Skin shape adjustment device and method for manufacturing interior components using the skin shape adjustment device

Abstract

To provide a novel skin shape adjusting device using a far-infrared ray.SOLUTION: A skin shape adjusting device includes: a support on which a resin sheet forming a skin of an interior member is placed; and an irradiation device for irradiating the resin sheet with a far-infrared ray.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to an epidermal shape adjustment device and a method for manufacturing an interior member using the epidermal shape adjustment device.

Background Art

[0002] Conventionally, an example of using a far-infrared device as a drying device is known (for example, see Patent Document 1).

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Patent Document 1 uses far-infrared rays for the purpose of drying an object to be dried. However, Patent Document 1 does not disclose the use of far-infrared rays for adjusting the epidermal shape.

[0005] An object of the present disclosure is to provide a novel epidermal shape adjustment device using far-infrared rays.

Means for Solving the Problems

[0006] An epidermal shape adjustment device according to an aspect of the present disclosure includes a support on which a resin sheet forming an epidermis of an interior member is disposed, and an irradiation device that irradiates far-infrared rays toward the resin sheet.

[0007] A method for manufacturing an interior member using the epidermal shape adjustment device according to an aspect of the present disclosure includes a step of setting the resin sheet, a step of irradiating far-infrared rays from the irradiation device toward the resin sheet, a step of injecting a gas toward the resin sheet, and a step of injecting a foamed resin between the resin sheet and a base material of the interior member.

[0008] This surface shape adjustment device allows for the adjustment of the surface shape using far-infrared rays. Furthermore, since the surface shape can be adjusted using this surface shape adjustment device for manufacturing interior components, the interior components can be manufactured with high precision. [Effects of the Invention]

[0009] According to this disclosure, a novel skin shape adjustment device using far-infrared rays can be provided. [Brief explanation of the drawing]

[0010] [Figure 1] Front view of a skin shape adjusting device according to an embodiment of the present disclosure. [Figure 2] A top view of the skin shape adjustment device according to an embodiment of the present disclosure. [Figure 3] A figure showing a method for manufacturing an interior component using a surface shape adjustment device according to an embodiment of the present disclosure. [Modes for carrying out the invention]

[0011] Hereinafter, an embodiment of the present disclosure will be described with reference to the figures. In the specification and drawings, the right side of the skin shape adjustment device 1, when viewed from the front, will be referred to as "right," the left side as "left," the upper side as "up," and the lower side as "down." Also, when viewed from the front of the skin shape adjustment device 1, the front side (lower side in Figure 2) will be referred to as "front," and the back side (upper side in Figure 2) will be referred to as "rear."

[0012] As shown in Figures 1 and 2, the surface shape adjustment device 1 comprises a support base 2, an irradiation device 4, an injection device 6, an adjustment mechanism 8, and a control device 10. In this embodiment, the surface shape adjustment device 1 for adjusting a resin sheet 12 used as the surface of an instrument panel (an example of an interior component) to match the design surface shape of the base material 14 of the instrument panel will be described as an example.

[0013] The support base 2 supports the base material 14 of the interior component, and the resin sheet 12 that forms the surface of the interior component is placed on top of the design surface 14a of the base material 14. In this embodiment, the support base 2 is a plate-shaped member on which the base material 14 of the instrument panel is placed so that the design surface 14a is the upper surface. The base material 14 is supported by a support fitting 2a attached to the support base 2. The resin sheet 12 is placed on top of the design surface 14a of the base material 14 that faces upward.

[0014] The support base 2 is provided with wheels 2c at the lower end of each of its four legs 2b and is positioned to be movable at least in the front-to-back direction. After the resin sheet 12 is placed on it, the support base 2 moves toward the rear of the irradiation device 4 and is positioned beneath the irradiation device 4.

[0015] The irradiation device 4 is a device that irradiates far-infrared rays toward the resin sheet 12 from the side where the resin sheet 12 is placed. When the resin sheet 12 is irradiated with far-infrared rays, the resin sheet 12 is instantly heated, drying and removing the moisture from the resin sheet 12. This induces shrinkage due to the decrease in the moisture content of the resin sheet 12.

[0016] Multiple irradiation devices 4 are arranged along the design surface 14a. In this embodiment, five are arranged in a row in the left-right direction, with one additional one placed in front of the right side. Each irradiation device 4 is supported by a gate-shaped frame 4a. In the surface shape adjustment device 1 of this embodiment, the devices are arranged along the shape of the resin sheet 12 so that far-infrared rays can be irradiated onto the entire resin sheet 12. This allows the far-infrared rays to be evenly irradiated onto the resin sheet 12.

[0017] Furthermore, each irradiation device 4 is detachable from the frame 4a. Therefore, for example, if there is a part of the resin sheet 12 that does not require far-infrared irradiation, the irradiation device 4 at the position corresponding to that part can be removed. More specifically, for example, as shown in Figure 2, the meter hood resin sheet 12a at the position corresponding to the meter hood portion 14b of the base material 14 of the instrument panel does not require far-infrared irradiation. In this case, of the multiple irradiation devices 4, the irradiation device 4b corresponding to the meter hood portion 14b is removed. This prevents the meter hood resin sheet 12a from being irradiated with far-infrared rays and thus prevents it from drying out.

