Shaping material for vehicle and manufacturing method

Abstract

To provide a shaping material for a vehicle that enables weight reduction and a manufacturing method of the shaping material for a vehicle.SOLUTION: A shaping material for a vehicle 10 includes a base body 12, and a urethane layer 14 provided on the base body 12. The base body 12 is formed of at least one of polystyrene foam and urethane foam. A surface of the urethane layer 14 is shaved and smoothed. A manufacturing method of the shaping material for a vehicle 10 includes steps of providing the urethane layer 14 on the base body 12, and shaving a surface layer portion of the urethane layer 14 and smoothing the surface.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a vehicle shaping material that can be used for a mock-up model of a vehicle and a method for manufacturing the same.

Background Art

[0002] In the development of vehicle design and styling, mock-up models are used (see Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] An object of the present invention is to provide a vehicle shaping material capable of achieving weight reduction and a method for manufacturing the same.

Means for Solving the Problems

[0005] The vehicle shaping material of the present invention comprises a base body, and a urethane layer provided on the base body, wherein the base body is made of at least one of expanded polystyrene and expanded urethane, and the surface of the urethane layer is shaved and smoothed.

[0006] The method for manufacturing the vehicle shaping material of the present invention comprises a step of providing a urethane layer on the base body, and a step of shaving and smoothing the surface layer portion of the urethane layer, wherein the base body is made of at least one of expanded polystyrene and expanded urethane.

Brief Description of the Drawings

[0007]

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Embodiments for Carrying Out the Invention

[0008] Hereinafter, preferred embodiments of the present invention will be described in detail. 1. Method for Producing a Conceivable Mock-up Model In the automotive industry, in design development and design engineering, development is carried out using exterior mock-up models and interior mock-up models. When producing a mock-up model, the following are conceivable production methods.

[0009] (1) First Method There is a strategy of machining chemical wood by numerical control (hereinafter referred to as "NC machining"), finishing it by hand with sandpaper, and then painting it.

[0010] (2) Second Method There are measures such as NC machining the foam material, manually applying clay, NC machining the clay, and attaching a silver film. In the case of this measure, painting cannot be performed.

[0011] (3) The third method There are measures such as NC machining the foam material, manually applying the discharge resin of the two-component curing kneaded resin, NC machining the resin, manually finishing with sandpaper, and painting.

[0012] However, for each method, the mock-up model itself is very heavy, the material cost is high, and there are many manual operations, so it takes time to manufacture and affects the schedule. When it becomes a mock-up model of a vehicle, the vehicle itself is very heavy, and it is generally at the level of a weight greater than that of an actual vehicle (about 3t), and it is also dangerous to move the mock-up of the vehicle. The completed mock-up of the vehicle may need to be transported not only domestically but also overseas, and the cost for such transportation is also high. The compatibility of the adhesion between the expanded polystyrene and the clay or the discharge resin is very poor, and troubles such as the self-weight dropping of the front and rear bumpers and the rear spoiler may occur.

[0013] 2. Specific technology The vehicle shaping material 10 includes a base body 12 and a urethane layer 14 provided on the base body 12. The base body 12 can be made of at least one of expanded polystyrene and expanded urethane. The surface of the urethane layer 14 is shaved and smoothed.

[0014] The vehicle shaping material 10 can be manufactured, for example, as follows. Apply a urethane paint coating on the base body 12 once or a plurality of times to provide a urethane layer, for example, with a thickness of 8 mm to 15 mm. Specifically, the urethane paint can be applied, for example, 5 times to provide a urethane layer 14 with a film thickness of 10 mm. Machine the urethane layer 14 to leave, for example, 4 to 7 mm, preferably 5 to 6 mm, and particularly preferably about 5 mm, and smooth the urethane layer 14.

[0015] It can be fixed to various support materials (for example, plywood) with embedded nuts or the like.

