Jig for placement and manufacturing method thereof

Abstract

To provide a jig for placement that enables weight reduction and a manufacturing method of the jig for placement.SOLUTION: A jig for placement 10 is for placement of a vehicle component and includes a base body 12 having a recess 16 corresponding to a shape of the vehicle component, and a urethane layer provided on the base body 12 at least in the recess 16. The base body 12 is formed of at least one of polystyrene foam and urethane foam. A manufacturing method of the jig for placement for placing a vehicle component includes a step of providing the urethane layer 14 on the base body 12 having the recess 16 corresponding to a shape of the vehicle component. The base body is formed of at least one of polystyrene foam and urethane foam.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a mounting jig that can be used in the production of vehicles and a method for manufacturing the same.

Background Art

[0002] In automobile production, assembly work of automobile parts is performed using a panel part holding jig (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 mounting jig that can achieve weight reduction and a method for manufacturing the same.

Means for Solving the Problems

[0005] The first mounting jig of the present invention is a mounting jig for mounting vehicle components, a base body having a concave portion corresponding to the shape of the vehicle component, and includes a urethane layer provided at least on the base body in the concave portion, wherein the base body is made of at least one of expanded polystyrene and expanded urethane.

[0006] The manufacturing method of the first mounting jig of the present invention is a manufacturing method of a mounting jig for mounting vehicle components, and includes a step of providing a urethane layer on a base body having a concave portion corresponding to the shape of the vehicle component, wherein the base body is made of at least one of expanded polystyrene and expanded urethane. In the present invention, a step of shaving and smoothing the surface layer portion of the urethane layer can be included.

[0007] The second mounting jig of the present invention is a mounting jig for mounting a vehicle component, a base body having a concave portion or shape corresponding to the shape of the vehicle component, and at least a urethane layer provided on the base body in the concave portion, the mounting jig is used when mounting interior parts or exterior parts in a production line for manufacturing or assembling a vehicle, the urethane layer is a coating layer provided by coating with a spray gun, the mounting jig is fixed to a plate-shaped support material, the thickness of the urethane layer is in the range of 8 to 15 mm, the urethane layer is obtained by coating multiple times, has no joints, no separated portions, and is a continuous urethane layer that can form a single layer.

[0008] The third mounting jig of the present invention is a mounting jig for mounting a vehicle component, a base body having a concave portion or shape corresponding to the shape of the vehicle component, and at least a urethane layer provided on the base body in the concave portion, the mounting jig is used when mounting interior parts or exterior parts in a production line for manufacturing or assembling a vehicle, the urethane layer is a coating layer provided by coating with a spray gun, the urethane layer is provided on the surface of the base body having the concave portion or shape and on the side surface of the base body, the urethane layer provided on the surface of the base body having the concave portion or shape and the urethane layer provided on the side surface of the base body are continuous, the mounting jig is fixed to a plate-shaped support material, The urethane layer has a smoothed surface, the thickness of the urethane layer is in the range of 4 to 7 mm, the urethane layer is obtained by coating multiple times, has no joints, no separated parts, has a uniform thickness, and is a continuous urethane layer that can form a single layer.

[0009] The manufacturing method of the second mounting jig of the present invention is a manufacturing method of a mounting jig for mounting the second vehicle component of the present invention, and may include a step of providing a urethane layer with a thickness in the range of 8 to 15 mm on a base body having a concave portion or shape corresponding to the shape of the vehicle component by spraying with a spray gun.

[0010] The manufacturing method of the third mounting jig of the present invention is a manufacturing method of a mounting jig for mounting the third vehicle component of the present invention, and may include a step of providing a urethane layer with a thickness in the range of 8 to 15 mm on the surface of a base body having a concave portion or shape corresponding to the shape of the vehicle component and on the side surface of the base body by spraying with a spray gun, and a step of smoothing the urethane layer to a thickness within the range of 4 to 7 mm.

[0011] The fourth mounting jig of the present invention is a mounting jig for mounting a vehicle component, and includes a base body having a concave portion corresponding to the shape of the vehicle component, and at least a urethane layer provided on the base body in the concave portion, the urethane layer is a coating layer, has no joints, no separated parts, has a uniform thickness, and is a continuous urethane layer that forms a single layer, and the base body can be made of at least one of expanded polystyrene and expanded urethane.

