Interior component, method for manufacturing interior component, and apparatus for manufacturing interior component

Abstract

To provide an interior member in which a skin 8 can be bonded to a base material 6 with stitches that do not deviate from a prescribed position.SOLUTION: An interior member comprises a base material and a skin. The skin has a first face forming a design surface and a second face on a side opposite to the first face, and the second face is bonded to at least one face of the base material. The skin has a stitch which is formed in such manner that a thread penetrates from the first face to the second face, and a plurality of insertion holes through which the thread of the stitch is inserted from the first face toward the second face. The base material has a plurality of open holes which penetrate from one face to the other face, and at least two of the plurality of insertion holes and at least two of the plurality of open holes are arranged in an overlapping manner.SELECTED DRAWING: Figure 4

Description

Technical Field

[0001] The present disclosure relates to an interior member and a method for manufacturing the interior member.

Background Art

[0002] Conventionally, an interior member having stitches has been known (see, for example, Patent Document 1). The interior member of Patent Document 1 folds back the end portion of the skin inward and sews the folded-back portion into a three-dimensional shape by double stitches. Such stitches are mainly used as an interior member of an automobile to produce a high-quality feeling of the interior of the automobile.

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In recent years, such stitches are not used for the treatment of folding back the end portion of the skin, but are increasingly used simply as a decoration for sewing the design surface of the skin. When stitches are used as a decoration in this way, it is necessary to attach the skin to the base material so that the stitches are in a predetermined position.

[0005] An object of the present disclosure is to provide an interior member, a method for manufacturing the interior member, and a manufacturing apparatus for the interior member, which can attach the skin to the base material without the stitches coming off from a predetermined position.

Means for Solving the Problems

[0006] The interior component according to this disclosure comprises a base material and a surface. The surface has a first surface that forms a design surface and a second surface opposite to the first surface, and the second surface is attached to at least one surface of the base material. The surface has stitches formed by threads passing through from the first surface to the second surface, and a plurality of through holes through which the threads of the stitches are inserted from the first surface to the second surface. The base material has a plurality of through holes that penetrate from one surface to the other, and at least two of the plurality of through holes and at least two of the plurality of through holes are arranged in an overlapping manner.

[0007] Furthermore, the method for manufacturing an interior component according to this disclosure includes the steps of: setting a base material having through holes with one side facing outwards; irradiating the other side of the base material with light; attaching a skin having through holes to one side of the base material such that the through holes overlap with the through holes; and confirming whether or not the light is passing through the first side.

[0008] Furthermore, the manufacturing apparatus for interior components according to this disclosure comprises a light source, a support capable of setting the interior component within the irradiation range of the light emitted from the light source, and a device for detecting light that has passed through the first surface.

[0009] According to this method of manufacturing interior components, light irradiated onto the base material passes through the through-holes in the base material, and by aligning the insertion holes in the surface material with the position of the light that has passed through, the insertion holes overlap with the through-holes. This allows the surface material to be attached to the base material so that the stitches are in the predetermined positions. As a result, this interior component has a good appearance. Furthermore, by using this manufacturing apparatus for interior components, it is possible to attach the surface material to the base material so that the stitches are in the predetermined positions, thus producing an interior component with a good appearance. [Effects of the Invention]

[0010] According to this disclosure, it is possible to provide an interior component that can be attached to a base material without the stitches coming off their predetermined positions, a method for manufacturing the interior component, and an apparatus for manufacturing the interior component. [Brief explanation of the drawing]

[0011] [Figure 1] A diagram showing the interior components of the embodiment of this disclosure attached to a vehicle. [Figure 2] A front view of the interior component of this disclosure, with the component removed from the instrument panel. [Figure 3] Enlarged view of the stitching area in Figure 2. [Figure 4] Cross-sectional view of section AA in Figure 3. [Figure 5] A schematic diagram showing the positional relationship between the insertion hole and the through hole. [Figure 6] A figure showing a manufacturing apparatus for interior components in an embodiment of the present disclosure. [Figure 7] A figure showing a method for manufacturing interior components in an embodiment of the present disclosure. [Modes for carrying out the invention]

[0012] Hereinafter, an embodiment of the present disclosure will be described with reference to the drawings. In Figures 1 and 2, the upper part of the automobile is denoted as U. As shown in Figure 1, the interior member 1 of this embodiment is, for example, a member attached to the instrument panel 2 of an automobile. The instrument panel 2 has a first interior member 1a having a single stitch S1 at the top and a second interior member 1b having a single stitch S2 at the bottom. For example, when the first interior member 1a and the second interior member 1b are attached to the instrument panel 2, the single stitch S1 and single stitch S2 are formed parallel to each other, so that they appear as double stitches in appearance. When decorative single stitches S1 and S2 are used on the interior member 1 in this way, it is preferable to form the single stitches S1 and S2 with precision at predetermined positions (pre-determined positions) in order to create a high-quality feel for the automobile's interior.

