CN107487039A - 一种汽车顶蓬气帘爆破线的切割生产工艺 - Google Patents

一种汽车顶蓬气帘爆破线的切割生产工艺 Download PDF

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CN107487039A
CN107487039A CN201710788485.9A CN201710788485A CN107487039A CN 107487039 A CN107487039 A CN 107487039A CN 201710788485 A CN201710788485 A CN 201710788485A CN 107487039 A CN107487039 A CN 107487039A
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姜峰
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WUXI JIXING AUTO PARTS CO Ltd
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Abstract

本发明涉及一种汽车顶蓬气帘爆破线的切割生产工艺，属于汽车内饰件生产技术领域。具体操作步骤如下：将PU板材双面滚胶，经过喷洒纯净水、压制成型、冷却定型、水刀切割、基材切割，附件安装、包边、气帘爆破线切割、完检后即可制得。本发明设计的切割汽车顶蓬气帘爆破线的设备及操作工艺简单，这种进行汽车气帘爆破线切割的顶蓬能保证在汽车发生碰撞过程时，气帘能及时爆破，保证乘车人员安全，有利于提高公司产品竞争力。

Description

一种汽车顶蓬气帘爆破线的切割生产工艺
技术领域
本发明涉及一种汽车顶蓬的生产工艺，尤其涉及一种汽车顶蓬气帘爆破线的切割生产工艺，属于汽车内饰件生产技术领域。
背景技术
汽车顶蓬安装于汽车车舱内，起到美化的作用。随着汽车内饰件行业的快速发展以及人们对汽车内饰件的要求越来越高，汽车内饰件更加注重产品的高性能、环保性以及轻量化，而现有的汽车顶蓬无气帘爆破线切割，气帘在汽车碰撞过程中，可能存在不爆破或爆破不及时现象，造成乘客受伤甚至死亡。
发明内容
本发明的目的是为了提高驾乘人员的安全性能，提供一种汽车顶蓬气帘爆破线的切割工艺，保证在汽车发生碰撞过程时，气帘能及时爆破，保证乘车人员安全，
按照本发明提供的技术方案，一种汽车顶蓬气帘爆破线的切割生产工艺，步骤如下：
（1）滚胶：将PU板材置于滚胶机上进行胶水涂布；
（2）喷洒纯净水：将涂布好胶水的PU板材经过喷水装置，在PU板材上层和下层均匀喷洒上纯净水；
（3）压制成型：按照针织面料、上层玻纤、PU板材、下层玻纤、三层膜、底布的顺序依次将材料叠放好，并将材料放入模具进行压制成型，成型后得到汽车顶蓬半成品；
（4）冷却定型：将压制成型后的汽车顶蓬半成品放置于冷却工装治具上进行真空吸附冷却定型，室温冷却，
（5）水刀切割：将冷却定型的汽车顶蓬半成品按照所需形状进行水刀切割；
（6）基材切割：将汽车顶蓬半成品放在切割机上进行定位，按所需形状进行前沿和天窗切割，通过控制切割机，实现对除面料以外的各层材料进行切割，切割完后，对切割下的各层材料和未切割的面料进行剥离，得到半成品零件。
（7）附件安装：将切割好的半成品放置于组立工装上并进行定位，再将零附件定位在工装设备上后进行打胶、压制；
（8）包边：对半成品顶蓬前沿和天窗切割位置进行喷胶，将喷胶好的半成品放置于包边工装上并进行定位，通过包边工装进行压制，将涂有胶水的面料黏结到基材上；
（9）气帘爆破线切割：包边完的半成品放置在组立工装上进行定位，再将特定部位按所需形状进行自动切割；
（10）检验：检验产品，将合格产品装箱入库。。
对上述方案的进一步改进：
步骤（1）中，滚胶机的滚筒电机频率控制在25~35Hz，滚轮温度为30~40℃；喷胶量设置为：上层 PU板材涂布为15~25g/m2，下层PU板材涂布为35~45g/m2。
步骤（2）中，电机的频率控制在40~60Hz，喷洒的纯净水量为25~35g/m2；
步骤（3）中，压制成型温度设定为上模温度：100~110℃，下模温度：130~140℃；成型压力控制在7.5~8.5MPa，成型时间控制在45~50s。
步骤（4）中，冷却时间在40~50s，真空度为-2~-5mbar；
步骤（5），切割时水压控制在40000~50000psi，切割气压为0.6~0.8MPa。
步骤（7）中，压制时，保压压力控制在0.6~0.8MPa；保压时间为35s，
步骤（8）中，压制时，保压压力控制在0.6~0.8MPa；保压时间为30s。
步骤（9）中，切割后长度尺寸公差在±5mm范围，位置尺寸公差±2mm，深度设置为2.5mm±0.5mm。
对上述方案的进一步改进：在步骤1中，所述胶水的主要成分为聚酯类化合物。
本发明的有益效果：本发明工艺方法简单，设计的汽车顶蓬气帘爆破线切割的生产工艺简单，且驾乘人员安全性能得到提升，属于汽车内饰件生产技术领域。
具体实施方式
对一种型号为2TW全景天窗汽车顶蓬气帘爆破线进行切割，具体切割的生产工艺步骤如下：
（1）滚胶：将PU板材置于滚胶机上进行胶水涂布；滚筒电机频率为25~35Hz，滚轮温度为30~40℃；喷胶量：上层 PU板材涂布为15~25g/m2，下层PU板材涂布为35~45g/m2，胶水的主要成分为聚酯类化合物；
（2）喷洒纯净水：将涂布好胶水的PU板材经过喷水装置，在PU板材上层和下层均匀喷洒上纯净水；电机频率：40~60Hz，喷洒的纯净水量为25~35g/m2；
（3）压制成型：按照针织面料、上层玻纤、PU板材、下层玻纤、三层膜、底布的顺序依次将材料叠放好，并将材料放入模具进行压制成型，压制成型温度：上模温度控制在100~110℃，下模温度控制在130~140℃；成型压力控制在7.5~8.5MPa，成型时间：45~50s，成型后得到汽车顶蓬半成品；
（4）冷却定型：将压制成型后的汽车顶蓬半成品放置于冷却工装治具上进行真空吸附冷却定型，室温冷却，冷却时间为40~50s，真空度为-2~-5mbar。
（5）水刀切割：将冷却定型的汽车顶蓬半成品按照所需形状进行水刀切割；切割水压为40000~50000psi，切割气压为0.6~0.8MPa；
（6）基材切割：将汽车顶蓬半成品放在切割机上进行定位，按所需形状进行前沿切割，所用的切割机为特制的切割机，通过控制切割机，实现对除面料以外的各层材料的切割，切割完后，对切割下的各层材料和未切割的面料进行剥离，得到半成品零件；
（7）附件安装：将切割好的半成品放置于组立工装上并进行定位，再将零附件定位在工装设备上后进行打胶、压制，保压压力：0.6~0.8MPa；保压时间为35s，根据天窗切割的大小在天窗四周安装固定上加强框；
（8）包边：对半成品顶蓬前沿和天窗切割位置进行喷胶，将喷胶好的半成品放置于包边工装上并进行定位，通过包边工装进行压制，将涂有胶水的面料黏结到基材上，保压压力：0.6~0.8MPa；保压时间为30s；
（9）气帘爆破线切割：包边完的半成品放置在组立工装上进行定位，再将特定部位按所需形状进行自动切割，确保长度尺寸公差±5mm，位置尺寸公差±2mm，深度设置为2.5mm±0.5mm；
（10）检验：检验产品，将合格产品装箱入库。
在其他实施例中，切割天窗的形状可以是型号为2TW的小天窗。
最后所应说明的是，以上具体实施方式仅用以说明本发明的技术方案而非限制，尽管参照实例对本发明进行了详细说明，本领域的普通技术人员应当理解，可以对本发明的技术方案进行修改或者等同替换，而不脱离本本发明技术方案的精神和范围，其均应涵盖在本发明的权利要求范围当中。