[0012] The fourth mounting jig of the present invention is The urethane layer is provided on the surface of the base body having the recess and on the side surface of the base body, the urethane layer provided on the surface of the base body having the recess and the urethane layer provided on the side surface of the base body can be continuous.

[0013] The manufacturing method of the fourth placing jig of the present invention is a manufacturing method of a placing jig for placing the fourth vehicle component of the present invention, including a step of providing a urethane layer on a base body having a recess corresponding to the shape of the vehicle component by painting, the base body can be made of at least one of polystyrene foam and urethane foam.

Brief Description of the Drawings

[0014]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Embodiments for Carrying Out the Invention

[0015] Hereinafter, preferred embodiments of the present invention will be described in detail.

[0016] The mounting jig 10 is for mounting vehicle components, and includes a base body 12 having a recess corresponding to the shape of the vehicle component, and a urethane layer 14 provided at least on the base body 12 in the recess 16. The base body 12 can be made of at least one of expanded polystyrene and expanded urethane.

[0017] To prevent damage to the object to be mounted, flocking may be applied to the urethane layer 14 or the layer (such as a coating layer) when any layer is provided on the urethane layer 14. A urethane paint coating is applied once or multiple times on the base body 12 having the recess 16 corresponding to the object to be mounted, for example, to provide a urethane layer 14 of 8 mm to 15 mm. Specifically, the urethane paint coating can be applied, for example, 5 times to provide a urethane layer 14 with a film thickness of 10 mm. If necessary, the urethane layer 14 is machined by cutting, leaving, for example, 4 to 7 mm, preferably 5 to 6 mm, and particularly preferably about 5 mm, to smooth the urethane layer 14. As shown in FIG. 5, the urethane paint can be applied to the foam material as the base body 12.

[0018] It can be fixed to various support materials (such as plywood) with embedded nuts or the like.

[0019] FIG. 2 and FIG. 3 show photographs of the mounting jig according to the embodiment. As shown in FIG. 2, the mounting jig 10 can be a three-dimensional body having a recess 16 and a curved surface or a flat surface. Further, as shown in FIG. 3, even when the mounting jig 10 does not have a recess, as a shape corresponding to the object to be mounted, the mounting jig 10 and the mounting portion are combined, and the object to be mounted may be mounted so as not to move from the mounting jig 10.

[0020] According to this embodiment, for example, the following effects are obtained.

[0021] In the production line for manufacturing and assembling automobiles, it is conceivable to use a receiving jig for placing interior parts (e.g., doors) and exterior parts (e.g., various garnishes). From the perspective of ease of processing to make the concave portion of the receiving part have a corresponding shape, it is also conceivable to configure the receiving jig with chemical wood. However, when configured with chemical wood, it is very heavy, difficult for a single person to hold, has poor workability, and is dangerous. On the other hand, according to the present embodiment, the inventors of the present application have confirmed that even a receiving jig with a shape that would be about 120 kg if made of chemical wood can be reduced to about 40 kg.

[0022] It is possible to achieve weight reduction, reduction of processing man-hours and processing time, cost reduction, and reduction of production schedule. Also, it is possible to produce an accurate design surface, has high adhesion to the foaming material, and has the effect of being difficult to peel off. By reducing man-hours (schedule), processing costs, and material costs, costs can be reduced from these aspects. Since weight reduction can be achieved, transfer becomes easier, movement such as detachment and transportation is facilitated, and the labor and cost of movement can also be reduced. Scraping / patching is also possible. It is possible to attach a finishing / stain-preventing film, perform exterior painting, and attach a skin.

[0023] From a design perspective, it has the effect that the design surface can be scraped and corrected and finally decorated. From the perspectives of safety and workability, since it becomes lighter, it leads to improvement in safety and workability. It has high recyclability after use, makes destruction and disposal easier, and can also reduce the disposal cost.

