Method for creating repair sheet and method for managing repair sheet

Abstract

To provide a repair sheet production method which can achieve flawless repair, and to provide a repair sheet management method which enables easy search of the repair sheet.SOLUTION: A repair sheet production method includes: a first step S1 in which non-polar resin plates are attached to positions, which correspond to repair portions formed with paint coats to be repaired, of a dummy vehicle body; a second step S2 in which the dummy vehicle body is moved on a top coat application line and a colored layer and a clear layer are respectively formed on the non-polar resin plates under same conditions as top coat application of a vehicle body actually painted; a third step S3 in which the dummy vehicle body is moved on a paint dry line and the non-polar resin plate formed with the colored layer and the non-polar resin plate formed with the clear layer are dried under the same conditions as paint dry of the vehicle body actually painted; and a fourth step S4 in which the non-polar resin plate formed with the colored layer and the non-polar resin plate formed with the clear layer are removed from the dummy vehicle body to be cut.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a method for creating a repair sheet for repairing a paint film on a vehicle body and a method for managing the repair sheet.

Background Art

[0002] As a method for creating a repair sheet for repairing a damaged portion of a paint film, for example, there is one described in Patent Document 1. In this Patent Document 1, a method is disclosed in which a base layer, a pattern layer, and a clear layer are sequentially formed on a peelable surface using a paint having the same composition as the damaged paint film, and the formed product is dried to create a repair sheet. Then, when repairing the damaged portion of the paint film, the created repair sheet is cut to an appropriate size and attached to the damaged portion with an adhesive.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, even when using a paint having the same composition as the damaged paint film, the color tone of the created repair sheet may change due to differences in drying conditions and the like. For this reason, it has been difficult to repair the damaged portion without a sense of incongruity.

[0005] The present invention has been made to solve such technical problems, and an object thereof is to provide a method for creating a repair sheet and a method for managing the repair sheet that can achieve a repair without a sense of incongruity.

Means for Solving the Problems

[0006] The method for creating a repair sheet according to the present invention is a method for creating a repair sheet for repairing a paint film on a vehicle body, including: a first step of detachably attaching a non-polar resin plate to a corresponding position of a dummy vehicle body corresponding to a repair site where the paint film to be repaired is formed; a second step of flowing the dummy vehicle body through a topcoat painting line and forming a colored layer or a clear layer, or both the colored layer and the clear layer, on the non-polar resin plate under the same conditions as the topcoat painting of an actually painted vehicle body; and a third step of flowing the dummy vehicle body through a paint drying line and drying the non-polar resin plate on which the colored layer or the clear layer, or both the colored layer and the clear layer are formed, under the same conditions as the paint drying of an actually painted vehicle body.

[0007] According to the method for creating a repair sheet of the present invention, by forming and drying a colored layer or a clear layer, or both a colored layer and a clear layer on a non-polar resin plate under the same conditions as the topcoat painting and paint drying of an actually painted vehicle body, it is possible to create a repair sheet having a color tone close to the paint color of the actually painted vehicle body. In addition, since the topcoat painting and paint drying are performed with the non-polar resin plate attached to the corresponding position of the dummy vehicle body corresponding to the repair site where the paint film to be repaired is formed, it is possible to prevent a difference in color tone due to a positional deviation, and it is possible to create a repair sheet having almost the same color tone as the paint color of the actually painted vehicle body. Then, when performing repair using the repair sheet created in this way, it is possible to realize a repair without a sense of incongruity.

[0008] In the method for creating a repair sheet according to the present invention, in the second step, when forming the colored layer, or both the colored layer and the clear layer, on the non-polar resin plate, it is preferable to form the colored layer so as to change the thickness. By forming the colored layer so as to change the thickness, it is possible to impart a gradation to the color tone of the repair sheet. As a result, among the repair sheets, by selecting a portion matching the color tone of the paint film to be repaired and performing repair with the selected portion, it is possible to easily perform color adjustment of the paint film to be repaired, and it becomes easier to realize a repair without a sense of incongruity.

[0009] Further, the method for managing a repair sheet according to the present invention is characterized by associating and managing vehicle lot information including paint information applied to a vehicle body and repair sheet lot information including paint information used for a repair sheet for repairing a paint film of the vehicle body.

[0010] In the method for managing a repair sheet according to the present invention, since the vehicle lot information and the repair sheet lot information are associated and managed, the lot information of the vehicle can be specified based on the vehicle having the paint film to be repaired, and further, the lot information of the repair sheet can be specified based on the lot information of the vehicle. As a result, it is possible to easily search for a repair sheet corresponding to the paint film to be repaired, and it becomes easier to adjust the color of the paint film to be repaired.

