urethane-based lacquer. Furthermore, the upper coating layer 37 has a grain size 38, such as a satin finish, on the outer surface 37a side.

[0058] In the second embodiment, the thickness dimension St2 of the sensor layer 33 is specified at approximately 5 to 50 µm, preferably 20 µm within a range of 10 to 30 µm, taking into account conductivity, lifetime, and sensitivity. The thickness dimension Ut2 of the upper coating layer 37 is specified at 20 µm within a range of 10 to 30 µm, thus clearly defining the lifetime (wear resistance) and the grain pattern.

[0059] The manufacturing process of the handle main body H2 of the second embodiment comprises a mold coating agent application process and a urethane layer forming process.

[0060] First, in the mold coating agent application process, as shown in (A) of Fig. As shown in Figure 11, the forming die 40 is used to form the urethane layer 31 as the covering layer 30. First, the initial mold coating agent 47, consisting of the urethane-based lacquer forming the upper coating layer 37, is applied to the die surfaces 41a and 42a of the partial dies 41 and 42 of the forming die 40 by means of the spray gun 44, which serves as the application device. The die surfaces 41a and 42a are formed with a predetermined unevenness on which the grain pattern can be formed. Furthermore, before applying the initial mold coating agent 47, the mold solvent is applied to the die surfaces 41a and 42a.

[0061] Then, after the applied first mold coating material 47 has cured, i.e., after the formation of the first mold coating layer 39, as in (B) and (C) of Fig. As shown in Figure 11, the urethane-based lacquer forming the sensor layer 33 is applied to the first mold coating layer 39 by means of the second mold coating agent 48, which is applied by the spray gun 45 as the application device. Furthermore, if the upper coating layer 37 is the first mold coating layer 39, the sensor layer 33 is formed by applying the second mold coating agent 48 a second time to the die surfaces 41a and 42a, thus forming the second mold coating layer 34.

[0062] Then the urethane layer formation process, as shown in (C) and (D) of Fig. Figure 11 shows that if the forming die 40 is closed and the urethane material for forming the urethane layer 31 is injected into the cavity 40a and cured, the handle section R2, which is obtained by forming the urethane layer 31 of the covering layer 30, is produced. The main handle body H2 can be obtained by removing it from the opened forming die 40.

[0063] In the main body of the handle H2, as in the first embodiment, if the projection 5a of the projection section B is tightened to the control shaft of the vehicle, while the lower cover (not shown) is attached to the lower side of the projection section B, and the airbag device 105 is attached to the upper side of the projection section B, the handle W2 can be assembled and the handle W2 can be mounted on the vehicle. When the airbag device 105 is attached, the sensor layer 33 and the handle detection circuit 100, which are capable of detecting the driver's grip, are connected by a predetermined connecting wire.

[0064] With the handle W2, which is mounted on the vehicle, if the driver's hand approaches the sensor layer 33 of the handle section R2 to grasp the handle section R2, the predetermined handle detection circuit 100 detects that the capacity has increased, and the handle detection circuit 100 can detect the driver's handle.

[0065] In this second embodiment, the urethane-based lacquer of the upper coating layer 37 is used as the first mold coating material 47, and the mold coating material forming the sensor layer 33 is used as the second mold coating material 48, and they are applied sequentially to the die surfaces 41a and 42a of the cover layer 30. During the molding of the cover layer 30, the sensor layer 33 and the protective layer 36 are arranged on the surface side of the cover layer 30.

[0066] Therefore, in the second embodiment, the first mold coating material 47 and the second mold coating material 48 are applied sequentially to the die surfaces 41a and 42a of the molding die 40 of the covering layer 30 for forming the covering layer 30. For example, the sensor layer 33 and the upper coating layer 37, which serves as the protective layer 36 protecting the sensor layer 33, can be formed simultaneously. As a result, in the second embodiment, the handle section R2, which is provided with the long-life sensor layer 33, can be formed more easily. Furthermore, since the sensor layer 33 is covered with the thin upper coating layer 37 and is located on the outer surface of the handle section R2, the handle W2 of the second embodiment exhibits good grip detection sensitivity.