[0013] Figure 2 is a front view of the first interior member 1a. As shown in Figure 2, a single stitch S1 is formed on the interior member 1a at a predetermined position near the upper end 4 of the design surface of the interior member 1a. In this embodiment, the single stitch S1 is formed from one end 16 to the other end 18 of the first interior member 1a, and is formed at a position where the distance L from the upper end 4 to the single stitch S1 is within a predetermined range along the entire length of the single stitch S1. It is preferable that the single stitch S1 is formed without deviating from the predetermined position on the design surface.

[0014] As shown in Figures 3 and 4, the interior member 1 comprises a base material 6 and a surface material 8. The base material 6 is a member that has hooks for attaching to an instrument panel 2 or the like, and serves as a base for supporting the surface material 8. In this embodiment, the base material 6 is formed by injection molding of a resin material such as PP (polypropylene). However, the base material 6 may be formed of metal. The base material 6 has a surface (an example of one side) 10 on the side to which the surface material 8 is attached, and a back surface (an example of the other side) 12 on the side to which it attaches to the instrument panel 2.

[0015] As shown in Figure 4, the base material 6 has a plurality of through holes 14 that penetrate from the surface 10 to the back surface 12. The plurality of through holes 14 are arranged along the extension direction of the single stitch S1 at predetermined intervals T1 (see Figure 3).

[0016] As shown in Figure 4, the surface layer 8 is attached to the base material 6 and forms the decorative surface of the interior component 1. The surface layer 8 has a first surface 22 that forms the decorative surface, a second surface 24 opposite to the first surface 22, a first layer 26 that forms the first surface 22, and a second layer 28 that forms the second surface 24. In this embodiment, the first layer 26 is made of a material such as leather, synthetic leather, or woven fabric. The second layer 28 is made of a foamed resin, for example. In this embodiment, the second layer 28 further has a laminate layer (not shown) made of thermoplastic resin on the surface facing the first layer 26. The first layer 26 and the second layer 28 are welded together by the melting of the laminate layer. However, the first layer 26 and the second layer 28 may be bonded together by other methods, such as adhesive bonding.

[0017] As shown enlarged in Fig. 4, the single stitch S1 is formed by a thread passing through from the first surface 22 to the second surface 24. The single stitch S1 is formed by passing through the first layer 26 and the second layer 28 after the first layer 26 and the second layer 28 are adhered. For this reason, the thread of the single stitch S1 that has penetrated to the second surface 24 pulls up the foamed resin of the second layer 28, causing the second layer 28 to be recessed. As a result, a recess 30 is formed on the second surface 24 of the skin 8. Also, since the thread of the single stitch S1 passes through from the first surface 22 to the second surface 24 and passes through the first layer 26 and the second layer 28, a plurality of insertion holes 32 through which the thread of the single stitch S1 is inserted are formed. As shown in the enlarged views of Figs. 3 and 4, at least two of the plurality of insertion holes 32 and at least two of the plurality of through holes 14 are arranged at overlapping positions in a cross-sectional view.

[0018] As shown in Fig. 5, the predetermined interval T1 at which the through holes 14 are arranged is determined based on the intervals T2A and T2B between the insertion holes of the single stitch S1. In the present embodiment, for example, one through hole 14 is provided for every four stitches of the single stitch S1. That is, the interval T1 is four times the sum of the intervals T2A and T2B. In this way, by determining the interval T1 of the through holes 14 corresponding to the intervals T2A and T2B of the insertion holes 32 of the single stitch S1, when the single stitch S1 is on the line X1 at a predetermined position, as shown by the solid line in Fig. 5, the through holes 14 and the insertion holes 32 overlap in a cross-sectional view when the skin 8 is attached to the base material 6.

[0019] On the other hand, as shown by the two-dot chain line in Fig. 5, when the single stitch S1 is on the line X2 deviated from the predetermined position, the through holes 14 and the insertion holes 32 do not overlap in a cross-sectional view when the skin 8 is attached to the base material 6. In such a state, the light irradiated from the manufacturing apparatus 40 of the interior member 1 described later does not pass through the insertion holes 32. For this reason, it is easy to detect that the single stitch S1 is on the line X2 deviated from the predetermined position.

