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 technology]

[0002] In automobile production, assembly work of automobile parts is carried out using a panel parts holding jig (see Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Utility Model Application Publication No. 54-45231 Summary of the Invention [Problem to be solved by the invention]

[0004] An object of the present invention is to provide a mounting jig that can be made lighter and a method for manufacturing the same. [Means for solving the problem]

[0005] The first mounting jig of the present invention is A mounting jig for mounting a vehicle component, a base body having a recess corresponding to the shape of the vehicle component; a urethane layer provided on the base at least in the recess; The substrate is made of at least one of polystyrene foam and urethane foam.

[0006] The first method for manufacturing a mounting jig of the present invention includes the steps of: A method for manufacturing a mounting jig for mounting a vehicle component, providing a urethane layer on a substrate having a recess corresponding to the shape of the vehicle component; The substrate is made of at least one of polystyrene foam and urethane foam. In the present invention, The method may include a step of scraping and smoothing the surface portion of the urethane layer.

[0007] The second mounting jig of the present invention is A mounting jig for mounting a vehicle component, a base having a recess or shape corresponding to the shape of the vehicle component; a urethane layer provided on the base at least in the recess; The mounting jig is used when mounting an interior part or an exterior part in a production line for manufacturing or assembling a vehicle, the urethane layer is a coating layer formed by painting 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 applying it multiple times, and is a continuous urethane layer without any joints or separated areas, and can constitute a single layer.

[0008] The third mounting jig of the present invention is A mounting jig for mounting a vehicle component, a base having a recess or shape corresponding to the shape of the vehicle component; a urethane layer provided on the base at least in the recess; The mounting jig is used when mounting an interior part or an exterior part in a production line for manufacturing or assembling a vehicle, the urethane layer is a coating layer formed by painting with a spray gun, the urethane layer is provided on the recessed or shaped surface of the base and on the side surface of the base, the urethane layer provided on the surface of the base having the recess or shape and the urethane layer provided on the side surface of the base 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 applying it multiple times, and has no seams or separated areas, and is a continuous urethane layer of uniform thickness, which can constitute a single layer.

[0009] The second method for manufacturing a mounting jig of the present invention includes the steps of: A method for manufacturing a mounting jig for mounting a second vehicle component of the present invention, The method may include a step of applying a urethane layer having a thickness in the range of 8 to 15 mm by spray gun onto a substrate having a recess or shape corresponding to the shape of the vehicle component.

[0010] The third method for manufacturing a mounting jig of the present invention includes the steps of: A manufacturing method of a mounting jig for mounting a third vehicle component of the present invention, a step of providing a urethane layer having a thickness of 8 to 15 mm on a surface of a base having a recess or shape corresponding to the shape of the vehicle component and on a side surface of the base by painting with a spray gun; and smoothing the urethane layer to a thickness in 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, a base body having a recess corresponding to the shape of the vehicle component; a urethane layer provided on the base at least in the recess; The urethane layer is a coating layer, and is a continuous urethane layer with no seams or separated portions, having a uniform thickness, and constituting a single layer; The substrate may be made of at least one of polystyrene foam and urethane foam.

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

[0013] A fourth method for manufacturing a mounting jig according to the present invention includes the steps of: A fourth method for manufacturing a mounting jig for mounting a vehicle structural member according to the present invention, a step of providing a urethane layer by painting on a substrate having a recess corresponding to the shape of the vehicle component; The substrate may be made of at least one of polystyrene foam and urethane foam. [Brief explanation of the drawings]

[0014] [Figure 1] FIG. 2 is a diagram schematically illustrating a mounting jig according to an embodiment. [Figure 2] 1 is a photograph of a mounting jig according to an embodiment. [Figure 3] 1 is a photograph of a mounting jig according to an embodiment. [Figure 4] 3A and 3B are diagrams illustrating a layer structure of a mounting jig according to an embodiment. [Figure 5] This is a photo to explain how to paint urethane paint on foam material. [Figure 6] 1 is a photograph of a mounting jig according to an example. [Figure 7] 10 is a photograph of a mounting jig according to a comparative example. DETAILED DESCRIPTION OF THE INVENTION

[0015] Preferred embodiments of the present invention will now be described in detail.

