JP3339606B2 - Manufacturing method of sun visor for automobile - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a sun visor for an automobile installed above a front window of a vehicle. The present invention relates to a method of manufacturing an automotive sun visor.

[0002]

2. Description of the Related Art Normally, a sun visor for a vehicle is installed on a driver's seat side and an auxiliary seat side above a front window in a vehicle interior, and shields sunlight and headlights of an oncoming vehicle at night, so that the driving visibility is reduced. To ensure effective.

For example, the configuration of a sun visor on the driver's seat side will be described with reference to FIG. 7. In the sun visor 1, a rotating shaft 3 is rotatably inserted into one end of a sun visor body 2 for shielding sunlight and the like. The rotating shaft 3 is rotatably inserted into a bracket 3a attached to the vehicle body.

The sun visor body 2 has a good cushioning property, a decorative property, and a good feel at the time of operation. A pad material 5 such as a polyurethane foam having a cushioning property is laminated on the back surface side, and their outer surfaces are covered with a skin material 6 such as a PVC sheet.

[0005] The core member 4 is composed of a wire frame 4a bent in a loop shape and a reinforcing board 4b for restraining the pad member 4 from hanging down by its own weight.

The manufacturing process of the conventional sun visor body 2 will be described with reference to a process chart of FIG. 8 and an explanatory view showing a welding process of FIG.
After a is bent into a loop, a reinforcing board 4b such as a cardboard is bonded and fixed to the inner space of the wire frame 4a to produce the core material 4.

Thereafter, two pad members 5 previously punched into a substantially product shape by a punching die are separated from each other by hot melt adhesive or the like so that the core members 4 are sandwiched from the front and back sides of the core members 4. to paste together.

Then, a skin material 6 such as a PVC sheet is attached to both outer surfaces of the pad material 5 bonded so as to sandwich the core material 4.
Is positioned and positioned at an appropriate location on the high frequency welder jig 7, and then the upper electrode (welder bar) is applied to the lower electrode 8 a installed on the outer periphery of the high frequency welder jig 7.
By lowering 8b, a high-frequency current is supplied through the upper and lower electrodes 8a and 8b for a predetermined time to fuse and blow the skin material 6 along the peripheral portion of the product, thereby completing the manufacture of the sun visor body 2 shown in FIG.

[0009]

However, in the conventional method of manufacturing the sun visor body 2 using the high-frequency welding method, the pad material 5 needs to be punched in advance into a product shape. In addition, since the pad material 5 and the skin material 6 are roughly cut and cut in separate steps, the number of steps is increased, which is a major factor in lowering production efficiency.

Furthermore, when the pad material 4 punched into the product shape is set on the jig 7 for high frequency welding, when a set displacement occurs, when the skin material 6 is welded and fused with the welding electrodes 8a and 8b, Since the material 5 bites and causes welding failure, the setting of the pad material 5 must be positioned at an appropriate position, which requires skill and requires a lot of time for the setting operation. Was a factor in lowering.

Also, in the structure of the manufactured sun visor body 2, since the pad material 5 and the skin material 6 are not bonded together, a PVC sheet having excellent high-frequency characteristics is usually used as the material of the skin material 6. , Pad material 5 and skin material 6
Due to the difference in the heat shrinkage between these two, the shrinkage force is likely to act on the skin material 6, causing poor appearance such as floating and wrinkles on the surface of the product of the sun visor body 2, resulting in a decrease in aesthetic appearance. .

The present invention has been made in view of such circumstances, and covers the front and back surfaces of a core material with a pad material, covers the outer surface with a skin material, and extends along the periphery of the product shape of the sun visor. In the manufacturing method of the sun visor for automobiles, which is welded and blown off by high-frequency welding, the man-hours for processing the pad material and the skin material can be shortened, the processing equipment can be simplified, and the setting work for the high-frequency welding mold It is an object of the present invention to provide a method for manufacturing a sun visor for an automobile, which can easily perform the above-mentioned steps and can suppress poor appearance such as floating on a product surface and wrinkles due to long-term use.

