CN112171998B - Process for manufacturing special-shaped foamed product - Google Patents
Process for manufacturing special-shaped foamed product Download PDFInfo
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- CN112171998B CN112171998B CN202010918703.8A CN202010918703A CN112171998B CN 112171998 B CN112171998 B CN 112171998B CN 202010918703 A CN202010918703 A CN 202010918703A CN 112171998 B CN112171998 B CN 112171998B
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- foaming
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/08—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles using several expanding or moulding steps
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
- B29C44/1285—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed part being foamed
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/34—Auxiliary operations
- B29C44/58—Moulds
- B29C44/582—Moulds for making undercut articles
Landscapes
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Abstract
The invention discloses a manufacturing process of a special-shaped foaming product, which comprises the following steps: firstly, decomposing a foaming product to form three sections of areas, preparing a primary foaming mould, opening an upper mould of the mould, and flatly paving soft leather on a lower mould; secondly, paving a reinforcing layer on the whole soft leather, then injecting a PU foaming material into a foaming area in a primary foaming mould for primary foaming, and pressing an upper mould on the soft leather connecting area; thirdly, demoulding is carried out after the primary foaming and curing, and a semi-finished product is taken out; preparing a secondary foaming mould, wherein the upper mould of the foaming mould is designed to just press the material injection area, the semi-finished product is placed on the lower mould, and the soft leather is laid on the material injection area; paving a reinforcing layer on the soft leather, and injecting a foaming material into a material injection area for secondary foaming; sixthly, curing and demolding the secondary foaming material. The back-off structure is eliminated by secondary foaming, the mold cost is low, the design, installation and taking out of a loose piece are omitted, the production efficiency of the foaming molding process is high, and the product percent of pass is high.
Description
Technical Field
The invention relates to the field of automotive upholstery, in particular to a manufacturing process of a special-shaped foaming product.
Background
Along with the development of the passenger car industry, the requirements of people on passenger car parts are also remarkably increased, the characteristics of the materials of the traditional passenger car front ceiling can not meet the requirements of people generally, and polyurethane foaming materials are widely used on the interior decoration of the passenger car due to the excellent performance of the polyurethane foaming materials. Because the front top interior trim structure is complex, the manufacturing process of using the foaming material is complex, and generally comprises the working procedures of skin hot plastic molding, foaming molding and the like. According to the traditional hot plastic suction mold, a plastic suction product is tightly attached to the surface of the mold after being molded, when the product structure is recessed into the mold (inverted), the product is easily clamped on the inverted structure and is difficult to demould, the qualification rate is low, the hot plastic suction product with a complex structure in the industry has the defects of skin explosion, thinning and the like, and the qualification rate is lower than 75%; the foaming product meets the back-off structure that the structure is complicated, no matter be the foaming product or go up the mould and can't take off or open from the mould after the shaping, traditional solution is to make the back-off structure position into the loose piece region, use metal aluminum product as preparation foaming mould according to product design precision, the material of loose piece, process manufacturing to mould body and loose piece respectively, mould body and loose piece installation adopt negative spout structure side-mounting mode, separate loose piece and main part mould when needs drawing of patterns, open the mould again, take out product and loose piece simultaneously, take out the loose piece from product one side direction at last again, accomplish the drawing of patterns. The mold with the inverted buckle structure has the advantages that the design, the installation and the taking out of the movable block are complex, the manufacturing process of the special-shaped foaming product is complex, the production efficiency is low, the requirement on the precision of the mold is high, and the design cost is also high.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provide a process for manufacturing a special-shaped foaming product, when the foaming product meets an inverted buckle structure with a complex structure, the manufacturing of the inverted buckle structure part can be smoothly completed without the need of performing loose piece design on a mould of the inverted buckle structure part, the qualification rate and the production efficiency of the special-shaped foaming product are high, and the mould design cost is low.