[0020] Here, the diameter D of the through-hole 14 may be set according to the allowable range of deviation of the single stitch S1. Specifically, it may be set according to the allowable range of deviation of the single stitch S1 with respect to the line X1 at the predetermined position during the interval T1. For example, when the allowable range of deviation during the interval T1 is plus or minus Y mm, the diameter D may be 2Y. Thus, by setting the diameter D according to the allowable range of deviation of the single stitch S1, when the deviation of the single stitch S1 from the predetermined position is within the allowable range, the through-hole 14 and the insertion hole 32 overlap. On the other hand, when the deviation of the single stitch S1 from the predetermined position deviates from the allowable range (for example, in the case of the two-dot chain line state in FIG. 5), the through-hole 14 and the insertion hole 32 do not overlap, and the light irradiated from the manufacturing apparatus 40 of the interior member 1 described later can be prevented from passing through the insertion hole 32.

[0021] Next, the manufacturing apparatus of the interior member 1 will be described with reference to FIG. 6.

[0022] As shown in FIG. 6, the manufacturing apparatus 40 of the interior member 1 includes a light source 42, a light detection device 44, and a support base 46 that supports the interior member 1. The light source 42 is a device that irradiates light. The light source 42 is arranged such that the through-hole 14 of the base material 6 is within the irradiation range of the light irradiated from the light source 42. In the present embodiment, a plurality of light sources 42 are provided according to the position and number of the through-holes 14 of the base material 6. However, the light source 42 may be arranged such that the through-hole 14 of the base material 6 is within the irradiation range of the light irradiated from the light source 42, and it may be a single light source that irradiates light from one point or a single light source that extends along the arrangement of the through-holes 14.

[0023] The light detection device 44 is a device that detects the light that has passed through the first surface 22, at least in the state where the base material 6 and the skin 8 are adhered. Specifically, the light detection device 44 is a light quantity sensor that detects the amount of light that has passed through the through-hole 14 of the base material 6 and the insertion hole 32 formed in the skin 8. In the present embodiment, like the light source 42, a plurality of light detection devices 44 are provided according to the position and number of the through-holes 14 of the base material 6.

[0024] The support base 46 is a stand on which the interior component 1 can be set such that the base material 6 of the interior component 1 is positioned within the light irradiation range of the light source 42. Specifically, the support base 46 is a stand on which the base material 6 can be set such that the through-hole 14 of the base material 6 is positioned within the light irradiation range of the light source 42. The support base 46 also uses location pins (not shown) or the like to hold the base material 6 in place so that it does not move when the surface layer 8 is attached to the base material 6 while the base material 6 is set.

[0025] Next, the manufacturing method of the interior component 1 will be explained with reference to Figure 7. In this embodiment, an example of manufacturing the interior component 1 using the manufacturing apparatus 40 for the interior component 1 will be described. Note that in Figure 7, the optical detection device 44 and the support base 46 of the manufacturing apparatus in Figure 6 are omitted from the description.

[0026] As shown in Figure 7(a), first the base material 6 having the through hole 14 is set so that the surface 10 is facing outwards. In this embodiment, the base material 6 is set so that the surface 10 is facing upwards. Next, the surface 8 with adhesive applied to the second surface 24 is set on the outwards side of the base material 6.

[0027] Next, light from the light source 42 is shone from the back side 12, and the light that passes through the through holes 14 leaks out from the surface 10. With the light irradiated in this state, as shown in Figure 7(b), the skin 8 is attached to the surface 10 of the base material 6 so that the insertion holes 32 of the skin 8 overlap with the through holes 14 of the base material 6. In other words, the single stitch S1 portion is attached first. At this time, the worker or robot performing this work is guided by the light leaking out from the through holes 14, making it easy to align the insertion holes 32 with the through holes 14. This makes it easy to align the single stitch S1 to the predetermined position.

[0028] As shown by the dashed line in Figure 7(b), the single-stitch S1 portion is attached to the base material 6, and then the remaining portion is attached to the surface 10 of the base material 6 (see arrow in Figure 7(b)). Then, as shown by the dashed line and arrow in Figure 7(c), the outer layer 8 is folded back from the surface 10 to the back surface 12 along the edge of the surface 10 of the base material 6 and attached, thereby forming the interior member 1.

[0029] Once the interior component 1 is formed, it is checked whether the light emitted from the light source 42 is passing through the first surface 22. Specifically, the amount of light is measured by the light detection device 44. If the insertion hole 32 and the through hole 14 overlap in a cross-sectional view, light passes through the first surface 22 and the light detection device 44 detects a sufficient amount of light. In this state, the single stitch S1 is formed in the predetermined position (for example, on line X1 in Figure 5).