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

[0017] To prevent damage to the object to be placed on it, the urethane layer 14, or any other layer (e.g., a paint layer) provided on the urethane layer 14, may be flocked. A urethane paint coating is applied once or multiple times to a substrate 12 having a recess 16 corresponding to the object to be placed on it, to provide a urethane layer 14 with a thickness of, for example, 8 mm to 15 mm. Specifically, the urethane paint coating may be applied, for example, five times, to provide a urethane layer 14 with a thickness of, for example, 10 mm. If necessary, the urethane layer 14 may be machined to smooth the urethane layer 14, leaving, for example, a thickness of 4 to 7 mm, preferably 5 to 6 mm, and particularly preferably about 5 mm. As shown in FIG. 5, the urethane paint may be applied to a foam material serving as the substrate 12.

[0018] It can be fixed to various supports (e.g. plywood) using embedded nuts or the like.

[0019] 2 and 3 show photographs of a mounting jig according to an embodiment. As shown in Fig. 2, the mounting jig 10 can be a three-dimensional body having a recess 16 and a curved or flat surface. Furthermore, as shown in Fig. 3, even if the mounting jig 10 does not have a recess, the mounting jig 10 and a mounting portion may be mated to accommodate an object to be mounted, so that the object does not move from the mounting jig 10.

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

[0021] In automobile manufacturing and assembly production lines, it is conceivable to use support jigs for placing interior parts (e.g., doors) and exterior parts (e.g., various garnishes). It is conceivable to construct the support jig out of chemical wood, as it is easy to process the recesses of the support parts into corresponding shapes. However, if it is constructed out of chemical wood, it will be very heavy, making it difficult for one person to carry it, making it difficult to work with and dangerous. On the other hand, the inventors of this application have confirmed that, according to this embodiment, a support jig of a shape that would weigh approximately 120 kg if made out of chemical wood can be made to weigh approximately 40 kg.

[0022] It is possible to reduce weight, reduce processing labor and time, cut costs, and shorten production schedules. It also allows for the production of precise design surfaces, has strong adhesion to foam materials, and is less likely to peel off. Costs can be reduced through reduced labor (schedule), processing costs, and material costs. Because it is lightweight, it is easy to transport, remove, and move, reducing the labor and cost of transportation. It can also be scraped / puttyed. Finishing and stain-resistant film can be applied, and exterior painting and skin application are possible.

[0023] From a design perspective, it has the effect of allowing for the design surface to be scraped and corrected, and final decoration to be added. From the perspective of safety and workability, it is lighter, which leads to improved safety and workability. It is highly recyclable after use, making destruction disposal easier and reducing disposal costs.

[0024] The inventors of the present invention have also confirmed that a mirror-like surface can be achieved. When light from a fluorescent lamp is reflected, the surface is not distorted, and the reflected light appears as a line.

[0025] It was confirmed that the adhesive is tightly adhered and does not easily produce bubbles even when applied multiple times, making it possible to form a single layer without gaps.

[0026] In an actual comparison with a manufacturing method using chemical wood, the inventors confirmed that the resin mass was approximately 1 / 6, and a significant reduction of approximately 70% in total weight was achieved, and that this method is also effective in terms of safety measures. This leads to reduced material and processing costs, thereby confirming a reduction in costs and construction time. It can be carried by one person, improving portability. There is no need for two or more workers for safety measures during transportation and use.

[0027] A comparison is made with methods described in the prior art literature. A. Regarding Prior Art Document 1 (JP 2014-016328 A) The document states that "the present invention relates to an inspection jig for inspecting the accuracy of interior materials of automobiles, etc." 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 a production line for manufacturing or assembling vehicles.

[0028] The document states that "a kneaded resin 12 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 hardened, and after the kneaded resin 12 is hardened..." It is not painted with a spray gun.

[0029] The document states, "After 48 hours, the thermosetting resin hardened and adhered to the rigid resin foam base. The thermosetting resin placed on the base was then set in an NC processing machine, and the base was machined until the surface of the thermosetting resin conformed to the automotive interior material to be inspected. The surface was then painted with urethane resin (20 μm thick) to create a reference surface for inspection." This description reveals that no one had ever thought of painting urethane resin directly onto a base in an automotive inspection jig. It also reveals that no one had ever thought of painting urethane resin on a millimeter-order surface, even if it was painted.

[0030] In this document, there is no explanation for the pedestal 14 in the specification, and it is only shown in Figure 1 of the document. The document only describes that the pedestal 14 is provided partially at the edge and center to prevent the base 11 from directly contacting the ground. The pedestal 14 is not plate-shaped.