In order to solve the technical problems, the invention adopts the following technical scheme that the manufacturing process of the special-shaped foaming product comprises the following steps: firstly, decomposing a foaming product into foaming areas at two ends and a middle connecting area to form three sections of areas, preparing a primary foaming mould by taking the middle connecting area as a reverse buckling structure part, opening an upper mould of the primary foaming mould, and flatly paving soft leather on the lower mould; secondly, laying the enhancement layer on the whole soft leather, then injecting a PU foaming material into a foaming area in a primary foaming mould for primary foaming, pressing an upper mould against the soft leather connecting area to ensure that the soft leather connecting area is not influenced by the primary foaming injection material, and closing the mould and curing; thirdly, opening an upper die of the primary foaming die for demoulding after the primary foaming and curing, and taking out a foamed semi-finished product; preparing a secondary foaming mold, wherein the upper mold of the secondary foaming mold is designed to just press the material injection area, opening the upper mold of the secondary foaming mold, and then placing the foamed semi-finished product on the lower mold of the secondary foaming mold according to the final shape, wherein the soft leather in the soft connection area is laid on the material injection area of the secondary foaming mold; injecting a PU foaming material into a material injection area of a secondary foaming mold for secondary foaming, adding a paving reinforcing layer on the material injection area, closing an upper mold for foaming and curing, and just closing the upper mold onto the secondary foaming material injection area by the upper mold through a press limiting device; and sixthly, opening the upper die of the secondary foaming die to demould after the secondary foaming material is solidified, and taking out the foamed product.
Because the manufacturing process of the special-shaped foaming product uses the secondary foaming process, when the product structure is inwards recessed into the inverted groove of the mold, the inverted groove is foamed step by the secondary foaming process, the inverted structure on the mold is eliminated, the loose piece design is not needed to be carried out on the inverted structure part of the mold, the manufacturing of the inverted structure part of the foaming product is smoothly completed, the secondary foaming has low requirement on the precision of the mold, the design cost of the simple mold is low, the complex design, installation and taking out of the loose piece are omitted, the foaming molding process is simplified, modularized and precise, the qualification rate of the special-shaped foaming product and the production efficiency are high.
TABLE 1 comparison of the Secondary foaming Process with the old Process
The invention will be further explained with reference to the drawings.
Drawings
FIG. 1 is a schematic view of a one-time foaming mold
FIG. 2 is a partially enlarged view of the mold of FIG. 1
FIG. 3 is a schematic view of a secondary foaming mold
FIG. 4 is an enlarged partial view of the mold of FIG. 3
FIG. 5 is a schematic view of a cross-section structure of a foamed product at the front top of a passenger car
FIG. 6 is a schematic view of a conventional mold for hot plastic molding
FIG. 7 is a schematic view of a conventional foaming mold
The specific implementation mode is as follows:
referring to fig. 1-7, the process for manufacturing the profiled foamed product comprises the following steps: firstly, dividing a foaming product 5 into foaming areas 1 and 3 at two ends, forming three sections of areas by a middle connecting area 2, preparing primary foaming molds 1-1 and 1-2 by taking the middle connecting area 2 as a reverse buckling structure part, opening an upper mold 1-1 of the primary foaming mold, and flatly paving soft leather on the lower mold 1-2; secondly, laying the enhancement layer on the whole soft leather, then injecting PU foaming material into the foaming areas 1 and 3 in the primary foaming mould for primary foaming, pressing the upper mould 1-1 against the soft leather connecting area 2 to ensure that the soft leather connecting area 2 is not influenced by the primary foaming injection material, and closing the mould for curing; thirdly, opening an upper die 1-1 of the primary foaming die to demould after the primary foaming and curing, and taking out the foamed semi-finished product; preparing secondary foaming molds 2-1 and 2-2, wherein the upper mold 2-1 of the secondary foaming mold is designed to just press the material injection area 4, the upper mold 2-1 of the secondary foaming mold is opened, then the foamed semi-finished product is placed on the lower mold 2-2 of the secondary foaming mold according to the final shape, and the soft leather of the soft connection area 2 is laid on the material injection area 4 on the lower mold 2-2 of the secondary foaming mold; injecting a PU foaming material into a material injection area 4 of the secondary foaming mold for secondary foaming, additionally laying a reinforcing layer on the material injection area 4, closing an upper mold 2-1 for foaming and curing, and just closing the upper mold 2-1 to the material injection area 4 by the upper mold 2-1 through a press limiting device; sixthly, opening the upper die 2-1 of the secondary foaming die to demould after the secondary foaming material is solidified, and taking out the foamed product 5.