[0067] Furthermore, in the second embodiment, the upper coating layer 37 is arranged with the grain size 38. That is, if the upper coating layer 37 has the same black scheme color as that of the sensor layer 33, the black scheme color of the sensor layer 33 will not be noticeable from the outer surface of the handle section R2, even if it is thin. Therefore, in the handle W2 of the second embodiment, the handle section R2 can have a matte black design, and the design of the handle section R2 can be improved.

[0068] Of course, the upper coating layer 37 can be formed by incorporating a pigment or the like of a desired color other than the black scheme into the first mold coating material 47.

[0069] Next, a handle W3 of a third embodiment, which is in Fig. 12, Fig. 13, Fig. 14 to Fig. Figure 15 is shown and described. Even in the case of the handle W3 of the third embodiment, the core material 3, the airbag device 105, the lower cover (not shown) and the like are the same as those of the first embodiment, and the difference is that the structure covering the core material 3 of the handle section R3, i.e. the handle core material section 4, is different from that of the first embodiment.

[0070] In the third embodiment, as in the first embodiment, the handle section R3 comprises the handle core material section 4 of the core material 3, a covering layer 50 made of urethane foam, which is arranged by the die forming process to cover the circumference of the handle core material section 4, and a sensor layer 57. As in the first embodiment, the sensor layer 57 is formed from a mold coating material 75, which is formed from the urethane-based lacquer containing a conductive material (conductive carbon) (see Fig. 15). The mold coating agent 75 is applied to the die surfaces 68a and 69a of a molding die 67 (see Fig. 15) for forming a second urethane layer 52, which will be described later, the covering layer 50, such that at the time of forming the second urethane layer 52, the covering layer 50 is arranged as the second sensor layer 57 on the surface side of the second urethane layer 52. Furthermore, the sensor layer 57 is covered with a protective layer 60, which is arranged on the surface side.

[0071] In the third embodiment, the protective layer 60 is a skin material 61 that is attached to an outer surface of the sensor layer 57. In the third embodiment, the skin material 61 is made of leather.

[0072] Furthermore, in the third embodiment, the covering layer 50, which is made of urethane foam, has a first urethane layer 51 on the handle core material section 4 side of the core material 3, a second urethane layer 52 on a rear surface side of the sensor layer 57, and a shielding layer 54, which is arranged between the first urethane layer 51 and the second urethane layer 52.

[0073] The shielding layer 54 is formed from a first mold coating material 74, which consists of the urethane-based lacquer containing the conductive material (e.g., conductive carbon). Therefore, the sensor layer 57 is formed from a second mold coating material 75. That is, the first mold coating material 74 is applied to the mold surfaces 64a and 65a of a molding die 63 during the die forming process (see figure). Fig. 14) the first urethane layer 51. Then, during the forming of the first urethane layer 51, the shielding layer 54 is formed as the first mold coating layer 55 by being applied to the surface side of the first urethane layer 51. Furthermore, during the mold forming, the second mold coating material 75, which forms the sensor layer 57, is applied to the mold surfaces 68a and 69a of the forming die 67 of the second urethane layer 52. Then, during the forming of the second urethane layer 52, the sensor layer 57 is applied as the second mold coating layer 58 to the surface side of the second urethane layer 52.

[0074] In the third embodiment, the thickness dimension St3 of the sensor layer 57 is specified to approximately 5 to 50 µm, preferably 20 µm, within a range of approximately 10 to 30 µm, taking into account conductivity, lifetime, and sensitivity. The thickness dimension Sts of the shield layer 54 is specified to approximately 10 to 100 µm, preferably 50 µm, within a range of approximately 30 to 60 µm. The thickness dimension Ut3 of the second urethane layer 52 is specified to 2 mm within a range of approximately 1 to 3 mm, taking into account the lifetime, sensitivity, and sensitivity of the sensor layer 57.

[0075] Furthermore, the first urethane layer 51 and the second urethane layer 52, which are made of urethane foam, have essentially the same density.

[0076] The manufacturing process of the handle main body H3 of the third embodiment comprises a screen mold coating agent application process, a first urethane layer forming process, a sensor mold coating agent application process, a second urethane layer forming process and a leather winding process.