[0031] Regarding Prior Art Document 2 (JP Patent Publication No. 08-276934) The document states, "Therefore, it is possible to provide a foam pallet that is lightweight, has sufficient strength, does not easily peel off even when subjected to impact, and is easy to install, and therefore has the necessary and sufficient qualities for use as a pallet for transporting cargo." The invention described in Prior Art Document 2 is for use in transporting cargo, and is not for placing interior or exterior parts used in automobile production lines.

[0032] The document states, "The foam pallet of this embodiment has a pallet body 2 made of a flat, foamed synthetic resin bead molded body, as shown in Figure 2. Two fork insertion openings 3·3 for inserting the forks of a forklift are formed on the front of this pallet body 2, and similar fork insertion openings 4·4 are formed on the side. Note that, although the fork insertion openings 3·4 in this embodiment are open on the bottom, this is not necessarily the case, and for example, holes may be formed on the front or side." From these descriptions, it can be seen that the invention is premised on the formation of fork insertion openings in the pallet body, and there is no mention of providing a support material on the pallet body.

[0033] The document states, "This urethane resin film 7 is formed by spraying a two-component, fast-curing, solvent-free urethane resin, such as Efuretan F-400 (manufactured by Nippon Synthetic Chemical Industry Co., Ltd.), in two separate coats to a thickness of, for example, about 1 mm." This description reveals that there is no idea of ​​applying a thick coat of urethane resin to a thickness of 8 to 15 mm.

[0034] Regarding Prior Art Document 3 (JP Patent Publication No. 07-096554) The document states, "The present invention has been made in consideration of the above circumstances, and aims to make it possible to express excellent surface textures using foamed plastics." From this description, it can be seen that the invention described in Prior Art Document 3 is not intended to carry heavy interior or exterior vehicle parts.

[0035] The document states, "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 micropores on the surface) using an air spray gun or the like. Then, the surface of the foamed plastic to which the sealer liquid has been applied is dried at a predetermined temperature for a predetermined time (for example, at 55°C for 20 minutes) using, for example, an oven or a dryer, and a sealer layer (the area indicated by diagonal lines in the figure) is uniformly formed as a hardened film, as shown in FIG. 7." From this description, it is clear that the sealer layer is only formed thinly on the surface inside the micropores, and there is no mention of applying a urethane layer to improve strength. It is clear that Prior Art Document 3 does not at all mention the concept of applying a thick coat of urethane resin to a thickness of 8 to 15 mm using a spray gun.

[0036] The document states, "Because the surface of foamed plastic is covered with a sealing layer, it is possible to express fine shapes by processing the shape of this sealing layer." It also states, "For example, when used in a product model, it is possible to obtain textures and the like equivalent to the actual product." From these statements, it can be considered that the invention described in Prior Art Document 3 is an invention whose main purpose is to express fine shapes and obtain textures and the like equivalent to the actual product.

[0037] The document states, "The present invention relates to a surface treatment method and a workpiece suitable for use in processing foamed plastics, such as polystyrene foam or foamed ABS resin, into a predetermined shape to produce design models, etc." As is clear from this description, the surface treatment method described in Prior Art Document 3 is a surface treatment method for design models that has absolutely no relation to jigs for mounting interior or exterior vehicle parts.

[0038] Regarding prior art document 4 (microfilm of Japanese Utility Model Application No. 57-082221 (Japanese Utility Model Application No. 58-184234))

[0039] The document states, "The present invention relates to an improvement in an assembly jig used in assembling power tools and other components" (lines 6-7 from the beginning of the paragraph on page 1). It does not relate to an assembly jig applied to a production line for manufacturing or assembling vehicles. Furthermore, the document does not disclose a specific method for forming the coating film, nor does it mention the thickness of the coating film. Furthermore, it does not mention that the coating film is made of urethane resin.

[0040] The present embodiment will be compared with prior art documents. (A) Comparison of the present embodiment with prior art document 1 Prior Art Document 1 states, "The present invention relates to an inspection jig for inspecting the accuracy of automobile interior materials, etc." Inspection jigs for inspecting the accuracy of automobile interior materials, etc., have different uses from jigs used on vehicle manufacturing or assembly production lines. Since inspection jigs require high precision, the urethane layer also needs to be quite thick. Therefore, Prior Art Document 1 is not a prior art document that serves as the primary cited invention for the present embodiment. It can be said that the invention described in Prior Art Document 1 actively excludes the application of the urethane resin of the present invention, which is directly applied to a base, and does not include the idea of ​​applying the urethane resin within a range of 4 to 7 mm using a spray gun.