[0018] Alternatively, the operation of each of the multiple irradiation devices 4 may be controlled separately by the control device 10. This makes it possible, for example, to not operate only the irradiation device 4b corresponding to the meter hood portion 14b, or to reduce the output of far-infrared rays. As a result, it is possible to not dry only the resin sheet 12a portion of the meter hood, or to reduce the degree of drying. In any case, by arranging multiple irradiation devices 4 along the design surface 14a, each irradiation device 4 can be removed, or the operation of each irradiation device 4 can be adjusted. This makes it possible to dry (or not dry) only specific areas of the resin sheet 12, or to adjust the degree of drying for each part of the resin sheet 12. In the above embodiment, the resin sheet 12a portion of the meter hood was used as an example, but the part of the resin sheet 12 is not limited to this, and any part may be used.

[0019] The injection device 6 injects gas toward the resin sheet 12 from the side where the resin sheet 12 is placed. In this embodiment, the injection device 6 has a pipe through which air passes, with a plurality of holes 6a directed toward the resin sheet 12. The injection device 6 is an air blow device that injects pressurized air from a compressor through the holes 6a. In this embodiment, the pipe of the injection device 6 is fixed above the position where the resin sheet 12 is placed and below the irradiation device 4, and gas is injected toward the resin sheet 12 from this pipe. This allows the heated resin sheet 12 to be cooled by air. The injection device 6 is not limited to the structure of this embodiment; any device capable of injecting gas toward the resin sheet 12 may be used.

[0020] When humid air is present between the irradiation device 4 and the resin sheet 12, the far-infrared energy emitted by the irradiation device 4 is used to heat the water molecules contained in this humid air. To prevent such energy loss, the spraying device 6 injects air between the irradiation device 4 and the resin sheet 12. In this way, the spraying device 6 replaces the air between the irradiation device 4 and the resin sheet 12. As a result, the effect of far-infrared irradiation can be enhanced.

[0021] The adjustment mechanism 8 is a mechanism for adjusting the distance D between the resin sheet 12 and the irradiation device 4. In this embodiment, a lift mechanism is provided between the four legs 2b of the support base 2 and the support base 2. The adjustment mechanism 8 can change the distance D from the resin sheet 12 to the irradiation device 4 by lifting the support base 2 relative to the legs 2b. The distance D is adjusted, for example, according to the degree of rise in the surface temperature of the resin sheet 12 when the irradiation device 4 is activated. The adjustment mechanism 8 is not limited to the structure of this embodiment, and any structure that can change the distance D is acceptable.

[0022] The control device 10 is electrically connected to the irradiation device 4 and the injection device 6, and controls the operating time of the irradiation device 4 and the injection device 6. The control device 10 is actually a microcomputer having a memory, an arithmetic unit, and the like. The control device 10 operates the irradiation device 4 for a first time period and operates the injection device 6 for a second time period. The first time period is, for example, from 30 seconds to 70 seconds. The second time period is, for example, from 40 seconds to 80 seconds. The first time period is a value that can be appropriately changed according to the rate of increase in the surface temperature of the resin sheet 12. Also, the second time period is a value that can be appropriately changed according to the rate of decrease in the surface temperature of the resin sheet 12. In the present embodiment, the control device 10 operates the injection device 6 for the second time period after operating the irradiation device 4 for the first time period. However, the control device 10 may operate the injection device 6 while the irradiation device 4 is operating. Thereby, the energy loss of the far infrared rays can be suppressed.

[0023] Next, the manufacturing method of the interior member of the present embodiment will be described using FIG. 3.

[0024] As shown in FIG. 3(i), in the first step, the base material 14 is set on the support base 2. In the second step, the resin sheet 12 is disposed so as to overlap the design surface 14a of the set base material 14. In that state, the support base 2 is pushed backward, and the support base 2 is advanced until the resin sheet 12 is positioned below the irradiation device 4. The distance D shown in FIG. 1 is adjusted in advance by the adjustment mechanism 8.

[0025] As shown in FIG. 3(ii), in the third step, far infrared rays are irradiated from the irradiation device 4 for a first time period toward the resin sheet 12 disposed below the irradiation device 4 to heat the resin sheet 12. Specifically, the control device 10 (see FIG. 1) operates the irradiation device 4 for the first time period, so that the far infrared rays are irradiated onto the resin sheet 12 for the first time period.

[0026] As shown in FIG. 3(iii), in the fourth step, a gas is injected from the injection device 6 toward the heated resin sheet 12 to cool it. Specifically, the control device 10 (see FIG. 1) operates the injection device 6 for the second time period, so that the gas is applied to the resin sheet 12 for the second time period.