[0077] First, in the screen mold coating agent application process, as shown in (A) and (B) of Fig. As shown in Figure 14, the forming die 63 is used to form the first urethane layer 51 as the covering layer 50. Then, the urethane-based lacquer, which forms the shielding layer 54, is applied to the die surfaces 64a and 65a of the sub-diees 64 and 65 of the forming die 63 as the first mold coating agent 74 by means of the spray gun 71 as the application device. Before applying the mold coating agent 74, the mold solvent is applied to the die surfaces 64a and 65a.

[0078] Then, in the first urethane layer forming process, as in (B) and (C) of Fig. As shown in Figure 14, the forming die 63 is closed, the urethane material for forming the first urethane layer 51 is injected into the cavity 63a and cured, and an intermediate product 56 is produced by forming the first urethane layer 51. The forming die 63 is opened, and the intermediate product 56 is removed.

[0079] Then, in the sensor mold coating agent application process, as shown in (A) of Fig. As shown in Figure 15, the forming die 67 is used to form the second urethane layer 52 as the covering layer 50. Then, the urethane-based lacquer, which forms the second sensor layer 57, is applied to the die surfaces 68a and 69a of the sub-diees 68 and 69 of the forming die 67 as the second mold coating agent 75 by means of the spray gun 72 as the application device. Before applying the mold coating agent 75, the mold solvent is applied to the die surfaces 68a and 69a.

[0080] Then, in the second urethane layer forming process, as in (A) and (B) of Fig. As shown in Figure 15, the intermediate mold product 56 is placed in the opened molding die 67, the molding die 67 is closed, and the urethane material for forming the second urethane layer 52 is injected into the cavity 67a and cured. Then, after forming the second urethane layer 52, if the die is opened and emptied, the intermediate mold product 59 can be obtained before skin wrapping (see Figure (C) of Figure 15). Fig. 15).

[0081] Then, if the skin material 61, which is made of leather, is wrapped around the outer surface of the sensor layer 57 while being attached to it, the handle section R3 of the main handle body H3 can be produced (see (D) of Fig. 15).

[0082] In the handle body H3, manufactured in this way, the handle W3 can be assembled if the projection 5a of the projection section B is tightened to the vehicle's control shaft, while the lower cover (not shown) is attached to the underside of the projection section B, and the airbag device 105 is attached to the upper side of the projection section B. At the same time, the handle W3 can be mounted on the vehicle. Once the airbag device 105 is attached, the sensor layer 57 and the handle detection circuit 100, which are capable of detecting the driver's grip, are connected by a predetermined connecting wire.

[0083] In the handle W3, which is mounted on the vehicle, when the driver's hand approaches the sensor layer 57 of the handle section R3 to grasp the handle section R3, the predetermined handle detection circuit 100 detects that the capacity has increased, and the handle detection circuit 100 can detect the driver's handle.

[0084] Then, in the handle W3 of the third embodiment, the first mold coating layer 55, formed from the first mold coating material 74 containing the conductive material, is arranged on the core material 3 (handle core material section 4) side of the sensor layer 57 as the shielding layer 54. Therefore, in the handle W3, the influence of the parasitic capacitance of the handle core material section 4 side can be suppressed, and the sensitivity of a handle detection in the sensor layer 57 can be improved. Naturally, the protective layer 60, which covers the sensor layer 57 on the surface side of the handle section R3, can serve as the skin material 61 attached to the sensor layer 57, and the design of the handle section R3 can be improved by the design of the skin material 61.

[0085] In a case where the protective layer is arranged as the skin material to be applied to the outer surface of the sensor layer, it can be arranged as in the case of the handle W4 of the fourth embodiment, which is described in Fig. 16, Fig. 17 to Fig. Figure 18 shows the following configuration. The handle W4 comprises the handle section R4 of the handle main body H4. The handle section R4 comprises the handle core material section 4 of the core material 3, a covering layer 80 made of urethane foam for covering the handle core material section 4, a sensor layer 83, and a skin material 87 as a protective layer 86 that protects the sensor layer 83.

[0086] As in the first embodiment, the sensor layer 83 is made of a mold coating material 96 (see Fig. 16), which is formed from the urethane-based lacquer containing the conductive material (conductive carbon).