[0041] The document states that "a kneaded resin 12 made of a thermosetting resin as a base material is roughly shaped to a predetermined thickness before it is completely hardened and is layered on the surface 11a of the base, and after the kneaded resin 12 is hardened..." Prior art document 1 differs from the present embodiment in that it does not use a spray gun for painting.

[0042] The document states, "After 48 hours, the thermosetting resin hardened and adhered to the rigid resin foam base. The thermosetting resin placed on the base was then set in an NC processing machine, and the base was machined until the surface of the thermosetting resin conformed to the automotive interior material to be inspected. The surface was then painted with urethane resin (20 μm thick) to create a reference surface for inspection." This description reveals that no one had ever considered painting urethane resin directly onto a base in an automotive inspection jig. Furthermore, the mention of a 20 μm thick paint film reveals that even if the urethane resin was applied by painting, no one had ever considered painting the urethane to a thickness of 8 to 15 mm.

[0043] In this document, the specification does not explain the pedestal 14, and it is only shown in Figure 1 of the document, where it is simply described that the pedestal 14 is provided partially at the edge and center to prevent the base 11 from directly contacting the ground. On the other hand, in this embodiment, the support material is plate-shaped. Therefore, according to this embodiment, the base can be supported by the plate-shaped support material, which can suppress distortion of the base.

[0044] In relation to Prior Art Document 1, when making a jig for a door, it is estimated that the work time required to manually apply 10 to 20 mm of kneaded resin would be approximately 16 hours, resulting in poor adhesion and the formation of air bubbles and holes. Compared to Prior Art Document 1, this embodiment has the advantageous effect that when making a jig for a door, the urethane resin can be applied within one hour, the adhesion is high, and air bubbles and holes are less likely to form.

[0045] The problem with kneaded resin is that it is heavy, with a thickness of approximately 10 to 15 mm. The kneaded resin, containing thermosetting epoxy resin, is manually mixed with an aliphatic amine-based curing agent, placed between punching presses, and the kneaded resin mass is hammered and expanded. It is then placed on a rigid resin foam and manually pressed to adhere to the surface of the base, requiring 48 hours for hardening. This process is difficult to work with and requires slow speed. Its adhesion to the foam is very poor, resulting in peeling. Kneaded resin often develops unintended holes (so-called voids) on the surface, as shown in Figure 7, requiring frequent repairs. Specifically, it is not possible to achieve a layer of uniform thickness with kneaded resin; adjacent pressed kneaded resins separate, or visible seams are visible.

[0046] On the other hand, according to this embodiment, a urethane layer with a thickness of about 4 mm can be achieved, and weight can also be reduced. Even complex shapes can be covered by layering spray paint films. It is easy to work with and can be worked quickly. The curing time is about 4 hours. It has excellent adhesion to the foam material, and as shown in Figure 6, it has the advantage of not causing unintended holes (so-called voids). Unlike kneaded resin, there are no seams or separated areas, and a continuous urethane layer with uniform thickness and a uniform surface is achieved.

[0047] (A) Comparison of the present embodiment with prior art document 2 Prior art document 2 states that "This urethane resin film 7 is formed by spraying a two-component, fast-curing, solvent-free urethane resin, such as Efuretan F-400 (manufactured by Nippon Synthetic Chemical Industry Co., Ltd.), in two separate coats to a thickness of, for example, about 1 mm," and does not anticipate providing a urethane layer in the range of 8 to 15 mm, as in the present embodiment.

[0048] (C) Comparison of this embodiment with prior art document 3 Although Prior Art Document 3 does not specifically describe the film thickness, it is assumed that a very thin coating layer is used, as it is thick enough to cover the surface of the micropores. On the other hand, in the present embodiment, if there are micropores in the substrate, the coating film is provided with a thickness that actively fills the micropores.

