CN117183553A - Method for producing a vehicle interior trim part and vehicle interior trim part - Google Patents

Method for producing a vehicle interior trim part and vehicle interior trim part Download PDF

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Publication number
CN117183553A
CN117183553A CN202210605325.7A CN202210605325A CN117183553A CN 117183553 A CN117183553 A CN 117183553A CN 202210605325 A CN202210605325 A CN 202210605325A CN 117183553 A CN117183553 A CN 117183553A
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CN
China
Prior art keywords
adhesive
foil
skin
base layer
interior trim
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Pending
Application number
CN202210605325.7A
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Chinese (zh)
Inventor
张家东
胡勇
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Faurecia China Holding Co Ltd
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Faurecia China Holding Co Ltd
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Publication date
Application filed by Faurecia China Holding Co Ltd filed Critical Faurecia China Holding Co Ltd
Priority to CN202210605325.7A priority Critical patent/CN117183553A/en
Publication of CN117183553A publication Critical patent/CN117183553A/en
Pending legal-status Critical Current

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  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)

Abstract

The invention relates to a method for producing a vehicle interior trim part, comprising at least the following steps: a gluing step, in which a foil (1) for forming the skin of the vehicle interior trim part is provided, on the lower surface of which an adhesive is applied; a molding step in which a mold including a first mold (2) and a second mold (3) and a sealing frame (4) located at an edge of the second mold are provided, a foil is placed on the sealing frame to form a sealed space between the foil and the second mold, and then the mold is closed to heat-mold the foil; a sewing step, in which a sewing tool is used for sewing a decorative stitch on the upper surface of the foil after the heating forming so as to form the surface skin of the vehicle interior trim; and a laminating step in which a base layer is provided, and the skin of the vehicle interior trim part and the base layer are laminated together by an adhesive applied to the lower surface of the foil to form the vehicle interior trim part. The invention also relates to the vehicle interior trim part manufactured by the method.