Effects of the Invention

[0011] According to the present invention, it is possible to realize a repair without a sense of incongruity.

Brief Description of the Drawings

[0012]

Figure 1

Figure 2A

Figure 2B

Figure 2C

Figure 2D

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Embodiments for Carrying Out the Invention

[0013] Hereinafter, a method for creating a repair sheet and a method for managing a repair sheet according to the present invention will be described with reference to the drawings. In the description of the drawings, the same reference numerals are given to the same elements, and the overlapping description thereof will be omitted.

[0014] [Regarding the method for creating a repair sheet] First, a method for creating a repair sheet will be described.

[0015] [First Embodiment] A first embodiment of a method for creating a repair sheet will be described based on FIGS. 1 to 5. The method for creating a repair sheet according to this embodiment is a method for creating a repair sheet used for repairing a paint film of a vehicle body. As shown in FIG. 1, this method for creating a repair sheet includes a first step S1 of attaching a non-polar resin plate to a corresponding position of a dummy vehicle body, a second step S2 of forming a colored layer and a clear layer on the non-polar resin plate under the same conditions as the topcoat painting of the actually painted vehicle body, a third step S3 of drying the non-polar resin plate with the colored layer formed thereon and the non-polar resin plate with the clear layer formed thereon under the same conditions as the paint drying of the actually painted vehicle body, and a fourth step S4 of removing and cutting the non-polar resin plate with the colored layer formed thereon and the non-polar resin plate with the clear layer formed thereon from the dummy vehicle body. Hereinafter, these steps will be described in detail.

[0016] In the first step S1, an operator removably attaches a non-polar resin plate to the corresponding position of the dummy vehicle body corresponding to the repair part where the coating film to be repaired is formed. The part here is, that is, a vehicle body part, which constitutes the vehicle body and is a part that can be visually recognized externally (in other words, can be visually recognized from the outside of the vehicle), and includes the front door, rear door, hood, roof, trunk lid, front fender, rear fender, front pillar, center pillar, and rear pillar, etc. In this embodiment, an example will be described in which a damaged part (for example, a scratch) occurs in the coating film of the front door and the damaged part is repaired. Therefore, the coating film to be repaired is the coating film of the front door.

[0017] As shown in FIG. 2A, the dummy vehicle body 1 may be the same as the vehicle body 2 actually produced (in other words, the vehicle body 2 actually painted), or may be different from the vehicle body 2 actually produced in other structures except for the vehicle body parts described above. That is, the dummy vehicle body 1 may be the same vehicle type having the same shape and dimensions as the vehicle body 2 actually painted as a product, or the vehicle body parts such as the front door, rear door, hood, roof, trunk lid, front fender, rear fender, front pillar, center pillar, and rear pillar have the same shape and dimensions as the vehicle body 2 actually painted as a product, but the other parts may be different from the vehicle body 2 actually painted as a product.

[0018] The non-polar resin plate 20 is thinly formed of a so-called difficult-to-adhere resin that does not adhere to the coloring layer or clear layer formed thereon. The non-polar resin is preferably one or more selected from the group consisting of polypropylene-based resins, polyolefin-based resins, polydiene-based resins, polystyrene-based resins, ethylene vinyl acetate copolymers, styrene-based copolymer rubbers, styrene-based thermoplastic elastomers, and natural rubbers. By using the non-polar resin plate 20 in this way, the formed coloring layer or clear layer can be supported and can be easily separated from the formed coloring layer or clear layer (in other words, the formed coloring layer or clear layer can be easily peeled off from the non-polar resin plate 20).

[0019] As described above, since the coating film to be repaired is the coating film of the front door, the operator removably attaches the non-polar resin plate 20 to the front door of the dummy vehicle body 1 (see Fig. 2A). The attachment operation of the non-polar resin plate 20 is performed, for example, at the primary storage yard of the vehicle body. Also, in order to easily remove the non-polar resin plate 20 from the dummy vehicle body 1 later, the non-polar resin plate 20 is attached to the dummy vehicle body 1 using, for example, wires or jigs. Further, in order to easily peel the formed colored layer or clear layer from the non-polar resin plate 20, unlike the painting of a normal resin bumper, an adhesive such as a primer is not applied to the non-polar resin plate 20.