[0030] On the other hand, if the insertion hole 32 and the through hole 14 are outside the acceptable range, and the single stitch S1 is formed outside the predetermined position (for example, on line X2 in Figure 5), the light detection device 44 cannot detect a sufficient amount of light. In this way, the manufacturing apparatus 40 can evaluate the accuracy of the alignment between the surface layer 8 and the base material 6 using the amount of light detected by the light detection device 44. This allows evaluation of whether the single stitch S1 is accurately in the predetermined position.

[0031] The interior component 1 manufactured in this manner is formed with precision, with the single stitch S1 remaining in its predetermined position. In this embodiment, as shown in Figure 2, the single stitch S1 is formed uniformly at a distance L from the upper end 4 of the interior component 1 without any vertical distortion. This results in a visually appealing design surface and makes it easier to create a sense of quality.

[0032] As described above, this disclosure provides an interior component 1, a method for manufacturing the interior component 1, and an apparatus for manufacturing the interior component 40, which enable the surface 8 to be attached to the base material 6 without the single stitch S1 coming off its predetermined position.

[0033] <Other Embodiments> Although embodiments of the present disclosure have been described above, the present disclosure is not limited to the embodiments described above, and various modifications are possible without departing from the spirit of the invention.

[0034] (a) In the above embodiment, an interior component 1 attached to the instrument panel 2 was described as an example, but this disclosure is not limited thereto. The interior component 1 may be any interior component used in the interior of an automobile, such as an armrest or a door trim. Furthermore, the interior component 1 is not limited to automobiles, but may also be an interior component 1 for railways, aircraft, etc.

[0035] (b) In the above embodiment, a single stitch S1 was used as an example for explanation, but the stitch may be a double stitch or a triple stitch. [Explanation of Symbols]

[0036] 1: Interior components 1a: First interior component 1b: Second interior component 2: Instrument panel 4:Top edge 6: Base material 8: Epidermis 10: Surface 12: Back side 14: Through hole 16: one end 18: Other end 22: 1st page 24:Second side 26 :1st layer 28: 2nd layer 30: Recess 32: Through hole 40: Manufacturing equipment S1: Single stitch S2: Single stitch

Claims

1. Substrate and A surface having a first surface that forms a design surface and a second surface opposite to the first surface, wherein the second surface is attached to at least one surface of the base material, Equipped with, The surface has a stitch formed by threads passing through from the first surface to the second surface, and a plurality of through holes through which the threads of the stitches are inserted from the first surface to the second surface. The substrate has a plurality of through holes that penetrate from one surface to the other surface. One through-hole is provided for each of the multiple insertion holes. At least two of the multiple insertion holes and at least two of the multiple through holes are arranged in a superimposed configuration. Interior components.

2. A base material and A surface having a first surface that forms a design surface and a second surface opposite to the first surface, wherein the second surface is attached to at least one surface of the base material, Equipped with, The surface has a stitch formed by threads passing through from the first surface to the second surface, and a plurality of through holes through which the threads of the stitches are inserted from the first surface to the second surface. The substrate has a plurality of through holes that penetrate from one surface to the other surface. At least two of the multiple insertion holes and at least two of the multiple through holes are arranged in a superposition. A method for manufacturing interior components, A step of setting the substrate having the through hole so that one of its sides is the front side, A step of irradiating light from the other surface of the substrate, A step of attaching the skin having the insertion holes to one surface of the base material such that the insertion holes overlap with the through holes, A step of confirming whether the light has passed through the first surface, A method for manufacturing interior components, comprising:

3. A method for manufacturing an interior member according to claim 2, further comprising the step of evaluating the accuracy of the alignment between the surface and the substrate based on the amount of light that has passed through the first surface.

4. A base material and A surface having a first surface that forms a design surface and a second surface opposite to the first surface, wherein the second surface is attached to at least one surface of the base material, Equipped with, The surface has a stitch formed by threads passing through from the first surface to the second surface, and a plurality of through holes through which the threads of the stitches are inserted from the first surface to the second surface. The substrate has a plurality of through holes that penetrate from one surface to the other surface. At least two of the multiple insertion holes and at least two of the multiple through holes are arranged in a superposition. A manufacturing apparatus for interior components, A light source, and a support base on which the interior component can be set within the illumination range of the light emitted from the light source, A device for detecting light that has passed through the first surface, A manufacturing apparatus for interior components equipped with the following features.

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