KR-20260063447-A - The Crash Pad of Forming Method For A Vehicle

KR20260063447AKR 20260063447 AKR20260063447 AKR 20260063447AKR-20260063447-A

Abstract

The present invention relates to a method for manufacturing a vehicle crash pad, comprising: a skin layer heating step of heating a skin layer using a heating unit; a cushion layer attachment step of attaching a cushion layer to the skin layer; a mold placement step in which a lower mold is placed on the lower side corresponding to an upper mold that moves up and down; a molding member forming step of forming a molded member using the lower mold; a vacuum forming step in which a mold is placed on a fabric composed of the skin layer and the cushion layer and the molded member, and the upper mold is lowered to perform vacuum forming; and a laser processing step in which the fabric and the molded member are laser processed using a processing unit, wherein in the processing step, the fabric and the molded member are sensed by a sensor, and through holes are processed by adjusting the intensity of the laser irradiated onto the fabric and the molded member based on the sensing data.

Inventors

안재헌
한인수
박홍진
최기철
김재현

Assignees

현대자동차주식회사
기아 주식회사
주식회사 비에스피

Dates

Publication Date: 20260507
Application Date: 20241030

Claims (16)

In a method for manufacturing a vehicle crash pad, Skin layer heating step of heating the skin layer using a heating unit; A cushion layer attachment step of attaching a cushion layer to the above-mentioned skin layer; A mold placement step in which a lower mold is placed on the lower side corresponding to the upper mold that moves up and down; A step of forming a molded member using the lower mold above; A vacuum forming step of placing a mold on a fabric composed of the skin layer and the cushion layer and the molding member, and lowering an upper mold to perform vacuum forming; and It includes a laser processing step of laser processing the fabric and the molded member using a processing unit, and A method for forming a crash pad of a vehicle, wherein in the above processing step, the fabric and the molded member are sensed by a sensor, and through holes are formed by adjusting the intensity of a laser irradiated onto the fabric and the molded member based on the sensing data.
In claim 1, A method for forming a vehicle crash pad, wherein the skin layer, the cushion layer, and the molded member are laminated in that order.
In claim 1, A method for forming a crash pad of a vehicle, wherein the above-mentioned sensor is composed of one or more sensors and is composed of a laser receiving sensor.
In claim 1, A method for forming a crash pad of a vehicle, wherein a spin lens is arranged to irradiate light onto the fabric and the molding member using the above laser, and the light is transmitted to the fabric and the molding member.
In claim 4, A method for forming a vehicle crash pad, wherein the above laser passes through a reflector and irradiates light onto the above spin lens.
In claim 1, A method for forming a vehicle crash pad, wherein the above laser is composed of a CO2 low-power laser.
In claim 1, The above skin layer is an inner skin layer located on the inside; and A crash pad for a vehicle and a method for forming the same, comprising an outer skin layer located on the outside.
In claim 7, A method for forming a crash pad of a vehicle, wherein the inner skin layer of the above-mentioned skin layer is made of any one of TPO (Thermoplastic Olefin), PU (polyurethane), PVC (Polyvinyl Chloride), TPU (Thermoplastic Poly-Urethane), PET (Polyethylene TerephThalate), knitting, and non-woven fabric, and the outer skin layer is made of any one of TPO (Thermoplastic Olefin), PU (polyurethane), PVC (Polyvinyl Chloride), TPU (Thermoplastic Poly-Urethane), and PET (Polyethylene TerephThalate).
In claim 1, A method for forming a vehicle crash pad, wherein the cushion layer is made of any one of PP (Polypropylene) foam, TPO (Thermoplastic Olefin) foam, PU (polyurethane) foam, knitting, nonwoven fabric, or filament.
In claim 1, A method for forming a crash pad of a vehicle, wherein at least one through hole is formed, the through hole penetrates the entire layer of the molded member and the fabric, the size of the through hole penetrating the fabric is formed to be between Φ0.1 and Φ1.0, and the size of the through hole penetrating the molded member is formed to be between Φ0.6 and Φ1.6.
In claim 1, A method for forming a vehicle crash pad, wherein in the above processing step, the thickness of the fabric and the molded member is sensed by the sensor, the sensed data is transmitted to a controller, and the intensity and time of light irradiated from the laser are controlled by the controller and the angle of the spin lens is controlled.
In claim 1, A method for forming a crash pad of a vehicle, wherein the molding member and the fabric are placed on a fixing jig, the fixing jig is positioned adjacent to the sensor, and the molding member and the fabric are fixed so that a through hole can be accurately processed in the molding member and the fabric.
A crash pad for a vehicle, formed by stacking a molded member, a cushion layer, and a skin layer, and having through holes processed by adjusting the intensity of a laser irradiated onto the molded member and the fabric composed of the skin layer and the cushion layer.
In claim 13, A crash pad for a vehicle, wherein the through hole is formed as at least one or more, the through hole penetrates the entire layer of the molded member and the fabric, the size of the through hole penetrating the fabric is formed to be between Φ0.1 and Φ1.0, and the size of the through hole penetrating the molded member is formed to be between Φ0.6 and Φ1.6.
In claim 13, A crash pad for a vehicle, comprising an air blower that blows air to a sensor for sensing the fabric and the molded member.
In claim 15, The above sensor is a crash pad of a vehicle, configured such that the position of the centerline for laser processing moves in the up and down direction.