[0020] In the second step S2, first, the operator sends the dummy vehicle body 1 with the non-polar resin plate 20 attached thereto to the topcoat painting line 3. At this time, for example, based on the daily production plan information, the dummy vehicle body 1 may be introduced between the vehicle bodies 2 that are actually painted as products, or the dummy vehicle body 1 may be introduced after the last painted vehicle body of the day.

[0021] Subsequently, a colored layer and a clear layer are respectively formed on the non-polar resin plate 20 under the same conditions as the topcoat painting of the vehicle body 2 that is actually painted. That is, for the non-polar resin plate 20 attached to the dummy vehicle body 1, a colored layer and a clear layer are respectively formed under the same conditions as the vehicle body 2 that is actually painted as a product. The same conditions here mean that all of the paint used, equipment such as the automatic painting machine 4, painting conditions, and the environment of the painting booth are the same.

[0022] In this embodiment, as shown in FIGS. 3 and 4, a colored layer 30 and a clear layer 40 are respectively formed on the separately prepared non-polar resin plate 20 (more specifically, on the outer surface of the non-polar resin plate 20). Therefore, for example, the colored layer 30 is formed on the non-polar resin plate 20 attached to the front door on the left side of the dummy vehicle body 1, and the clear layer 40 is formed on the non-polar resin plate 20 attached to the front door on the right side. Accordingly, when forming the colored layer 30, the automatic painting machine 4 on the right side of the topcoat painting line 3 is stopped, and the non-polar resin plate 20 attached to the front door on the left side is painted using the automatic painting machine 4 on the left side. When forming the clear layer 40, the automatic painting machine 4 on the left side of the topcoat painting line 3 is stopped, and the non-polar resin plate 20 attached to the front door on the right side is painted using the automatic painting machine 4 on the right side.

[0023] The colored layer 30, also referred to as a base layer, is a layer having a coloring pigment. This colored layer 30 may have a single-layer structure or a multi-layer structure. On the other hand, the clear layer 40 is a transparent layer having no coloring pigment, and is a layer for enhancing the weather resistance, chemical resistance, etc. of the colored layer 30 and bringing out the gloss and high-class feeling of the coating film.

[0024] In the third step S3, the operator sends the dummy vehicle body 1 to the painting drying line and dries the non-polar resin plate 20 on which the colored layer 30 is formed and the non-polar resin plate 20 on which the clear layer 40 is formed under the same conditions as the painting drying of the actually painted vehicle body 2. For example, the dummy vehicle body 1 after the topcoat painting is introduced into the heating drying booth, and the non-polar resin plate 20 on which the colored layer 30 is formed and the non-polar resin plate 20 on which the clear layer 40 is formed are dried under the same conditions as the vehicle body 2 actually painted as a product. Here, the same conditions mean that all the facilities, drying temperature, and drying time provided in the heating drying booth are the same.

[0025] In the fourth step S4, an operator introduces the dried dummy vehicle body 1, for example, into the primary storage yard of the vehicle body, removes the non-polar resin plate 20 with the colored layer 30 formed thereon and the non-polar resin plate 20 with the clear layer 40 formed thereon from the dummy vehicle body 1, and cuts them into predetermined sizes respectively using a laser or the like (see Fig. 2B). As a result, a repair sheet 10 (see Fig. 3) having a non-polar resin plate 20 and a colored layer 30 and a repair sheet 11 (see Fig. 4) having a non-polar resin plate 20 and a clear layer 40 are created respectively.

[0026] According to the method for creating a repair sheet according to the present embodiment, by forming and drying the colored layer 30 and the clear layer 40 on the non-polar resin plate 20 under the same conditions as the topcoat painting and painting drying of the actually painted vehicle body 2, it is possible to create the repair sheets 10 and 11 having a color tone close to the painting color of the actually painted vehicle body 2. In addition, since the topcoat painting and painting drying are performed with the non-polar resin plate 20 attached to the corresponding position of the dummy vehicle body 1 corresponding to the repair site where the coating film to be repaired is formed, it is possible to prevent the difference in color tone due to the difference in the arrangement position such as horizontal arrangement or vertical arrangement, and the repair sheets 10 and 11 having almost the same color tone as the painting color of the actually painted vehicle body 2 can be created. Therefore, when the damaged part of the coating film is repaired using the repair sheets 10 and 11 created in this way, a repair without a sense of incongruity can be realized.