Description

Method for producing a vehicle interior trim part and vehicle interior trim part
Technical Field
The invention relates to a method for producing a vehicle interior trim part and a vehicle interior trim part.
Background
The vehicle interior trim is an important component of the vehicle body. In recent years, consumers are increasingly focusing on the aesthetic degree of interior trim with respect to the exterior design of a vehicle, and the characteristics of the interior trim of a vehicle such as touch feeling, shape, color, etc. have become one of the main factors of purchasing a vehicle by consumers. For middle and high grade vehicle types, skin molding of interior trim parts (e.g., instrument panels, door inner panels, etc.) is an indispensable process.
It is known that related processes can be divided into three types according to the processing mode: the traditional male die vacuum forming, slush molding and in-mold forming IMG (In Mold Graining) processes are mainly characterized in that a mold carved with a dermatoglyph pattern is used for the IMG process, and the heated smooth film material is molded into the dermatoglyph-shaped surface skin of the interior trim part in the mold. Subsequent processing is also required after the skin is formed, such as sewing decorative stitches on the skin, and laminating the thermoformed skin to the substrate using an adhesive.
In the prior art, the aqueous adhesive is generally selected to be used for bonding the decorative layer and the base layer, however, the aqueous adhesive has a plurality of defects, in order to ensure the close bonding of the decorative layer and the base layer, the aqueous adhesive needs to be coated on the base layer and the decorative layer by adopting a spraying process, and when spraying, the adhesive is in an atomized state, more than 50 percent of the adhesive is splashed out and cannot be effectively attached to a set coating area, so that the extremely large adhesive waste is caused; in addition, if the water in the aqueous adhesive is not completely removed, the adhesive property is greatly influenced, even the adhesive cannot be adhered, so that the operation of flashing the water is needed before the adhesive is carried out, and the process flow is complex; in addition, since the shape of the skin after the heat molding is mostly irregular and complicated, the operation of coating the aqueous gel on the surface of the skin is very difficult and complicated.
Disclosure of Invention
It is noted that the present invention aims to overcome one or more of the drawbacks found in the background art, namely to provide a method for manufacturing an automotive interior part, which solves the technical problems of reduced gluing efficiency and increased process cost caused by coating an aqueous glue on a skin after thermoforming in the prior art, improves the process flow of the adhesive in the application of the automotive interior part, and improves the economic benefit.
For this purpose, the invention proposes a method for producing a vehicle interior trim part, wherein the method comprises at least the following steps:
a gluing step, wherein a foil for forming a skin of the vehicle interior trim part is provided, and an adhesive is coated on the lower surface of the foil;
a molding step in which a mold including a first mold and a second mold and a sealing frame located at an edge of the second mold are provided, the foil is placed on the sealing frame to form a sealed space between the foil and the second mold, and then the mold is closed to heat-mold the foil;
a sewing step, in which a sewing tool is used for sewing a decorative stitch on the upper surface of the foil after the heating forming so as to form the surface skin of the vehicle interior trim; and
and a laminating step in which a base layer is provided, and the skin of the vehicle interior trim part and the base layer are laminated together by an adhesive applied to the lower surface of the foil to form the vehicle interior trim part.
Preferably, in the sewing step, a manual stitch sewing machine (also referred to as a beading machine) is used to sew a decorative stitch on the thermoformed foil.
Unlike the conventional technological means in the prior art, according to the method disclosed by the invention, the skin of the vehicle interior trim part is coated with the adhesive before being heated and molded, so that the skin can be laminated with the base layer through the adhesive in a specific time after being heated and molded to be bonded together, the additional step of gluing after being heated and molded is omitted, and the manufacturing efficiency of the interior trim part is obviously improved.
In addition, the method is to glue the skin before forming, namely glue the flat surface, compared with the conventional technical means of coating the adhesive after forming the skin into a complex shape, the method greatly reduces the complexity and the process cost of the glue coating flow and improves the economic benefit under the condition of not affecting the appearance attractiveness of the decorative layer.
In addition, the adhesive is preferably a hot melt adhesive, and the heating operation of the skin before molding can simultaneously melt the hot melt adhesive from solid to fluid, so that the step of heating after the hot melt adhesive is coated in the conventional technical means is omitted, and the efficiency of the whole manufacturing method is improved.
In different embodiments of the method according to the invention, we can rely on one and/or more of the following configurations, alone or in combination:
in one embodiment, in the step of applying adhesive, a slit nozzle machine is used to apply adhesive to the lower surface of the foil.
In one embodiment, the adhesive applied to the lower surface of the foil forms an adhesive layer having a thickness of between 0.08mm and 0.12 mm.
In order to avoid waste of the adhesive, the adhesive layer formed on the lower surface of the foil is not preferably too thick, and in order to sufficiently adhere the skin and the base layer using the adhesive layer, the adhesive layer is also not too thin, preferably 0.1mm thick.
In one embodiment, the foil is in the form of a roll.
In one embodiment, the laminating step includes a hemming process step performed prior to laminating the skin with the base layer, wherein the edge of the skin is hemmed to enable the skin to encase the base layer after lamination.
Preferably, the skin is automatically hemmed using a hemmer.
In one embodiment, the laminating step includes a cooling step performed prior to laminating the skin with the base layer, wherein the surface of the base layer in contact with the skin is cooled to room temperature.
In one embodiment, the laminating step includes an air blowing step performed before laminating the skin with the base layer, wherein air is blown to the surface of the base layer in contact with the skin with the direction of air blowing directed toward the edge of the contact area.
Preferably, in the laminating step, three sub-steps of the hemming process step, the cooling step, and the air blowing step are sequentially performed in order.