[0013]

SUMMARY OF THE INVENTION In order to achieve the above object, the present invention provides a sun visor for automobiles comprising a pad material and a skin sheet covering the outer surface of a core material trimmed into a substantially product shape. Laminating a pad material on the back of the skin sheet to form a padded skin, and sandwiching the padded skin on the front and back of the core material formed in a substantially product shape with the front side facing outward and a setting step of the material to be set on the welder jig, Ri Do and a welder processing step a padded epidermis welded fused by the upper and lower electrodes for welder working along the outer periphery of the core, Pas
The expansion and contraction of the skin sheet is regulated by the pad material,
It is characterized by suppressing the occurrence of wrinkles, tarmi and floating .

[0014]

As is clear from the above configuration, the front and back surfaces of the core material are covered with a padded skin in which a pad material is adhered to the back surface of the skin sheet, and the padded skin is welded along the outer periphery of the product by high frequency welding. Since the cutting is performed, a punching die and a punching step for trimming the pad material in advance along the product shape as in the related art become unnecessary.

Further, when setting the material on the jig for the high-frequency welder, the setting work of the padded skin does not cause poor welding and poor appearance even if it is performed rougher than the conventional setting work of the pad material. .

In addition, since the pad material is adhered to the back surface of the skin sheet, the expansion and contraction of the skin material is suppressed by the rigidity of the pad material even if the elastic force acts on the skin material.

[0017]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of a method for manufacturing a sun visor for an automobile according to the present invention will be described below in detail with reference to the accompanying drawings.

FIGS. 1 and 2 are a front view and a sectional view, respectively, showing an automobile sun visor manufactured by the method of the present invention.
FIG. 4 is a process chart diagram showing each step of the method of the present invention, FIGS. 4 and 5 show the method of the present invention, FIG. 4 is a cross-sectional view showing a state where each material is set in a jig for a high frequency welder, and FIG. FIG. 6 is a sectional view showing a welding process, and FIG. 6 is a sectional view showing a modified example of a welding bar used in the method of the present invention.

First, as shown in FIGS. 1 and 2, an automobile sun visor 10 manufactured by the method of the present invention is provided on a sun visor main body 11 having a desired light shielding area, and on one end side of the sun visor main body 11. , Sun visor body 11
L-shaped rotating shaft 12 for rotatably supporting the shaft
At the end of the rotating shaft 12, a bracket 13 attached to the roof side of the vehicle is installed, and the rotating shaft 12 is rotatably inserted into the bracket 13 so that the bracket 13 can be operated at any position in the vertical and horizontal directions. It is possible.

Next, the configuration of the sun visor body 11 will be described with reference to FIG.
A core material 20 formed into a substantially product shape and having an appropriate shape retention property
Is covered with a padded skin 30 having good cushioning properties, surface appearance and surface feel.

More specifically, the structure of the core member 20 includes a wire frame 21 bent into a loop shape,
Along the inside of the wire frame 21, there is a reinforcing board 22 having a reinforcing function such as a cardboard board or a resin board bonded thereto.
A holder for bearing the rotating shaft 12 is fixed, and as a means for bonding the wire frame 21 and the reinforcing plate 22, in the present embodiment, the two are satisfactorily fixed and fixed at predetermined locations via an adhesive tape 23. .

On the other hand, the structure of the padded skin 30 that covers the outer surface of the core material 20 is a laminated structure in which a pad material 32 is attached to the back surface of a skin sheet 31 located on the product surface side. The material of the skin sheet 31 is not particularly limited as long as it is a material having good high frequency welder characteristics. In this embodiment, a PVC sheet is used.

As the pad material 32, a polyurethane foam is used in the present embodiment. However, in order to enhance rigidity and the like, a material such as a semi-rigid polyurethane foam or a compressed polyurethane foam is used depending on the desired use. The selection may be changed as appropriate.

As described above, the sun visor 10 for an automobile manufactured by the method of the present invention is configured such that the outer surface of the core material 20 formed in a substantially product shape is covered with the padded skin 30 as the configuration of the sun visor body 11. And
Since the skin sheet 31 and the pad material 32 are bonded in advance, even if an external force is applied to the skin sheet 31 in the direction of expansion and contraction due to the difference in the thermal expansion and contraction rate between the two, the pad material 32 causes the skin sheet 31 to adhere. Since the extension and shrinkage can be suppressed, there is an advantage that appearance defects such as wrinkles and floating do not occur on the product surface of the sun visor body 11, and the surface appearance and surface feel can be maintained well even after long-term use.