[0027] When repairing the damaged part of the coating film of the front door using the created repair sheets 10 and 11, as shown in Figs. 2C and 2D, first, the colored layer 30 is peeled off from the non-polar resin plate 20 of the repair sheet 10, and the colored layer 30 is pasted on the front door of the vehicle 5 to be repaired using an adhesive or the like. Next, the clear layer 40 is peeled off from the non-polar resin plate 20 of the repair sheet 11, and the clear layer 40 is pasted on the colored layer 30 using an adhesive or the like so as to cover the colored layer 30 pasted on the front door.

[0028] When the clear layer 40 is attached onto the colored layer 30, as shown in FIG. 5, it is preferable to prepare a clear layer 40 having an area larger than the area of the colored layer 30 attached to the front door 50, and attach it to the colored layer 30 and the front door 50 such that the colored layer 30 is covered and the peripheral edge of the clear layer 40 is in direct contact with the front door 50. Further, it is preferable to heat the peripheral edge of the clear layer 40 in direct contact with the front door 50 to make it conform to the surroundings. By doing so, at the peripheral edge of the repair portion, only the clear layer 40 remains, so that the thickness becomes thinner compared to the case of the peripheral edge having both the colored layer 30 and the clear layer 40. As a result, the peripheral edge of the repair portion becomes less conspicuous, and the visibility of the repair portion is reduced, making it easier to achieve a repair without a sense of incongruity.

[0029] Note that it is not always necessary to create the repair sheet 11 having the nonpolar resin plate 20 and the clear layer 40. For example, when the clear layer is spray-coated at the repair work site, it is sufficient to create only the repair sheet 10 having the nonpolar resin plate 20 and the colored layer 30.

[0030] [Second Embodiment] Next, a method for creating a repair sheet according to the second embodiment will be described with reference to FIG. 6. The method for creating a repair sheet of the present embodiment is different from the first embodiment in that a colored layer 31 having a two-layer structure is formed. Hereinafter, only the differences will be described.

[0031] As shown in FIG. 6, the colored layer 31 of the present embodiment has a color layer 32 formed on the nonpolar resin plate 20 and a color clear layer 33 formed on the color layer 32. Therefore, in the second step, when forming the colored layer 31 on the nonpolar resin plate 20 under the same conditions as the topcoat painting of the vehicle body 2 actually painted, first, the color layer 32 is formed on the nonpolar resin plate 20, and then, the color clear layer 33 is further formed on the formed color layer 32. Thereby, the repair sheet 12 having the nonpolar resin plate 20, the color layer 32, and the color clear layer 33 is created.

[0032] According to the method for creating a repair sheet according to this embodiment, in addition to obtaining the same operational effects as those of the above-described first embodiment, since the colored layer 31 has a two-layer structure (i.e., the color layer 32 and the color clear layer 33), the variations of the colored layer can be increased, and it becomes easier to adjust the color tone.

[0033] Then, when repairing the damaged part of the paint film on the front door using the created repair sheet 12, the colored layer 31 having the color layer 32 and the color clear layer 33 is peeled off together from the nonpolar resin plate 20 and attached to the front door of the vehicle 5 to be repaired, and then the clear layer 40 is further attached thereon.

[0034] [Third Embodiment] Next, a method for creating a repair sheet according to the third embodiment will be described with reference to FIG. 7. The method for creating a repair sheet of this embodiment is different from the first embodiment in that the colored layer 30 and the clear layer 40 are formed on the same nonpolar resin plate 20. Hereinafter, only the differences will be described.

[0035] That is, in the second step S2, under the same conditions as the topcoat painting of the vehicle body 2 actually painted, first, the colored layer 30 is formed on the nonpolar resin plate 20. Then, the clear layer 40 is further formed on the formed colored layer 30. Thereby, a repair sheet 13 having the nonpolar resin plate 20, the colored layer 30, and the clear layer 40 is created.

[0036] According to the method for creating a repair sheet according to this embodiment, in addition to obtaining the same operational effects as those of the above-described first embodiment, since the colored layer 30 and the clear layer 40 are formed on the same nonpolar resin plate 20, when repairing the damaged part of the paint film using the created repair sheet 13, the colored layer 30 and the clear layer 40 are peeled off together from the nonpolar resin plate 20 and attached to the front door of the vehicle 5 to be repaired. By doing so, compared with the first embodiment in which the colored layer 30 and the clear layer 40 are respectively formed on different nonpolar resin plates 20, the time for the repair work can be shortened.

[0037] [Fourth Embodiment] Next, a method for creating a repair sheet according to the fourth embodiment will be described with reference to FIG. 8. The method for creating the repair sheet of this embodiment is different from the first embodiment in that a colored layer 34 and a clear layer 41 are formed on the same non-polar resin plate 20 and the colored layer 34 is formed so as to change in thickness. Hereinafter, only the differences will be described.