[0027] As shown in Figure 3(iv), in the fifth step, the support 2 is moved forward, and as shown in Figure 3(v), the resin sheet 12 is set in the foam mold 100, and then the base material 14 is placed on top of it. The foam mold 100 is a mold for forming a foam. A cavity is formed in the foam mold 100 along the design surface 14a of the base material 14. The resin sheet 12 and the base material 14 are set in the cavity in an inverted state. Once the base material 14 and the resin sheet 12 are set in the cavity, the upper and lower molds of the foam mold 100 are closed, and foam resin material (an example of foam material) is poured between the base material 14 and the resin sheet 12.

[0028] As shown in Figure 3(v), in the sixth step, the upper and lower molds of the foam molding die 100 are closed, and foam resin material is injected between the resin sheet 12 and the base material 14 to form a foam. The interior component is manufactured in this manner.

[0029] Such a resin sheet 12 is formed from a hygroscopic material, such as thermoplastic polyurethane. Furthermore, the resin sheet 12 is formed to match the shape of the design surface 14a of the base material 14. However, such a resin sheet 12 expands when it absorbs moisture. When the resin sheet 12 is expanded, wrinkles are likely to occur in the resin sheet 12 that is set in the foam molding die 100 in the fifth step described above. Wrinkles in the resin sheet 12 can easily create gaps between the surface and the base material 14. This can also easily lead to defects in the appearance of the interior parts.

[0030] Conventionally, moisture in the resin sheets 12 was removed by placing them in a drying oven. However, drying ovens take time to remove moisture. Therefore, it was necessary to dry multiple resin sheets 12 together. As a result, there was a risk that the resin sheets 12 would reabsorb moisture between the drying stage and the foam formation stage.

[0031] On the other hand, far-infrared rays are excellent at quickly drying and removing moisture contained in the resin sheet 12. Therefore, in the surface shape adjustment device 1 of this embodiment, the irradiation device 4 is arranged along the shape of the resin sheet 12 so that far-infrared rays can be irradiated onto the entire resin sheet 12. This allows the resin sheet 12 to be dried in a short time. As a result, the resin sheets 12 can be dried one by one and immediately set into the foam molding mold 100. This allows the resin sheets 12 to be set into the foam molding mold 100 before they absorb moisture. As a result, wrinkles are less likely to occur in the resin sheet 12.

[0032] As described above, this disclosure provides a novel skin shape adjustment device 1 using far-infrared rays.

[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] For example, in the above embodiment, the resin sheet 12 is placed on the design surface 14a of the base material 14, but the resin sheet 12 does not necessarily have to be placed on the base material 14. The resin sheet 12 may be placed directly on the support 2, for example.

[0035] Furthermore, although the instrument panel was used as an example of an interior component in the above embodiment, other interior components used in automobiles, such as armrests or door trims, may also be used. [Explanation of Symbols]

[0036] 1: Epidermal shape adjustment device 2: Abutment 4: Irradiation device 6: Injection device 8:Adjustment mechanism 10: Control device 12: Resin sheet 14: Base material 14a: Design surface D: Distance

Claims

1. A support for the base material, in which a resin sheet forming the surface of the interior material is placed on top of the design surface side of the base material of the interior material, An irradiation device that irradiates far-infrared rays toward the resin sheet from the side where the resin sheet is placed, Equipped with, The irradiation devices are arranged in a plurality in a first direction along the design surface, and in a plurality in a second direction perpendicular to the first direction along the design surface. Epidermal shape adjustment device.

2. The irradiation device is further equipped with an adjustment mechanism for adjusting the distance between it and the resin sheet. The skin shape adjustment device according to claim 1.

3. The system further includes an injection device that injects gas toward the resin sheet from the side where the resin sheet is placed. The skin shape adjustment device according to claim 1 or 2.

4. The system further includes a control device that operates the irradiation device for a first hour and the injection device for a second hour. The skin shape adjustment device according to claim 3.

5. A step of overlapping the resin sheet onto the design surface side of the substrate, A step of irradiating the resin sheet with far-infrared rays from the irradiation device, A step of injecting gas toward the resin sheet, A step of setting the resin sheet and the substrate in the cavity of a foam molding die so that there is a gap between the resin sheet and the substrate, A step of injecting a foamed material between the resin sheet and the base material of the interior component, Equipped with, A method for manufacturing an interior component using the surface shape adjustment device according to claim 1.

6. A step of overlapping a resin sheet that forms the surface of the interior component onto the design surface side of the base material of the interior component, A step of irradiating the resin sheet with far-infrared rays, A step of cooling the aforementioned resin sheet, A step of setting the resin sheet and the substrate in the cavity of a foam molding die so that there is a gap between the resin sheet and the substrate, A step of injecting a foamed material between the resin sheet and the base material of the interior component, Equipped with, A method for manufacturing interior components.

7. The step of cooling the resin sheet includes the step of injecting gas toward the resin sheet. The method for manufacturing an interior component according to claim 6.

Images