[0024] The inventors of the present application have also confirmed that a surface like a mirror can be realized. When checking the reflection of light from a fluorescent lamp, since the surface is not distorted, it has also been confirmed that the reflected light becomes a line.

[0025] It has been confirmed that even when coated multiple times, bubbles are less likely to occur, and since it adheres closely, it is possible to form a single layer without gaps.

[0026] 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% could be achieved, and that it was also effective in terms of safety measures. This leads to a reduction in material costs and processing costs, and therefore a reduction in costs and construction schedules. It can be carried by one person, which also improves the ease of transportation. There is no need for two or more workers for safety measures when moving or using it.

[0027] A comparison is made with methods described in the prior art. Regarding Prior Art Document 1 (JP Patent Publication No. 2014-016328) "The present invention relates to an inspection tool for inspecting the accuracy of interior materials of automobiles" (paragraph

[0028] ) Therefore, since it is an inspection jig for inspecting the accuracy of interior materials of automobiles, it is not a jig to be applied to the production line of manufacturing or assembling vehicles.

[0029] The document states that "the kneaded resin 12, which is made of a thermosetting resin as a base material, is roughly shaped to a predetermined thickness and layered on the surface 11a of the base before it is completely cured, and after the kneaded resin 12 is cured" This is not painting with a spray gun.

[0030] The document states, "After 48 hours, the thermosetting resin hardened and adhered to the hard resin foam of the base, and the thermosetting resin placed on the base was set in an NC processing machine together with the base, and the surface of the thermosetting resin was cut until it became a surface equivalent to the automobile interior material to be inspected, and then painted with urethane resin (coating thickness 20 μm) to finish it as a reference surface for inspection." From this description, it is clear that there was no idea of ​​painting urethane resin directly onto a base in an automobile inspection jig. It is also clear that there was no idea of ​​painting urethane resin on the order of millimeters, even if it was applied by painting.

[0031] In this document, regarding the pedestal 14, there is no description in the specification and it is only shown in FIG. 1 of this document. The pedestal 14 is only described as being provided partially at the ends and in the center simply to prevent the base 11 from directly contacting the ground. The pedestal 14 is not plate-shaped.

[0032] (i) Regarding Prior Art Document 2 (Japanese Patent Application Laid-Open No. 08-276934) In this document, it is described that "Therefore, it is possible to provide a foam pallet having necessary and sufficient quality as a pallet used for transporting goods, which is lightweight, has sufficient strength, does not easily peel off even under impact, and is easy to construct." The invention described in Prior Art Document 2 is for use in transporting goods and is not for placing interior or exterior parts used in an automobile production line.

[0033] In this document, it is described that "As shown in FIG. 2, the foam pallet of this embodiment has a pallet body 2 made of a foamed bead molded body of synthetic resin formed in a flat plate shape. Two fork insertion ports 3·3 for inserting the forks of a forklift are formed on the front surface of this pallet body 2, and similar fork insertion ports 4·4 are also formed on the side surface. Note that the fork insertion ports 3·4 of this embodiment have an open lower surface, but are not necessarily limited to this, and for example, it is also possible to have a shape with holes formed on the front or side surface." (Paragraph

[0034] )). From these descriptions, since it is an invention premised on forming fork insertion ports in the pallet body, providing a support member in the pallet body is not described.

[0035] In this document, it is described that "this urethane resin film 7 is, for example, a two-component type and solvent-free type urethane resin such as the product name 'Effrethane F-400 (manufactured by Nippon Gosei Chemical Industry Co., Ltd.)', spray-coated in two steps to a thickness of about 1 mm." From this description, it can be seen that there is no idea of thickly coating the urethane resin to a thickness of 8 to 15 mm.

[0036] Regarding Prior Art Document 3 (Japanese Patent Laid-Open No. 07-096554) In this document, it is described that "the present invention has been made in view of such a situation, and aims to enable the expression of an excellent surface texture by means of a foamed plastic." (paragraph

[0037] ). From this description, it can be seen that the invention described in Prior Art Document 3 is not for mounting heavy interior or exterior parts of a vehicle.