In one embodiment, the surface of the base layer is not coated with an adhesive during the lamination step. In the case of using an aqueous adhesive as an adhesive, the same adhesive needs to be applied to the base layer, and since the hot melt adhesive has the excellent properties as described above, the lamination step can be easily accomplished by merely applying the adhesive to the decorative layer, and in addition, in the conventional art means, in order to prevent the adhesive from overflowing from the adhesive-applying area to affect the beauty of the interior trim, it is also necessary to scrape off a part of the aqueous adhesive, according to the method of the present invention, a large amount of adhesive consumption is reduced, thereby saving the cost.
In one embodiment, the lamination step is completed within a specific time after thermoforming the foil, the specific time being between 2 and 4 hours. Since the adhesive strength of the hot melt adhesive rapidly decreases after the open time, the lamination step must be completed within the open time of the hot melt adhesive after the foil is heated to mold and the adhesive applied to the lower surface of the foil is heated, so as to prevent the hot melt adhesive from losing adhesion and failing to bond the skin of the vehicle interior trim to the base layer.
Preferably, the entire manufacturing process is carried out using a single flow process to maximize the efficiency of product manufacture, ensuring that the completion time from the thermoforming of the foil to the lamination step is less than the open time of the adhesive.
In summary, the method of the invention can effectively solve a plurality of problems possibly existing in the prior art of forming the interior trim part, such as excessive adhesive consumption, complex gluing process, longer overall manufacturing process, and the like.
Another aspect of the invention also relates to a vehicle interior trim piece manufactured by the above method.
Drawings
It is to be understood that all of the features, variations and/or specific embodiments of the invention may be combined in various combinations, except where clearly contradicted or incompatible.
Other features and advantages of the invention will be apparent from reading the following detailed description, given as non-limiting illustrations, in conjunction with the accompanying drawings, in which:
fig. 1 is a flowchart illustrating a method for manufacturing a vehicle interior trim component according to an embodiment of the present invention.
Fig. 2 is a detailed schematic diagram showing the shaping step in the method according to the invention.
Figure 3 is a schematic diagram showing three sub-steps involved in the lamination step according to the present method.
Detailed Description
It is to be understood that the drawings are not to scale but are merely schematic representations of various preferred features which are employed to illustrate the basic principles of the invention. The design features disclosed herein, such as size, orientation, positioning and shape, are determined according to the specific application and environment of use.
The present invention will be described in detail with reference to examples and drawings. In the drawings, like reference numerals refer to the same or equivalent elements of the present invention throughout the several views.
Fig. 1 shows a method for manufacturing a vehicle interior trim part, which includes a gluing step, a molding step, a sewing step, and a laminating step, and each step of the method according to the present invention will be described in detail below.
Wherein, the gluing step includes: a foil 1 for forming a skin of a vehicle interior part is provided, and an adhesive is applied on a lower surface of the foil 1.
Preferably, the foil 1 used is in the form of a roll.
According to the method of the present invention, the adhesive is preferably a hot melt adhesive. The environment-friendly and environment-friendly high-speed assembly line has the characteristics of environment friendliness, no toxicity, no solvent, quick solidification and the like, is very suitable for automatic and high-speed assembly line operation in the automobile industry, has the characteristics of energy conservation, environment friendliness, low odor, low VOC and the like, and meets the requirements of the environment of the automobile interior trim. Compared with the aqueous adhesive, the solid content of the hot melt adhesive is 100%, and the hot melt adhesive has gap filling property, so that the defects of deformation, dislocation, shrinkage and the like of adhered pieces caused by edge rolling, air bubble and cracking of an adhesive coating area are avoided, and the solvent is not used, so that the moisture content of wood is not changed, and the risk of fire and poisoning is avoided; in addition, the bonding speed of the hot melt adhesive is high, and the flash-drying operation similar to that of the water-based adhesive is not needed before bonding, so that the efficiency of the process flow is greatly improved.
Specifically, a slit nozzle machine is used to apply adhesive to the lower surface of the foil 1.
After the gluing is completed, an adhesive layer formed by an adhesive is formed on the lower surface of the foil sheet 1, the thickness of the adhesive layer is between 0.08mm and 0.12mm, and the adhesive layer formed on the lower surface is not excessively thick in order to avoid the waste of the adhesive; in order to enable the skin and the base layer of the vehicle interior trim part to be sufficiently bonded, the adhesive layer should not be too thin, and is preferably 0.1mm thick.
Unlike the conventional technological means in the prior art, according to the method of the present invention, the skin of the interior trim part is coated with the adhesive before being heated and molded, so that the skin can be laminated with the base layer by the adhesive to be bonded together immediately after being heated and molded, thereby omitting the additional step of gluing after being heated and molded, and remarkably improving the manufacturing efficiency of the interior trim part.
In addition, according to the method disclosed by the invention, the adhesive is directly coated on the plane of the foil 1 before the skin is formed, compared with the conventional technical means of coating the adhesive after the skin of the vehicle interior trim part is formed into a complex shape, the method disclosed by the invention greatly reduces the complexity and the process cost of the gluing process under the condition that the appearance attractiveness of the decorative layer is not influenced, and the economic benefit is improved.
Referring to fig. 2, a molding step is performed after the gumming step, which includes: a mould comprising a first mould 2 and a second mould 3 and a sealing frame 4 is provided, the sealing frame 4 being located at the edge of the second mould 3, the foil 1 being placed on the sealing frame 4 to form a sealed space between the foil 1 and the second mould 3, and then the mould is closed to heat-mould the foil 1.
Since the lower surface of the foil 1 has been coated with the adhesive in the previous gluing step, the foil 1 is placed over the sealing frame 4 in the forming step to be spaced apart from the surface of the second mold 3 by a distance so as to prevent the adhesive coated on the lower surface of the foil 1 from contacting the second mold 3, and since the foil 1 needs to be heated after being clamped, the gas pressure in the sealing space increases with an increase in temperature so as to push the foil 1 toward the surface of the first mold 2 to effect the forming of the foil 1. The shaping step according to the invention thus ensures that the foil 1 does not lose adhesive during the thermoforming process due to contact with the surface of the second mould 3.