Traditional hot plastic suction mould 7 hugs closely 7 surfaces of mould after 5 shaping of product, and when the product structure appeared interior indent mould back-off slot 6 circumstances, product 5 blocked on back-off slot 6 easily and was difficult to the drawing of patterns.
In the foaming forming mold, a foaming product 5 meets an inverted structure of a complex inverted groove 6, and the foaming product 5 or an upper mold 2-1 cannot be taken down or opened from the mold after forming, and the traditional solution is to make the position of the inverted groove 6 into a loose piece 8.
The manufacturing process of the special-shaped foaming product adopts a secondary foaming process, the inverted buckle groove 6 of the foaming product is foamed step by the secondary foaming process, the inverted buckle groove 6 on the mould is eliminated, the movable block design of the inverted buckle structure part formed by the mould groove 6 is not needed, and the manufacture of the inverted buckle structure part of the foaming product 5 is smoothly completed.
Example 1, taking the interior of a passenger car front roof as an example, the product size is 2400mm x 600mm, refer to fig. 1-7.
The manufacturing process of the passenger car front top interior trim foaming product comprises the following steps: firstly, dividing a passenger car front top product 5 into two foaming areas 1 and 3 at two ends, forming three sections of areas by a middle connecting area 2, preparing two pairs of simple resins by the middle connecting area 2 which is a reverse buckling structure part, wherein the size of a primary foaming mould is 2650 × 1100 × 425mm, the size of a secondary foaming mould is 2700 × 600 × 850mm, preparing the primary foaming mould, opening an upper mould 1-1 of the primary foaming mould, and flatly paving PVC soft leather with the thickness of 1.2mm on the lower mould 1-2; thirdly, laying 300g of chopped strand mats on the whole soft leather, then injecting PU foaming materials into foaming areas 1 and 3 in a primary foaming mould, tightly pressing a PVC soft leather connecting area 2 by using an upper mould 1-1, enabling the PVC soft leather connecting area 2 not to be influenced by the primary foaming injection materials, and closing the mould and curing for 8 minutes; opening the upper die 1-1 of the primary foaming die for demoulding, and taking out the foamed semi-finished product; preparing a secondary foaming mold, wherein the upper mold 2-1 of the secondary foaming mold is designed to just press the material injection area 4, the upper mold 2-1 of the secondary foaming mold is opened, and then the foamed semi-finished product is placed on the lower mold 2-2 of the secondary foaming mold according to the final state, wherein the PVC soft leather in the soft connection area 2 is laid on the material injection area 4 on the lower mold 2-2 of the secondary foaming mold; sixthly, injecting the PU foaming material into a material injection area 4 of the secondary foaming mold, additionally paving a reinforcing layer on the material injection area 4, wherein the reinforcing layer is preferably glass fiber gridding cloth, closing the mold and curing for 8 minutes, opening an upper mold 2-1 of the secondary foaming mold after the secondary foaming material is cured, demolding, and taking out a foamed product 5.
Example 2, taking the interior of the rear roof of a passenger car as an example, the product size is 2400mm by 450mm, and refer to fig. 1 to 7.