[0038] In this document, it is described that "that is, in step S3, as shown in FIG. 6, a sealer liquid is uniformly applied to the surface of the foamed plastic (including the fine hole portions on the surface) using an air spray gun or the like. Then, at a predetermined temperature for a predetermined time (for example, 55 degrees for 20 minutes), the surface of the foamed plastic coated with the sealer liquid is dried using, for example, an oven or a dryer, and as shown in FIG. 7, a sealer layer as a cured film (the portion shown by diagonal lines in the figure) is uniformly formed." (paragraph

[0039] ). From this description, it can be seen that the sealer layer is only thinly provided on the surface inside the fine pores, and there is no description of coating a urethane layer to improve the strength. It can be understood that this Prior Art Document 3 does not describe at all the concept of thickly coating a urethane resin to a thickness of 8 to 15 mm.

[0040] In this document, it is described that "since the surface of the foamed plastic is covered with a blocking layer, by processing the shape of this blocking layer, it becomes possible to express a fine shape." Also, it is described that "for example, when used for a product model, a texture equivalent to the actual one can be obtained." From these descriptions, the invention described in the prior art document 3 is considered an invention aimed at expressing a fine shape and obtaining a texture equivalent to the actual one.

[0041] In this document, it is described that "the present invention relates to a surface treatment method and a workpiece suitable for use when processing a foamed plastic such as polystyrene foam or foamed ABS resin into a predetermined shape and manufacturing a design model or the like." As is also clear from this description, the surface treatment method described in the prior art document 3 is a surface treatment method for a design model that has nothing to do with a jig for mounting interior or exterior parts of a vehicle.

[0042] E. Regarding Prior Art Document 4 (microfilm of Japanese Utility Model Application No. 57-082221 (Japanese Utility Model Publication No. 58-184234))

[0043] In this document, it is described that "the present invention relates to an improvement of an assembly jig used when assembling power tools and other members" (from the 6th to the 7th lines from Tokuraku on the first page). It does not relate to an assembly jig applied to a production line for manufacturing or assembling vehicles. Also, a specific method for forming the coating film is not disclosed, nor is the thickness of the coating film described. Furthermore, there is no description that the coating film is a urethane resin.

[0044] A comparison is made between this embodiment and the prior art documents. (A) Comparison between this embodiment and prior art document 1 In Prior Art Document 1, it is described that "the present invention relates to an inspection jig for inspecting the accuracy of automotive interior materials, etc." The uses of an inspection jig for inspecting the accuracy of automotive interior materials, etc. and a jig applied to a production line for vehicle manufacturing or assembly are different. Since high accuracy is required for the inspection jig, and a urethane layer also requires a considerable thickness, Prior Art Document 1 is not a prior art document that can be considered as the main cited invention that can lead to the present embodiment. It can be said that the invention described in Prior Art Document 1 actively excludes directly coating the urethane resin on the base, and there is no idea of coating the urethane resin within the range of 4 to 7 mm using a spray gun.

[0045] In this document, it is described that "before the kneaded resin 12 made of a thermosetting resin is completely cured, it is roughly shaped to a predetermined thickness and laminated on the surface 11a of the base, and after the kneaded resin 12 is cured". Since Prior Art Document 1 does not involve coating with a spray gun, it is different from the present embodiment.

[0046] In this document, it is described that "after 48 hours, the thermosetting resin is cured and adheres to the rigid resin foam of the base. Then, the thermosetting resin placed on the base is set together with the base in an NC machining machine, and cutting is performed until the surface of the thermosetting resin becomes a surface conforming to the automotive interior material to be inspected. Further, coating with urethane resin (coating film thickness: 20 μm) is performed to finish it as an inspection reference surface." From this description, it can be seen that in the inspection jig for automobiles, there was no idea of directly coating the urethane resin on the base. Also, from the description of the coating film thickness of 20 μm, it can be seen that even if the urethane resin is provided by coating, there was no idea of coating urethane with a thickness of 8 to 15 mm.

[0047] In that document, there is no description of the pedestal 14 in the specification, and it is only shown in FIG. 1 of that document. It is only described that it is partially provided locally at the ends and in the center simply to prevent the base 11 from directly contacting the ground. On the other hand, in the present embodiment, the support member is plate-shaped. Therefore, according to the present embodiment, since the base body can be received by the plate-shaped support member, the distortion of the base body can be suppressed.