Next, the sun visor 1 for an automobile shown in FIG.
The manufacturing process of the sun visor main body 11 at 0 will be described in detail with reference to the process chart shown in FIG.

First, the outline of the method of the present invention will be briefly described with reference to the chart of FIG.
Is bent into a loop, and the reinforcing plate 22 is adhesively fixed to the wire frame 21 via the adhesive tape 23,
The core material 20 is formed.

Since the process of forming the core member 20 is the same as that of the related art, it will not be described in detail.

Next, the pad material 3 is provided on the back surface of the skin sheet 31.
The two padded skins 30 with the two bonded together, one on the front side and the other on the back side of the core material 20 are prepared, and after going through a rough cutting and cutting process, the front and back surfaces of the core material 20 are prepared. And welding and fusing along the periphery of the product shape by high-frequency welding to complete the manufacture of the sun visor body 11 shown in FIGS.

Next, the method of the present invention will be described with reference to FIGS.
This will be described based on FIG.

First, as shown in FIG. 4, a jig 40 for a high-frequency welder is
And the padded skin 30 are set, and a lower electrode 41 is provided around the outer periphery of the high frequency welder jig 40, and a welder bar (upper electrode) 42 is provided above the lower electrode 41 so as to correspond to the lower electrode 41. The well bar 42 is connected to a press mechanism (not shown), can move up and down by a predetermined stroke, and the well bar 42 can apply a predetermined press pressure to the lower electrode 41 for a predetermined time. A current of a predetermined value is supplied to the electrode 41 and the well bar 42 from the high-frequency transmitter 43 for a predetermined time.

At this time, as shown in FIG. 4, the padded skin 30 on one side is set on a high frequency welder jig 40 with the skin sheet 31 facing downward, and the core material 20 is placed on the upper surface thereof.
After setting the pad, the padded skin 30 is set from the upper surface side of the core material 20 with the skin sheet 31 facing the upper surface, so that the setting of the material on the jig 40 for the high-frequency welder is completed. The skin 30 can be roughly set on the high-frequency welding jig 40, and the setting time can be greatly reduced as compared with the conventional setting work requiring precise positioning of the pad material.

Further, since the pad material 32 is previously bonded to the back surface of the skin sheet 31 as the padded skin 30, it is necessary to separately cut and cut the skin sheet 31 and the pad material 32 separately as in the conventional case. There is no need to punch the pad material, and the skin sheet 3
1. The man-hours for processing the pad material 32 can be simplified, and the equipment does not become large.

Thereafter, as shown in FIG. 5, the weld bar 42 is lowered by a predetermined stroke, and the lower electrode 41 and the weld bar 42 weld and blow the outer skin sheets 31 along the outer periphery of the product of the sun visor 10. The manufacture of the sun visor body 11 is completed.

The shape of the weld bar 42 is as follows.
Since it is preferable to have a function of fusing the offcuts at the time of high frequency mounting, the tip is tapered so as to have a cutting function.

The shape of the well bar 42 is the thickness of the padded skin 30 (skin sheet 31, pad material 32).
It is preferable to appropriately change the taper angles a and b at the tip of the well bar 42 or the joining positions c and d between the well bar 42 and the lower electrode 41 as shown in an enlarged manner in FIG. Welding is possible.

Also, as shown in FIG.
2 may be set to a flat surface.

The sun visor body 11 thus manufactured
In the case, when the welding strength of the skin sheets 31 is measured, a normal polyurethane foam of 1 mm to 6 mm as the pad material 32 is bonded to the back surface of the PVC sheet,
When the peel strength after welding welding is measured, 5 to 14 k
gf / 3cm width, average 9.0kgf / 3cm width,
When a semi-rigid polyurethane foam of 1 mm to 4 mm is bonded to the back of the PVC sheet, 4 to 9 kgf / 3c
Satisfactory measurement results of m width and average width of 6.0 kgf / 3 cm were obtained.

As described above, according to the method of the present invention, by using the padded skin 30, the skin sheet 31,
The number of processing steps for each pad material 32 can be reduced, and
The productivity can be remarkably improved, for example, the punching step of the pad material 32 can be eliminated, and also in the setting work to the jig 40 for the high-frequency welder, good forming is possible even if the work is set relatively rough. There are advantages such as the work efficiency can be remarkably increased and automation can be facilitated.