Claims (3)

1.一种汽车顶蓬气帘爆破线的切割生产工艺，其特征在于，具体操作步骤如下：
（1）滚胶：将PU板材置于滚胶机上进行胶水涂布；
（2）喷洒纯净水：将涂布好胶水的PU板材经过喷水装置，在PU板材上层和下层均匀喷洒上纯净水；
（3）压制成型：按照针织面料、上层玻纤、PU板材、下层玻纤、三层膜、底布的顺序依次将材料叠放好，并将材料放入模具进行压制成型，成型后得到汽车顶蓬半成品；
（4）冷却定型：将压制成型后的汽车顶蓬半成品放置于冷却工装治具上进行真空吸附冷却定型，室温冷却；
（5）水刀切割：将冷却定型的汽车顶蓬半成品按照所需形状进行水刀切割；
（6）基材切割：将汽车顶蓬半成品放在切割机上进行定位，按所需形状进行前沿和天窗切割，通过控制切割机，实现对除面料以外的各层材料进行切割，切割完后，对切割下的各层材料和未切割的面料进行剥离，得到半成品零件；
（7）附件安装：将切割好的半成品放置于组立工装上并进行定位，再将零件定位在工装设备上后进行打胶、压制；
（8）包边：对半成品顶蓬前沿和天窗切割位置进行喷胶，将喷胶好的半成品放置于包边工装上并进行定位，通过包边工装进行压制，将涂有胶水的面料黏结到基材上；
（9）气帘爆破线切割：包边完的半成品放置在组立工装上进行定位，再将特定部位按所需形状进行自动切割；
（10）检验：检验产品，将合格产品装箱入库。
2.如权利要求1所述汽车顶蓬气帘爆破线切割的生产工艺，其特征在于，
所述步骤（1）中，滚胶机的滚筒电机频率控制在25~35Hz，滚轮温度为30~40℃；喷胶量设置为：上层 PU板材涂布为15~25g/m2，下层PU板材涂布为35~45g/m2；
所述步骤（2）中，电机的频率控制在40~60Hz，喷洒的纯净水量为25~35g/m2；
所述步骤（3）中，压制成型温度设定为上模温度：100~110℃，下模温度：130~140℃；成型压力控制在7.5~8.5MPa，成型时间控制在45~50s；
所述步骤（4）中，冷却时间在40~50s，真空度为-2~-5mbar；
所述步骤（5）中，切割时水压控制在40000~50000psi，切割气压为0.6~0.8MPa；
所述步骤（7）中，压制时，保压压力控制在0.6~0.8MPa；保压时间为35s，
所述步骤（8）中，压制时，保压压力控制在0.6~0.8MPa；保压时间为30s；
所述步骤（9）中，切割后长度尺寸公差在±5mm范围，位置尺寸公差±2mm，深度设置为2.5mm±0.5mm。
3.如权利要求1或2所述汽车顶蓬气帘爆破线切割的生产工艺，其特征在于，
在步骤1中，所述胶水的主要成分为聚酯类化合物。
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