[0048] In relation to the prior art document 1, when pasting 10 to 20 mm with kneaded resin by hand, it is assumed that the working time takes about 16 hours when making a jig for the door. The adhesion is low, and bubbles and voids are generated. Compared with the prior art document 1, the present embodiment has an advantageous effect that when making a jig for the door, urethane resin can be applied within 1 hour, the adhesion is high, and bubbles and voids are less likely to occur.

[0049] In the case of kneaded resin, the thickness is about 10 to 15 mm, and there is a problem of being heavy. Manually mix an aliphatic amine-based curing agent into a kneaded resin containing a thermosetting epoxy resin, place it between punching presses, pound and expand the mass of the kneaded resin, place it on a rigid resin foam, and press it by hand to make it adhere to the surface of the base. The curing time also takes 48 hours (paragraph

[0050] ). The workability is poor and the working speed is slow. The adhesion to the foam material is very poor and it peels off. In the case of kneaded resin, many unintended holes (so-called honeycombs) as shown in FIG. 7 are generated on the surface and need to be repaired each time. Specifically, in the case of kneaded resin, a layer of uniform thickness cannot be realized, and separation occurs between adjacent pressed kneaded resins, or a line indicating a joint can be seen.

[0051] On the one hand, according to this embodiment, a urethane layer with a thickness of about 4 mm can be realized, and weight reduction can also be achieved. Even for complex shapes, the coating film can be overlapped and covered by spraying. The workability is good, and the working speed can also be increased. The curing time is about 4 hours. The adhesion to the foaming material is very good, and as shown in FIG. 6, there is also the merit that unintended holes (so-called honeycombs) do not occur. There are no joints like kneaded resin, no separated parts are generated, and a uniform thickness, uniform surface, and continuous urethane layer are realized.

[0052] (A) Comparison between this embodiment and prior art document 2 In prior art document 2, it is described that "this urethane resin film 7 is, for example, a two-component type and solvent-free type urethane resin such as the product name 'Effrethane F-400 (manufactured by Nippon Synthetic Chemical Industry Co., Ltd.)' sprayed and coated in two steps to a thickness of about 1 mm." (Paragraph

[0053] ), it is not assumed to provide a urethane layer in the range of 8 to 15 mm as in this embodiment.

[0054] (C) Comparison between this embodiment and prior art document 3 Although the film thickness is not specifically described in prior art document 3, it is considered that it is premised on a very thin coating layer because it is thick enough to cover the surface of the micropores. On the other hand, in this embodiment, a coating film is provided with a thickness that actively fills the micropores if there are micropores in the substrate.

[0055] (E) Comparison between this embodiment and prior art document 3 Prior art document 4 describes that "the present invention relates to an improvement of an assembly jig used when assembling power tools and other members", so it is not related to an assembly jig applied to a production line for manufacturing or assembling vehicles, which is different from this embodiment. In addition, a specific formation method of the coating film is not disclosed, and the thickness of the coating film is not described either. Furthermore, there is no description that the coating film is a urethane resin.

Example

[0056] Hereinafter, examples according to the present invention will be described. (Example) A urethane paint coating was applied to the substrate five times to provide a urethane layer 14 with a film thickness of 10 mm. The urethane layer 14 was machined by cutting, leaving about 4 mm, and the urethane layer 14 was smoothed. In this example, a urethane layer with a thickness of about 4 mm can be realized, and weight reduction can also be achieved. Even for complex shapes, the spray coating film can be overlapped and covered. The workability is good, and the working speed can also be increased. The curing time is about 4 hours. The adhesion to the foam material is very good, and as shown in FIG. 6, there is also an advantage that no unintended holes are generated. There are no joints like kneaded resin, no separated parts are generated, and a uniform thickness and continuous urethane layer are realized.