Further, the skin sheet 31 can be used for a long time.
Extremely practical value, such as the ability to mass-produce high practical value automotive sun visors with simple equipment, such as no wrinkles, floating, etc., and good surface appearance and surface feel over a long period of time. high.

[0040]

As described above, the method for manufacturing a sun visor for an automobile according to the present invention has the following special effects.

(1) According to the method of the present invention, the front and back surfaces of the core material are covered with the padded skin, and the padded skin material is welded and melted by high-frequency welding, so that the skin sheet and the pad material are used. Can significantly reduce the number of processing steps compared to the past, and also eliminates the step of punching the pad material using a special punching die as before, thereby reducing the processing steps for the skin material and pad material and simplifying the processing equipment. This leads to a significant cost reduction.

(2) According to the method of the present invention, after the padded skin material is positioned on the front and back sides of the core material, the padded skin material is welded and melted along the product periphery by high-frequency welding. Therefore, the positioning work of the padded skin material can be set relatively rough on the jig for the high frequency welder, and the workability in the positioning work has been greatly improved compared to the conventional case where severe positioning accuracy is required This has the effects of significantly improving production efficiency and facilitating automation.

[0043] (3) According to the method of the present invention, since the skin sheet back surface to the mating previously attaching the pad material, the outer surface of the <br/> core material by padded epidermis is a configuration that encapsulation, and the skin sheet Due to the difference in thermal expansion and contraction rate between the pad material and the pad material, the expansion and contraction of the skin sheet can be regulated by the pad material even if a stretching force acts on the skin sheet. No effect is produced, and good surface appearance and surface feel can be guaranteed.

[Brief description of the drawings]

FIG. 1 is an external view showing an automotive sun visor manufactured by the method of the present invention.

FIG. 2 is a sectional view taken along line II-II in FIG.

FIG. 3 is a process chart showing a manufacturing process of an automobile sun visor in the method of the present invention.

FIG. 4 is a cross-sectional view illustrating a step of setting each material in a jig for high-frequency welding in the method of the present invention.

FIG. 5 is a sectional view showing a high-frequency welding process in the method of the present invention.

FIG. 6 is a sectional view showing a modified example of a well bar used in the method of the present invention.

FIG. 7 is a partial cross-sectional perspective view showing the configuration of a conventional automotive sun visor.

FIG. 8 is a chart of a manufacturing process of a conventional automotive sun visor.

FIG. 9 is a cross-sectional view showing a state in which a conventional sun visor for an automobile is set in a jig for a high-frequency welder.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Sun visor for automobiles 11 Sun visor main body 20 Core material 21 Wire frame 22 Reinforcement plate 30 Padded skin 31 Skin sheet 32 Pad material 40 High frequency welder jig 41 Lower electrode 42 Welder bar 43 High frequency transmitter

 ──────────────────────────────────────────────────続 き Continuation of front page (56) References JP-A-64-51922 (JP, A) JP-A-58-8423 (JP, A) JP-A-1-136817 (JP, A) JP-A-61-1986 135826 (JP, A) Fully open sho 60-108517 (JP, U) Fully open sho 64-35119 (JP, U) Really open sho 57-416 (JP, U)

Claims (1)

(57) [Claims] 1. A core material (20) trimmed to a substantially product shape.
In an automotive sun visor having an outer surface covered with a pad material (32) and a skin sheet (31), a pad material (32) is laminated on the back surface of the skin sheet (31) to form a padded skin (30). And forming a padded skin (30) on the front and back surfaces of the core material (20) formed in a substantially product shape, with the front surface side facing outward, respectively, on a high frequency welder jig (40). a set to set the material step, a welder processing step a padded skin (30) are welded fused by the upper and lower electrodes for welder working along the outer peripheral edge (41, 42) of the core (20), Ri Tona, Skin sheet (31) with pad material (32)
Restricts the expansion and contraction of the product, causing wrinkles, tarmi, and floating on the product surface.
A method for manufacturing a sun visor for an automobile, characterized in that generation of the sun visor is suppressed .