A sewing step is performed after the molding step is completed, which includes: a decorative stitch is sewn to the upper surface of the thermoformed foil sheet 1 using a sewing tool to form the skin of the vehicle interior trim.
Preferably, in the sewing step, a manual stitch sewing machine (also referred to as a beading machine) is used to sew a decorative stitch on the thermoformed foil sheet 1.
A lamination step is performed after the sewing step, the lamination step comprising: providing a base layer, and laminating the skin of the vehicle interior trim component with the base layer by an adhesive applied to the lower surface of the foil to form the vehicle interior trim component.
In order to enhance the bonding effect, the base layer is preferably made of a material which is attracted with the polarity of the hot melt adhesive used in the method. Optionally, the material used for the base layer has the characteristic of density, so that the material is easy to be permeated by the heated hot melt adhesive, and meanwhile, the surface temperature of the base layer needs to be controlled, and if the surface temperature is too low, the wetting and permeation of the hot melt adhesive can be affected; if too high, curing time is prolonged.
Preferably, the surface of the base layer is not coated with an adhesive.
Unlike the process of applying an adhesive to a base layer when using an aqueous adhesive as an adhesive, since the hot melt adhesive has the excellent properties as described above, the lamination step can be easily completed only after the adhesive is applied to the decorative layer, and the aqueous adhesive is scraped off in a conventional manner to prevent the adhesive from overflowing from the adhesive-applied area to affect the beauty of the interior trim, the amount of the hot melt adhesive used according to the method of the present invention is only about 30% of the amount of the aqueous adhesive used in the conventional manner (i.e., 70% of the adhesive consumption can be saved), thereby saving a large amount of costs.
Fig. 3 shows a schematic representation of sub-steps of a lamination step according to the present method, said lamination step comprising at least: sub-steps of hemming process, cooling, blowing and laminating. The substeps of hemming process, cooling and blowing in the lamination step will be specifically described below.
The laminating step further comprises: and a hemming process step which is performed before the skin is laminated with the base layer, wherein the edge of the skin is hemmed so that the skin can cover the base layer after lamination.
Preferably, the skin is automatically hemmed using a hemmer.
The laminating step further comprises: and a cooling step, which is performed before laminating the skin and the base layer, wherein the surface of the base layer in contact with the skin is cooled to room temperature.
In order to prevent the occurrence of the condition that the surface of the base layer is affected by the hot melt adhesive softened by heating, so that the tightness between the skin and the base layer is deteriorated, the surface of the base layer may be cooled at room temperature before lamination, preferably the surface of the base layer is made to have a temperature lower than the softening point of the hot melt adhesive, so that the tightness is prevented from being deteriorated by the hot melt adhesive.
The laminating step further comprises: and a blowing step performed before laminating the skin and the base layer, wherein the surface of the base layer in contact with the skin is blown with a blowing direction toward an edge of the contact area.
The blowing operation ensures the flatness of the surface of the base layer, thereby preventing the phenomenon of uneven surface of the base layer possibly occurring in the lamination step, simultaneously playing the role of strengthening the cooling effect of the surface of the base layer, further reducing the temperature of the surface of the base layer to reduce the influence of hot melt adhesive on the surface of the base layer and furthest preventing the problem of tightness possibly occurring after lamination.
Preferably, in the lamination step, the above three sub-steps of the hemming process step, the cooling step, and the air blowing step are sequentially performed.
Furthermore, the lamination step needs to be completed within a specific time, between 2 and 4 hours, after the thermoforming of the foil 1.
The heated hot melt adhesive has very strong adhesive strength in a specific time, the time interval is called open time, and if the open time is missed, the hot melt adhesive is solidified or crystallized, so that the capability of wetting an adhesive object is lost, and any part cannot be adhered.
In the whole process flow, the opening time of the hot melt adhesive can be set, and different components of the hot melt adhesive have different opening times. The open time can be prolonged by increasing the melt adhesive temperature of the equipment, but if the melt adhesive temperature is too high and exceeds the melting point, the carbonization phenomenon of the adhesive can occur, and the use quality of the melt adhesive is seriously affected; the larger the glue output, the slower the cooling and the longer the opening time, and in order to avoid the unnecessary waste caused by the overlarge consumption of the adhesive, the use quantity of the adhesive needs to be controlled; in addition, the lower the ambient and material temperature, the faster the hot melt adhesive cools, resulting in a shorter open time. In view of the above, it is necessary to comprehensively control various factors to achieve the expected opening time.
The open time can directly affect the bond strength and cure speed of the hot melt adhesive. If the opening time is too long, the bonding strength of the hot melt adhesive can be obviously reduced, the curing speed can be also slowed down, and the bonding of the decorative layer is not facilitated; in order to be able to complete the lamination step perfectly with sufficient time, the opening time is not set too short. Preferably, the open time is set to 4 hours, and a specific time is set according to the open time such that the specific time is smaller than the set open time.
Preferably, the entire manufacturing process is performed using a single-piece flow process to maximize the manufacturing efficiency of the product, ensuring that the completion time from the gumming step to the lamination step is less than the open time of the adhesive.
Another aspect of the invention also relates to a vehicle interior trim component comprising a base layer and a skin. Wherein the skin is laminated with the base layer by an adhesive, and the skin may be manufactured by any of the methods described above. Preferably, the surface of the base layer is not coated with an adhesive.
In particular, the adhesive is a hot melt adhesive, preferably applied by a roll coater.
The above embodiments are merely examples and do not limit the scope of the present invention. On the basis of this, a person skilled in the art can envision other embodiments that achieve the same functionality within the scope of the claims below.
Those skilled in the art will recognize various embodiments and variations and modifications. In particular, it is to be understood that the above-described features, variations and/or embodiments of the invention may be combined with each other, except where clearly contradicted or incompatible. All such embodiments and variations and modifications are intended to be within the scope of the present invention.