[0049] (D) Comparison of the present embodiment with prior art document 3 Prior Art Document 4 states that "the present invention relates to an improvement in an assembly jig used in assembling power tools and other components," and therefore does not relate to an assembly jig applied to a production line for manufacturing or assembling vehicles, and is different from the present embodiment. Furthermore, it does not disclose a specific method for forming the coating film, nor does it describe the thickness of the coating film. Furthermore, it does not state that the coating film is made of urethane resin. [Example]

[0050] Hereinafter, an embodiment of the present invention will be described. (Example) The substrate was coated with urethane paint five times to create a 10 mm thick urethane layer 14. The urethane layer 14 was then machined, leaving approximately 4 mm of the urethane layer 14, and smoothed. In this example, a urethane layer approximately 4 mm thick was achieved, which also contributes to weight reduction. Even complex shapes can be covered by layering spray-painted coatings. The process is easy to work with and allows for fast work speeds. The curing time is approximately 4 hours. It has excellent adhesion to the foam material, and as shown in Figure 6, it also has the advantage of preventing unintended pores. Unlike kneaded resins, there are no seams or separated areas, and a uniformly thick and continuous urethane layer was achieved.

[0051] (Comparative Example) An aliphatic amine-based curing agent was manually mixed into a kneaded resin containing a thermosetting epoxy resin, which was then placed between punching presses to beat and expand the kneaded resin mass. The kneaded resin was then placed on a rigid resin foam and manually pressed against the surface of the base. The kneaded resin was then applied to the base and allowed to harden. The kneaded resin hardened for 48 hours. The comparative method was difficult to work with and slow to operate. Its adhesion to the foam was very poor, resulting in peeling. In the case of the kneaded resin, many unintended holes (so-called voids) appeared on the surface, as shown in Figure 7. Specifically, the kneaded resin failed to achieve a layer of uniform thickness; adjacent pressed kneaded resins separated, and visible seams were visible.

[0052] It is particularly useful for mounting jigs that require light weight, ease of processing, workability, designability, and adhesion.

[0053] This embodiment can be modified in various ways within the scope of the present invention. [Explanation of symbols]

[0054] 10 Mounting jig 12 Base 14 Urethane layer 16 Recess

Claims

1. A mounting jig for mounting a vehicle component, a base having a recess or shape corresponding to the shape of the vehicle component; a urethane layer provided on the base at least in the recess; The mounting jig is used when mounting an interior part or an exterior part in a production line for manufacturing or assembling a vehicle, the urethane layer is a coating layer formed by painting 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 applying it multiple times, and is a continuous urethane layer without any seams or separated areas, and is a mounting jig that constitutes a single layer.

2. A mounting jig for mounting a vehicle component, a base having a recess or shape corresponding to the shape of the vehicle component; a urethane layer provided on the base at least in the recess; The mounting jig is used when mounting an interior part or an exterior part in a production line for manufacturing or assembling a vehicle, the urethane layer is a coating layer formed by painting with a spray gun, the urethane layer is provided on the recessed or shaped surface of the base and on the side surface of the base, the urethane layer provided on the surface of the base having the recess or shape and the urethane layer provided on the side surface of the base 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 applying it multiple times, and is a continuous urethane layer without any seams or separated areas, and is a mounting jig that constitutes a single layer.

3. A method for manufacturing a mounting jig for mounting the vehicle component according to claim 1, A method for manufacturing a mounting jig, comprising a step of applying a urethane layer having a thickness of 8 to 15 mm on a base having a recess 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 the vehicle component according to claim 2, a step of applying a urethane layer having a thickness of 8 to 15 mm on a surface of a substrate having a recess or shape corresponding to the shape of the vehicle component and on a side surface of the substrate by spray gun; and smoothing the urethane layer to a thickness in the range of 4 to 7 mm.

5. A mounting jig for mounting a vehicle component, a base body having a recess corresponding to the shape of the vehicle component; a urethane layer provided on the base at least in the recess; The urethane layer is a coating layer, has no joints or separated portions, is a uniformly thick, continuous urethane layer, and constitutes a single layer; The base is a mounting jig made of at least one of polystyrene foam and urethane foam.

6. In claim 5, the urethane layer is provided on a surface of the base having a recess and on a side surface of the base, The urethane layer provided on the surface of the base having the recess and the urethane layer provided on the side surface of the base are continuous with each other.

7. A method for manufacturing a mounting jig for mounting the vehicle component according to claim 5, a step of providing a urethane layer by painting on a substrate having a recess corresponding to the shape of the vehicle component; The method for manufacturing a mounting jig, wherein the base is made of at least one of polystyrene foam and urethane foam.

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