[0038] That is, in the second step S2, the colored layer 34 is first formed on the non-polar resin plate 20 under the same conditions as the topcoat painting of the vehicle body 2 that is actually painted. At this time, for example, in the longitudinal direction along the vehicle body front-rear direction of the non-polar resin plate 20, the colored layer 34 is formed so that the thickness gradually decreases from the central portion toward both end portions. Thereafter, a clear layer 41 is further formed on the formed colored layer 34. When forming the clear layer 41, the thickness of the clear layer 41 may be adjusted so that the total thickness of the colored layer 34 and the clear layer 41 is substantially the same in the longitudinal direction of the non-polar resin plate 20. Thereby, the repair sheet 14 having the non-polar resin plate 20, the colored layer 34, and the clear layer 41 is created.

[0039] According to the method for creating the repair sheet according to this embodiment, in addition to obtaining the same operational effects as those of the above-described first embodiment, since the colored layer 34 and the clear layer 41 are formed on the non-polar resin plate 20, when repairing the coating film of the vehicle body using the created repair sheet 14, the colored layer 34 and the clear layer 41 can be peeled off together from the non-polar resin plate 20 and attached to the front door of the vehicle 5 to be repaired. In this way, compared with the first embodiment in which the colored layer 30 and the clear layer 40 are respectively formed on different non-polar resin plates 20, the time required for the repair work can be shortened.

[0040] Furthermore, since the thickness of the formed colored layer 34 gradually decreases from the central portion toward both end portions, a gradation can be imparted to the color tone of the created repair sheet 14. As a result, among the repair sheet 14, a portion that matches the color tone of the coating film to be repaired can be selected, and the color adjustment of the coating film to be repaired can be easily performed by repairing with the selected portion. That is, among the repair sheet 14, a gradation closest to the color tone of the coating film to be repaired can be selected, and the damaged portion of the coating film can be repaired using the selected portion, so that it becomes easier to achieve a repair without a sense of incongruity.

[0041] [Method for managing repair sheet] Next, a method for managing the repair sheet will be described. The management method of the repair sheets 10, 11, 12, 13, 14 according to the embodiment associates and manages vehicle lot information including paint information applied to the vehicle body 2 and repair sheet lot information including paint information used for the repair sheet for repairing the coating film of the vehicle body 2. The paint information here includes information such as the lot number of the paint and the date and time of use. In the present embodiment, for example, an information processing device equipped with a computer or the like is used to associate and manage a vehicle and a repair sheet having the same lot number of the paint and the same date and time of use.

[0042] In this way, since the vehicle lot information and the repair sheet lot information are associated and managed, the lot information of the vehicle can be specified based on the vehicle having the coating film to be repaired, and the lot information of the repair sheet can be specified based on the specified vehicle lot information. As a result, the repair sheets 10, 11, 12, 13, 14 corresponding to the coating film to be repaired can be easily found, and the color adjustment of the coating film to be repaired becomes easier.

[0043] Although the embodiments of the present invention have been described in detail above, the present invention is not limited to the above-described embodiments, and various design changes can be made without departing from the spirit of the present invention described in the claims. [Description of reference numerals]

[0044] 1: dummy vehicle body, 2: vehicle body, 3: topcoat painting line, 4: automatic painting machine, 5: vehicle to be repaired, 10, 11, 12, 13, 14: repair sheets, 20: non-polar resin plate, 30, 31, 34: colored layer, 32: color layer, 33: color clear layer, 40, 41: clear layer

Claims

1. A method for creating a repair sheet for repairing a paint film on a vehicle body, comprising: a first step of detachably attaching a non-polar resin plate to a corresponding position of a dummy vehicle body corresponding to a repair portion where the paint film to be repaired is formed; a second step of flowing the dummy vehicle body through a topcoat painting line and forming a colored layer or a clear layer, or both the colored layer and the clear layer, on the non-polar resin plate under the same conditions as the topcoat painting of an actually painted vehicle body; a third step of flowing the dummy vehicle body through a paint drying line and drying the non-polar resin plate on which the colored layer or the clear layer, or both the colored layer and the clear layer, are formed under the same conditions as the paint drying of an actually painted vehicle body; The method for creating a repair sheet, characterized by including the above steps.

2. The method for creating a repair sheet according to claim 1, wherein in the second step, when forming the colored layer, or both the colored layer and the clear layer, on the non-polar resin plate, the colored layer is formed so as to change in thickness.

Images