[0057] (Comparative Example) Manually, an aliphatic amine-based curing agent was blended into a kneaded resin containing a thermosetting epoxy resin, placed between punching presses, and the mass of the kneaded resin was pounded and expanded. Then it was placed on a rigid resin foam and pressed by hand to adhere to the surface of the base. A kneaded resin was provided on the base and cured. The curing time of the kneaded resin was set to 48 hours (paragraph

[0058] ). According to the method of the comparative example, the workability is poor and the working speed is slow. The adhesion to the foam material is very poor and it peels off. In the case of the kneaded resin, as shown in FIG. 7, many unintended holes (so-called cavities) were generated on the surface. Specifically, in the case of the kneaded resin, a layer with a uniform thickness could not be realized, and separation occurred between adjacent pressed kneaded resins, or lines where joints could be seen appeared.

[0059] It is particularly useful for mounting jigs that require weight reduction, ease of processing, workability, design, and adhesion.

[0060] This embodiment can be variously modified within the scope of the present invention.

Explanation of Reference Numerals

[0061] 10 Placement jig 12 Substrate 14 Urethane layer 16 Recess

Claims

1. A mounting jig for mounting a vehicle component, comprising a base body having a concave portion or shape corresponding to the shape of the vehicle component, and a urethane layer provided at least on the base body in the concave portion, wherein the mounting jig is used for mounting interior or exterior components in a production line for vehicle manufacturing or assembly, the urethane layer is a coating layer provided by spraying with a spray gun, the mounting jig is fixed to a plate-shaped support member, the thickness of the urethane layer is in the range of 8 to 15 mm, the urethane layer is obtained by applying multiple coats, has no joints, no separated portions, and is a continuous urethane layer constituting a single layer, a mounting jig.

2. A mounting jig for mounting a vehicle component, comprising a base body having a concave portion or shape corresponding to the shape of the vehicle component, and a urethane layer provided at least on the base body in the concave portion, wherein the mounting jig is used for mounting interior or exterior components in a production line for vehicle manufacturing or assembly, the urethane layer is a coating layer provided by spraying with a spray gun, the urethane layer is provided on the surface of the base body having the concave portion or shape and on the side surface of the base body, the urethane layer provided on the surface of the base body having the concave portion or shape and the urethane layer provided on the side surface of the base body are continuous, the mounting jig is fixed to a plate-shaped support member, the urethane layer has a smoothed surface, the thickness of the urethane layer is in the range of 4 to 7 mm, the urethane layer is obtained by applying multiple coats, has no joints, no separated portions, and is a continuous urethane layer constituting a single layer, a mounting jig.

3. A method for manufacturing a mounting jig for mounting a vehicle component according to Claim 1, the method for manufacturing a mounting jig including a step of providing a urethane layer having a thickness in the range of 8 to 15 mm on a base body having a concave portion or shape corresponding to the shape of the vehicle component by spraying with a spray gun.

4. A method for manufacturing a mounting jig for mounting a vehicle component according to Claim 2, A step of providing, by spraying with a spray gun, a urethane layer having a recess corresponding to the shape of the vehicle component member or a surface of a base body having a shape, and a urethane layer having a thickness in the range of 8 to 15 mm on a side surface of the base body; A method for manufacturing a mounting jig, including a step of smoothing the urethane layer to a thickness within a range of 4 to 7 mm.

5. A mounting jig for mounting a vehicle component member, A base body having a recess corresponding to the shape of the vehicle component member, Including at least a urethane layer provided on the base body in the recess, The urethane layer is a coating layer, without joints, no separated portions occur, has a uniform thickness, and is a continuous urethane layer, constituting a single layer, The base body is a mounting jig made of at least one of expanded polystyrene and expanded urethane.

6. In Claim 5, The urethane layer is provided on a surface of the base body having the recess and on a side surface of the base body, A mounting jig in which the urethane layer provided on the surface of the base body having the recess and the urethane layer provided on the side surface of the base body are continuous.

7. A method for manufacturing a mounting jig for mounting a vehicle component member according to Claim 5, Including a step of providing a urethane layer on a base body having a recess corresponding to the shape of the vehicle component member by coating, The base body is a method for manufacturing a mounting jig made of at least one of expanded polystyrene and expanded urethane.

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