Method for manufacturing crash pad of vehicle
A method for manufacturing a vehicle crash pad includes heating a skin layer using a heater, attaching a cushion layer to the skin layer, placing a lower mold and an upper mold relative to a fabric including the skin layer and the cushion layer, forming a molded member on the lower mold, vacuum molding. The upper mold is lowered to perform the vacuum molding. The method further includes a laser processing of the fabric and molded member using a processing system, where a sensor senses the fabric and molded member, and based on sensed data, a through-hole is defined by adjusting the intensity of a laser's light irradiated to the fabric and molded member.
1 . A method for manufacturing a vehicle crash pad of an airbag, the method comprising:
heating a skin layer using a heater;
attaching a cushion layer to the skin layer to thereby form a fabric including the skin layer and the cushion layer disposed below the skin layer;
placing (i) a lower mold below the fabric and (ii) an upper mold above the fabric, at least one of the lower mold or the upper mold being configured to move up and down relative to the fabric;
providing a molded member on the lower mold, the molded member being disposed below the cushion layer;
performing a vacuum molding by moving the upper mold toward the lower mold, wherein the fabric and the molded member are disposed between the lower mold and the upper mold; and
performing a laser processing with the fabric and the molded member that are coupled by the vacuum molding,
wherein the laser processing comprises:
irradiating laser light to the fabric and the molded member to thereby define a through-hole through the fabric and the molded member,
sensing, by a sensor, laser light passing through the through-hole, and
adjusting an intensity of the laser light irradiated to the fabric and the molded member.
2 . The method of claim 1 , wherein the vehicle crash pad includes the skin layer, the cushion layer, and the molded member that are laminated in order.
3 . The method of claim 1 , wherein the sensor is a single laser light receiving sensor, or one of a plurality of laser light receiving sensors.
4 . The method of claim 1 , wherein the laser processing further comprises:
providing a spin lens that is configured to irradiate the laser light to the fabric and the molded member.
5 . The method of claim 4 , wherein the laser processing further comprises providing the laser light to the spin lens through a reflector, and
wherein the laser light is irradiated to the fabric and the molded member through the spin lens.
6 . The method of claim 1 , wherein the laser processing further comprises generating the laser light by a CO 2 low-power laser apparatus.
7 . The method of claim 1 , wherein the skin layer comprises:
an inner skin layer located inside the vehicle crash pad; and
an outer skin layer located outside the vehicle crash pad.
8 . The method of claim 7 , wherein the inner skin layer of the skin layer is made of any one material selected from thermoplastic olefin (TPO), polyurethane (PU), polyvinyl chloride (PVC), thermoplastic poly-urethane (TPU), polyethylene terephthalate (PET), knitted fabric, and nonwoven fabric, and
wherein the outer skin layer is made of any one material selected from thermoplastic olefin (TPO), polyurethane (PU), polyvinyl chloride (PVC), thermoplastic polyurethane (TPU), and polyethylene terephthalate (PET).
9 . The method of claim 1 , wherein the cushion layer is made of any one material selected from polypropylene (PP) foam, thermoplastic olefin (TPO) foam, polyurethane (PU) foam, knitted fabric, nonwoven fabric, and filament.
10 . The method of claim 1 , wherein the through-hole is a single through-hole or one of a plurality of through-holes, and passes through an entirety of the molded member and the fabric that are coupled,
wherein a diameter of a first portion of the through-hole through the fabric is Φ0.1 mm-Φ1.0 mm, and
wherein a diameter of a second portion of the through-hole through the molded member is Φ0.6 mm-Φ1.6 mm.
11 . The method of claim 1 , wherein the laser processing further comprises:
sensing a thickness of the fabric and the molded member that are coupled;
transmitting sensed data to a controller; and
adjusting, by the controller, (i) the intensity of the laser light, (ii) a duration of irradiation of the laser light, and (iii) an angle of a spin lens through which the laser light is irradiated.
12 . The method of claim 1 , wherein the laser processing further comprises:
holding the molded member and the fabric by a fixation jig, the fixation jig being positioned adjacent to the sensor and configured to fix the molded member and the fabric to thereby define a position of the through-hole in the molded member and the fabric.
13 . The method of claim 1 , wherein the laser processing further comprises blowing air by an air blower toward the sensor.
14 . The method of claim 1 , wherein the laser processing further comprises moving the sensor up and down during the laser processing along a center line of the sensor.