[0016] In the manner shown in FIG. 1, a urethane paint can be applied onto a substrate (e.g., a foamed material) 10. FIG. 2 shows a schematic diagram of the layer structure of the vehicle shaping material 10, and a urethane layer 14 with a surface cut and smoothed after urethane coating can be provided on the substrate 12. FIG. 3 shows the vehicle shaping material 10 of a car bonnet, and various coatings can be applied to the surface of this vehicle shaping material 10, and the design property can also be improved as shown in FIG. 5. FIG. 6 shows a photograph of the foamed material as the substrate 10 coated with urethane paint, indicating that the urethane layer 14 can be uniformly provided on the foamed material. FIG. 7 is a photograph showing a cross-section of the foamed material as the substrate 10 coated with urethane paint, indicating that the urethane layer 14 is provided on the foamed material with a uniform thickness. As shown in FIG. 8, the urethane layer 14 can be provided on a three-dimensional substrate 10 having concave portions, curved surfaces or flat surfaces. As shown in FIG. 9, the urethane layer 14 can also be provided at the angled portions.

[0017] 3. Effects According to this embodiment, for example, there are the following effects.

[0018] Weight reduction, reduction of processing man-hours and shortening of processing time, cost reduction, and reduction of production schedule can be achieved. Also, an accurate design surface can be produced, and it has the effects of high adhesion to the foamed material and being difficult to peel off. By reducing man-hours (schedule), processing costs, and material costs, the cost can be reduced from these aspects. Since weight reduction can be achieved, transportation becomes easier, and movements such as detachment and transportation are facilitated, and the labor and cost of movement can also be reduced. Scraping / patching is also possible. Affixing a finishing / stain-preventing film, painting, and skin pasting are possible.

[0019] From a design perspective, it has the effect that the design surface can be scraped, corrected, and finally decorated. From the perspectives of safety and workability, since it becomes lighter, it leads to improvements in safety and workability. It has high recyclability after use, makes destruction and disposal easier, and can also reduce the disposal cost.

[0020] The inventors of the present invention have also confirmed that they can achieve a mirror-like surface. When they checked the reflection of light from a fluorescent lamp, they confirmed that the reflected light was a line because the surface was not distorted.

[0021] It was confirmed that the adhesive is tightly adhered and air bubbles are unlikely to form even when applied multiple times, making it possible to form a single layer without gaps.

[0022] In an actual comparison with the chemical wood manufacturing method by the inventors of this application, it was confirmed that the resin mass was about 1 / 6, and a significant reduction of the total weight of about 70% was achieved, and that this was effective in terms of safety measures. The reduction in weight also reduced the risk of the product falling off. This led to a reduction in material costs and processing costs, and therefore a reduction in costs and construction schedules was also confirmed.

[0023] In an actual comparison with the manufacturing method of the present inventors, in which clay is attached to foam material, it was confirmed that the total weight could be reduced by approximately 20%, and that this method is effective in terms of safety measures. The weight reduction also reduced the number of falling-off problems. This leads to reduced material and processing costs, and therefore reduced costs and construction schedules. It was also confirmed that finishing, painting, and skin application can be performed, which are difficult with clay.

[0024] According to the above method, in the case of large-scale construction, an iron frame is made, plywood is fixed, and foam material is attached to the plywood, but according to this embodiment, the weight of the mock-up design itself can be reduced, so that even if it is large, the case of making an iron frame can be made much lighter. The product manufactured by the method according to this embodiment can also be easily attached to plywood.

[0025] 4.Applications The present invention is suitable for use as a vehicle mockup model, in particular as an exterior mockup model for an automobile and an interior mockup model for an automobile.

[0026] It is particularly useful for mock-up models that require lightweight, ease of processing, workability, design quality, and adhesion.

[0027] In this embodiment, various modifications are possible within the scope of the present invention. For example, as shown in FIG. 10, when unexpected recesses occur due to uneven coating or the like after the urethane layer 14 is applied, it may be repaired with putty 16 to obtain the desired surface shape.

Explanation of Reference Numerals

[0028] 10 Vehicle shaping material 12 Substrate 14 Urethane layer

Claims

1. a substrate, and a urethane layer provided on the substrate, wherein the substrate is made of at least one of expanded polystyrene and expanded urethane, and the urethane layer is a vehicle-shaped material having a surface that is shaved and smoothed.

2. a step of providing a urethane layer on a substrate, and a step of shaving and smoothing a surface layer portion of the urethane layer, wherein the substrate is a method for manufacturing a vehicle-shaped material made of at least one of expanded polystyrene and expanded urethane.

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