Claims (11)

1. A method for manufacturing a vehicle interior trim part, characterized in that the method comprises at least the steps of:
a gluing step, in which a foil (1) for forming the skin of the vehicle interior trim is provided, and an adhesive is applied to the lower surface of the foil (1);
a molding step in which a mold including a first mold (2) and a second mold (3) and a sealing frame (4) are provided, the sealing frame (4) being located at an edge of the second mold (3), the foil (1) is placed on the sealing frame (4) to form a sealed space between the foil (1) and the second mold (3), and then the mold is closed to heat-mold the foil (1);
a sewing step in which a sewing tool is used to sew a decorative stitch on the upper surface of the foil (1) after the heat molding to form the skin of the vehicle interior trim; and
and a laminating step in which a base layer is provided, and the skin of the vehicle interior trim part and the base layer are laminated together by an adhesive applied to the lower surface of the foil to form the vehicle interior trim part.
2. The method of claim 1, wherein the adhesive is a hot melt adhesive.
3. Method according to claim 1, characterized in that in the gluing step an adhesive is applied to the lower surface of the foil (1) using a slot die machine.
4. A method according to claim 1, characterized in that the adhesive applied to the lower surface of the foil (1) forms an adhesive layer, the thickness of which is between 0.08mm and 0.12 mm.
5. A method according to claim 1, characterized in that the foil (1) is in the form of a roll.
6. The method of claim 1, wherein the laminating step includes a hemming process step performed prior to laminating the skin with the base layer, wherein the edge of the skin is hemmed to enable the skin to encase the base layer after lamination.
7. The method of claim 1, wherein the laminating step comprises a cooling step performed prior to laminating the skin with the base layer, wherein the surface of the base layer in contact with the skin is cooled to room temperature.
8. The method according to claim 1, wherein the laminating step includes a blowing step performed before laminating the skin with the base layer, wherein the surface of the base layer in contact with the skin is blown with a blowing direction toward an edge of the surface of the base layer.
9. The method of claim 1, wherein during the laminating step, the surface of the base layer is not coated with an adhesive.
10. Method according to any of claims 1 to 9, wherein the lamination step is completed within a specific time after thermoforming the foil (1), the specific time being between 2 and 4 hours.
11. Vehicle interior trim part, characterized in that it is manufactured by a method according to any one of claims 1 to 10.
CN202210605325.7A 2022-05-31 2022-05-31 Method for producing a vehicle interior trim part and vehicle interior trim part Pending CN117183553A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CN202210605325.7A CN117183553A (en) 2022-05-31 2022-05-31 Method for producing a vehicle interior trim part and vehicle interior trim part

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CN202210605325.7A CN117183553A (en) 2022-05-31 2022-05-31 Method for producing a vehicle interior trim part and vehicle interior trim part

Publications (1)

Publication Number Publication Date
CN117183553A true CN117183553A (en) 2023-12-08

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Family Applications (1)

Application Number Title Priority Date Filing Date
CN202210605325.7A Pending CN117183553A (en) 2022-05-31 2022-05-31 Method for producing a vehicle interior trim part and vehicle interior trim part

Country Status (1)

Country Link
CN (1) CN117183553A (en)

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