[0087] The mold coating agent 96 is then applied to the die surfaces 91a and 92a of a molding die 90 for forming the covering layer 80, and is arranged on the surface side of the covering layer 80 as the mold coating layer 84, which is the sensor layer 83, during the forming of the covering layer 80. Furthermore, the sensor layer 83 is covered with a skin material 87 (protective layer 86) made of leather, which is arranged on the surface side.

[0088] In the case of the fourth embodiment, the thickness dimension St4 of the sensor layer 83 is set at approximately 5 to 50 µm, preferably 20 µm, within a range of approximately 10 to 30 µm, taking into account conductivity, lifetime and sensitivity.

[0089] The manufacturing process of the handle main body H4 of the fourth embodiment comprises a mold coating agent application process, a urethane layer forming process and a skin winding process.

[0090] First, in the mold coating agent application process, as shown in (A) of Fig. As shown in Figure 18, the forming die 90 is used to form the urethane layer 81 as the covering layer 80. Then, the urethane-based lacquer, which forms the sensor layer 83, is applied to the die surfaces 91a and 92a of the sub-diees 91 and 92 of the forming die 90 as the mold coating agent 96 by means of the spray gun 94 as the application device. Before applying the mold coating agent 96, the mold solvent is applied to the die surfaces 91a and 92a.

[0091] Then, in the urethane layer forming process, as in (B) and (C) of Fig. As shown in Figure 18, the forming die 90 is closed, and the urethane material for forming the urethane layer 81 is injected into the cavity 90a and cured to form the urethane layer 81 of the covering layer 80. Then, after forming the urethane layer 81, if the die is opened and emptied, an intermediate formed product 85 can be obtained in which the mold coating layer 84 is arranged as the sensor layer 83 on the outer circumferential surface.

[0092] Then, if the skin material 87, which is made of leather, is wrapped around the outer surface of the sensor layer 83 while being attached to it, the handle section R4 of the main handle body H4 can be produced (see (D) of Fig. 18).

[0093] In the main body of the handle H4, as in the first embodiment, if the projection 5a of the projection section B is tightened to the control shaft of the vehicle, while the lower cover (not shown) is attached to the lower side of the projection section B, and the airbag device 105 is attached to the upper side of the projection section B, the handle W4 can be assembled and mounted on the vehicle. When the airbag device 105 is attached, the sensor layer 83 and the handle detection circuit 100, which are capable of detecting the driver's grip, are connected by a predetermined connecting wire.

[0094] With the handle W4, which is mounted on the vehicle, if the driver's hand approaches the sensor layer 83 of the handle section R4 to grasp the handle section R4, the predetermined handle detection circuit 100 detects that the capacity has increased, and the handle detection circuit 100 can detect the driver's handle.

[0095] Even in the handle W4 of the fourth embodiment, since the sensor layer 83 is arranged at the same time as the covering layer 80 is formed, the handle W4, which includes the handle section R4 containing the sensor layer 83, can be manufactured more easily compared to a case where the sheet material provided with the sensor layer is wrapped separately around the covering layer 80. That is, the sensor layer 83 is a mold coating layer 84 (in-mold coating layer). Therefore, the mold coating agent 96, which consists of the urethane-based lacquer containing the conductive material, is applied in advance to the die surfaces 91a and 92a of the forming die 90 when the covering layer 80 is die-formed. Afterward, the covering layer 80, which is provided with the sensor layer 83, can be easily formed simply by forming the covering layer 80.Furthermore, since the sensor layer 83 is the same type of urethane-based lacquer as the covering layer 80, which is made of urethane foam, the meltability (adhesion) to the covering layer 80 is also good, and it is unlikely that the sensor layer 83 will be displaced relative to the covering layer 80. Moreover, since the sensor layer 83 of the handle W4 is provided with the protective layer 86 on its surface and is not directly exposed on the surface side of the handle section R4, the handle detection of the handle section R4 can be carried out with a good lifetime.