The manufacturing process of the passenger car rear roof interior trim foamed product comprises the following steps: firstly, dividing a passenger car rear roof product 5 into two foaming areas 1 and 3 at two ends, forming three sections of areas by a middle connecting area 2, preparing two pairs of simple resins by the middle connecting area 2 which is a reverse buckling structure part, wherein the size of a primary foaming mould is 2650 x 900 x 350mm, the size of a secondary foaming mould is 2700 x 500 x 650mm, preparing the primary foaming mould, opening an upper mould 1-1 of the primary foaming mould, and flatly paving PVC soft leather with the thickness of 1.2mm on the lower mould 1-2; thirdly, laying 300g of chopped strand mats on the whole soft leather, injecting PU foaming materials into foaming areas 1 and 3 in a primary foaming mould, tightly pressing a PVC soft leather connecting area 2 by using an upper mould 1-1 to ensure that the PVC soft leather connecting area 2 is not influenced by the primary foaming injection materials, and then closing the mould and curing for 8 minutes; opening the upper die 1-1 of the primary foaming die for demoulding, and taking out the foamed semi-finished product; preparing a secondary foaming mold, wherein the upper mold 2-1 of the secondary foaming mold is designed to just press the material injection area 4, the upper mold 2-1 of the secondary foaming mold is opened, and then the foamed semi-finished product is placed on the lower mold 2-2 of the secondary foaming mold according to the final state, wherein the PVC soft leather in the soft connection area 2 is laid on the material injection area 4 on the lower mold 2-2 of the secondary foaming mold; injecting the PU foaming material into a material injection area 4 of the secondary foaming mold, additionally paving a reinforcing layer on the material injection area 4, preferably selecting glass fiber mesh cloth as the material of the reinforcing layer, and closing and curing for 8 minutes; and opening the upper die 2-2 of the secondary foaming die to demould after the secondary foaming material is solidified, and taking out the foamed product 5.
Claims (1)
1. A manufacturing process of a special-shaped foaming product comprises the following steps: firstly, decomposing a foaming product into foaming areas at two ends and a middle connecting area to form three sections of areas, preparing a primary foaming mould by taking the middle connecting area as a reverse buckling structure part, opening an upper mould of the primary foaming mould, and flatly paving soft leather on the lower mould; secondly, laying the enhancement layer on the whole soft leather, then injecting a PU foaming material into a foaming area in a primary foaming mould for primary foaming, pressing an upper mould against the soft leather connecting area to ensure that the soft leather connecting area is not influenced by the primary foaming injection material, and closing the mould and curing; thirdly, opening an upper die of the primary foaming die for demoulding after the primary foaming and curing, and taking out a foamed semi-finished product; preparing a secondary foaming mold, wherein the upper mold of the secondary foaming mold is designed to just press the material injection area, opening the upper mold of the secondary foaming mold, and placing the foamed semi-finished product on the lower mold of the secondary foaming mold according to the final shape, wherein the soft leather in the soft connection area is laid on the material injection area of the secondary foaming mold; injecting a PU foaming material into a material injection area of the secondary foaming mold for secondary foaming, adding a paving reinforcing layer on the material injection area, closing an upper mold for secondary foaming, and just closing the upper mold onto the secondary foaming material injection area by the upper mold through a press limiting device; and sixthly, opening the upper die of the secondary foaming die to demould after the secondary foaming material is solidified, and taking out the foamed product.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
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| CN202010918703.8A CN112171998B (en) | 2020-09-04 | 2020-09-04 | Process for manufacturing special-shaped foamed product |
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| CN202010918703.8A CN112171998B (en) | 2020-09-04 | 2020-09-04 | Process for manufacturing special-shaped foamed product |
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| CN112171998A CN112171998A (en) | 2021-01-05 |
| CN112171998B true CN112171998B (en) | 2021-09-07 |
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| CN112171998A (en) | 2021-01-05 |
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Denomination of invention: A manufacturing process of special-shaped foaming products Effective date of registration: 20220419 Granted publication date: 20210907 Pledgee: Changsha Bank city branch of Limited by Share Ltd. Pledgor: ARTIE INDUSTRIAL Co.,Ltd. CHINA Registration number: Y2022980004188 |
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