Description

The Crash Pad Forming Method For A Vehicle The present invention relates to a method for forming a crash pad of a vehicle, and more specifically, to a method for processing a crash pad skin. Generally, automobiles are equipped with various devices to ensure the safety of occupants, and an airbag is installed in the steering wheel as an automotive safety assist device designed to prevent the driver from suffering severe impact in the event of a vehicle accident. Recently, as automobile performance has improved and road pavement conditions have become better, driving speeds have been gradually increasing, leading to a rise in rear-end collisions and resulting human casualties. The car is equipped with passenger airbags in the steering wheel, passenger seat, two knee areas, four seats, and three areas each on the pillars of the side windows. For example, in the case of a passenger airbag designed to protect a passenger in the front passenger seat, a crash pad positioned in front of the passenger seat is equipped with a soft airbag cover manufactured through plastic injection molding that is integrally formed with the crash pad, and an airbag is interposed therein so that the airbag cover ruptures and the airbag deploys upon impact or sudden braking of the vehicle. Meanwhile, the upper part of this crash pad is formed horizontally, with both ends connected to the left and right side members of the vehicle, respectively, and the central part, commonly referred to as the center fascia, extends downward and is formed vertically, connecting to the front floor, which is the floor surface of the passenger cabin. The reason crash pads have recently gained popularity is that they provide elastic cushioning through foam molding, thereby satisfying high durability against high temperatures and direct heat, excellent moldability and high-temperature properties through thermoforming, and possess excellent sensibility and comfort as they are parts that come into direct contact with the driver and passengers. These crash pads are classified into soft crash pads and hard crash pads; soft-type crash pads consist of a cross-section of three layers (skin, foam, and core), providing a soft cushioning feel in terms of appearance and touch, while hard-type crash pads consist of a single layer (core) and refer to injection-molded plastic products. The reason crash pads have recently gained popularity is that they provide elastic cushioning through foam molding, thereby satisfying high durability against high temperatures and direct heat, excellent moldability and high-temperature properties through thermoforming, and possess excellent sensibility and comfort as they are parts that come into direct contact with the driver and passengers. These crash pads are classified into soft crash pads and hard crash pads. The soft type crash pad consists of three layers (skin, foam, and core) in cross-section, allowing for a soft cushioning feel in appearance and touch, while the hard type crash pad consists of one layer (core) and refers to a product made of plastic injection molding. Recently, soft-type crash pads are being produced and applied due to their advantages in appearance, texture, and cushioning. In particular, a crash pad skin attached to the outer surface of the crash pad is manufactured and adhered to the crash pad to create a beautiful surface finish on the outer surface of the crash pad, so that the vehicle interior can feel luxurious, stimulating, and comfortable. These crash pad skins are manufactured using the PSM (Powder Slush Molding) method and/or vacuum forming method, etc. However, conventional crash pad skins are processed using high-power lasers, which cause the skin to carbonize, resulting in reduced appearance quality and a fire hazard. Additionally, the manufacturing process becomes complex because product processing is impossible depending on the molding state of the skin. Furthermore, while laser intensity can be measured using a robotic arm, there are issues with weight and speed limitations due to the payload constraints of the robotic arm. FIG. 1 is a block diagram sequentially illustrating a method for forming a crash pad of a vehicle according to the present invention. FIGS. 2(a) to (e) are drawings illustrating an exemplary method of forming a crash pad of a vehicle according to the present invention. FIG. 3 is a diagram exemplarily illustrating the sequence in which a processing unit for forming a crash pad of a vehicle according to the present invention is driven. FIG. 4 is a drawing illustrating a spin lens of a processing unit for a crash pad of a vehicle according to the present invention. FIG. 5 is a diagram roughly illustrating a method of forming a fabric while a processing unit for forming a crash pad of a vehicle according to the present invention is driven. FIG. 6 is a drawing illustrating the crash pad of a vehicle according to the present invention. FIG. 7 is a drawing showing through holes for