[0096] Furthermore, in the fourth embodiment, since the sensor layer 83 is covered with the skin material 87, which is made of thin leather and is arranged on the outer surface of the handle section R4, the sensitivity of the handle detection can be improved. Moreover, the protective layer 86, which covers the sensor layer 83 on the surface of the handle section R4, is the skin material attached to the sensor layer 83. Therefore, the design of the handle section R4 can be improved by the design of the skin material 87.

[0097] In each embodiment, the individual sensor layers 13, 33 and 57 are arranged on the handle sections R1, R2 and R3. However, as with a handle section R5 of a handle W5, which is in Fig. As shown in Figure 19, the sensor layer 13 of the first embodiment is formed from sensor layers 13L and 13R, which are separate on the left and right sides. In the case of the handle section R5, the handle can be detected separately in a left-side area R5L of sensor layer 13L and a right-side area R5R of sensor layer 13R.

[0098] Furthermore, in a case where the sensor layer 13 is subdivided, a handle section R6 of a handle W6, which is in Fig.Figure 20 is shown as an example. The grip section R6 consists of a sensor layer 13I and a sensor layer 13O, into which the sensor layer 13 is separated on an inner and an outer circumferential side of the grip section R6. Therefore, the grip can be detected separately in a region R6I on the inner circumferential side and a region R6O on the outer circumferential side of the grip section R6. In the case that the sensor layer is subdivided, it can easily be separated simply by masking the die surface when the mold coating material is applied.

[0099] Furthermore, the essentially ring-shaped handle sections R1, R1A, R2, R3, R4 and R5 of each embodiment of the handles W1, W1A, W2, W3, W4 and W5 are shown by way of example. However, the handle section is not limited to the ring-shaped form and can have various shapes, such as a square ring-shaped form and an elliptical ring-shaped form.

Claims

[1] Method for manufacturing a handle (W1, W4, W5, W6) with a handle section (R1, R4, R5, R6) which is grasped at the time of control and which comprises a core material (3), a covering layer (10, 80) formed of urethane foam which covers an outer circumferential section of the core material (3), a sensor layer (13, 83) which covers an outer circumferential section of the covering layer (10, 80) and is configured to detect that the handle section (R1, R4, R5, R6) is grasped, and a protective layer (16, 86) which covers an outer circumferential section of the sensor layer (13, 83), comprising: a first step to form the sensor layer (13, 83) by applying a urethane-based lacquer coating containing a conductive material to a forming die (20, 90); and a second step to form the covering layer (10, 80) in an inner circumferential section of the sensor layer (13, 83) by closing the forming die (20, 90) onto which the urethane-based lacquer coating is applied, injecting a urethane material into a cavity (20a, 90a) of the forming die (20, 90) and curing the urethane material. [2] Method according to claim 1, further comprising: a third step to form the protective layer (16) on the outer circumferential section of the sensor layer (13) by removing an intermediate molded product (15) consisting of the covering layer (10) and the sensor layer (13) which are integrated in the second step, from the molding die (20) and placing the intermediate molded product (15) into another molding die (24), injecting a urethane material into a cavity (24a) of the other molding die (24) and curing the urethane material, whereby a urethane density of the protective layer (16) is higher than a urethane density of the covering layer (10). [3] Method according to claim 2, wherein the sensor layer (13) is arranged separately in the first step on a left-hand area (R5L) of the grip section (R5) and a right-hand area (R5R) of the grip section (R5) by applying a masking to a matrix surface (21a, 22a) of the forming matrix (20), and a gripping of the left-hand area (R5L) and a gripping of the right-hand area (R5R) are detected separately. [4] Method according to claim 2, wherein the sensor layer (13) is arranged separately in the first step on an inner circumferential region (R6I) of the grip section (R6) and an outer circumferential region (R6O) of the grip section (R6) by applying a masking to a matrix surface (21a, 22a) of the forming matrix (20), and a gripping of the inner circumferential region (R6I) and a gripping of the outer circumferential region (R6O) are detected separately. [5] Method according to claim 1, further comprising: a third step to remove an intermediate molded product (85) consisting of the covering layer (80) and the sensor layer (83) which are integrated in the second step, from the molding die (90) and wrapping a skin material (87) around the outer circumferential section of the sensor layer (83).

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