KR100857881B1 - Al-Insert Injection Molding Method using Al-Sheet for multi-Pattern parts and ashtray - Google Patents

Abstract

The present invention relates to a method for molding interior parts such as an automobile instrument panel, an arm rest, an ashtray, a door lock cover, and the like.

Conventionally, the molding of interior parts of automobile interior materials has been produced by two methods through molding injection of wood grain and film insert, but there were irrationalities such as high defect rate and troublesome manufacturing process.

In the present invention, a molded aluminum sheet semi-finished product processed by a special processing process such as shading angle pattern, color, contrast, and sharpness on an aluminum sheet to enable various visual interior representation of molded interior molding parts is formed on an injection mold. A manufacturing method of molding and inserting an aluminum sheet so that inserts can be seated and exhibiting various shapes, the present invention relates to a method for manufacturing an insert part shaped by a press and a method of injection molding of an injection part, and a molded article thereof. .

Automotive Interior, Parts, Aluminum, Insert Molding, Injection Molding

Description

Al-Insert Injection Molding Method using Al-Sheet for multi-Pattern parts and ashtray}

1 is a flow chart for the aluminum insert molding injection process of the present invention.

Figure 2 is a front view of the ashtray for cars manufactured by the aluminum insert molding injection method of an embodiment of the present invention.

3 is a cross-sectional view taken along the line A-A of FIG.

4 is a cross-sectional view taken along the line C-C of FIG.

5 is a cross-sectional view taken along line B-B in FIG. 2.

FIG. 6 is an enlarged view of a portion D of FIG. 5.

7 is a process chart for forming an aluminum sheet in which a blanking process is completed.

<Description of Major Symbols in Drawing>

10 car ashtray 20 aluminum semi-finished products

30: bond 40: resin layer

50: ashtray body 60: bent portion

70: clip part

The present invention relates to a manufacturing method of automotive interior parts, and according to the shape of automotive interior parts aluminum sheet (Al-Sheet) by forming a blanking (Blanking), forming (Forming) process to reduce the process, cost reduction and high quality The present invention relates to an aluminum insert molding injection method for manufacturing a multi-pattern automobile part using an aluminum sheet capable of molding an interior decoration product, and a component manufactured using the same.

Conventional molding production methods for passenger car interior products such as Center Facia, Knob, and Gear Box Cover, which are parts of the instrument instrument panel, are made of wood grain or wood grain. As a molding injection through film insert, the manufacturing process is complicated and many defects occur, resulting in low productivity and inability to produce various products. In particular, regardless of the customer's needs (Needs), the color of the appearance and the items to be applied to the production (Item) was subject to a lot of restrictions could not produce a variety of products.

In addition, a method of manufacturing insert molding injection of automotive interior parts is shown by applying a film to a flowing water to cover the outer surface of an injection molded resin product and forming a surface by vacuum injection of a dry film. Film insert molding injection method that inserts shaped film by injection molding the outer surface of interior product by vacuum injection as the first shape, but manufactured interior parts of automobile by two methods such as this, but it is unreasonable in multi-step manufacturing process Excessive defects in manufacturing and manufacturing methods have contributed to the increase in manufacturing costs, which has increased consumer burden.

In addition, both of the bubbles and vacuum dark spots generated during the manufacturing method are partially expressed on the exterior of the exterior material, which may be a complaint to the consumer. Separate quality issues have often arisen.

In particular, the conventional method was not able to produce a variety of products because the color of the appearance and the application items are subject to a lot of restrictions regardless of the customer's needs (Needs) could not produce a variety of products.

Therefore, in the present invention, the surface of the desired product is formed by blanking and forming, which is a press working process, by using an aluminum sheet (Al-Sheet) patterned in various shapes, and then applying an adhesive after applying an adhesive ( Insert) A production process method of molding molding is presented.

Molding injection of aluminum insert (Al-Insert) is a process to produce beautiful automotive interior parts through special bonding process of Al-Plate, which has been highly processed with resin, and has no development and production results in Korea. Therefore, in Korea car makers, general insert injection technology has been commercialized, but automotive interior parts production through aluminum insert molding injection has not been applied yet.

When domestically developing and commercializing the interior parts of automobiles through Al-Insert molding injection, they can be applied to almost all high-end passenger cars produced in Korea, and the automobiles can be extended to parts of electronic parts with water. The impact on all industries is expected to be significant.

The present invention is to solve the problems of the prior art, an object of the present invention is to shape the aluminum sheet (Al-Sheet) in the blanking (Forming) process, according to the shape of the automotive interior parts, ashtray The present invention provides a method of insert molding injection molding a synthetic resin molding material for mounting on a main body.

As a technical idea for achieving the object of the present invention, in the present invention, a process of blanking the aluminum sheet to match the shape of the automotive interior parts to be manufactured, and forming the aluminum sheet after the blanking process ( Forming process) to produce the semi-finished product, the process of washing the semi-finished product, applying the adhesive on the inside of the semi-finished product, drying the adhesive in the semi-finished product, heating and melting before inserting, semi-finished product melted adhesive Aluminum inserts for manufacturing a variety of automotive parts using multi-patterned aluminum sheet, which includes a process of integrally molding a synthetic resin molding material including a clip boss portion to be mounted on an ashtray body at the same time as injection molding with resin on an adhesive part of the resin A molding injection method is presented.

According to the present invention, if any product of the automotive interior is a product that is injected into the resin blanking, forming the aluminum sheet (Al-Sheet) according to the shape of the desired interior product by a relatively simple method that can improve the appearance beauty It is characterized by the fact that it can be formed by (Forming) process to shorten the process, reduce the cost and form high quality decorative products.

Hereinafter, with reference to the accompanying drawings, the configuration and operation of the invention for the embodiment of the present invention will be described in detail.

1 is a flow chart for the aluminum insert molding injection process of the present invention.

As shown in Figure 1, the aluminum insert molding injection method for producing a multi-pattern automotive part using the aluminum sheet of the present invention,

Blanking the aluminum sheet to conform to the shape of the automotive interior component to be manufactured (S100);

A first forming process (S102) of forming a semi-finished product by forming a simple shape and a sample product on the aluminum sheet after the blanking process;

A second forming process (S104) of forming a semi-finished product by forming a complicated curved surface or an end portion, a resin bonded surface, a minimum curvature radius, and a difficult shape after the first forming;

Washing and drying the semi-finished product (S106);

Applying an adhesive to the inside of the semifinished product (S108);

Drying the adhesive from the semi-finished product (S110);

Melting the dried adhesive of the semi-finished product before inserting (S112);

Mounting the semi-finished product on a mold (S114);

In the injection molding of the resin into a mold in which the semi-finished product is mounted, the surface of the semi-finished adhesive is bonded to the resin and molded, wherein the mold is molded to include a clip boss for mounting on the ashtray body. The synthetic resin molten material including the clip boss portion is molded integrally (S116). Therefore, it is possible to manufacture a variety of automotive parts using a multi-pattern aluminum sheet.
In other words, the semi-finished product is seated on the moving side mold of the mold for injection molding so that the surface coated with the adhesive of the semi-finished product faces toward the fixed side mold, and the clip boss portion is fixed on the fixed side mold having the resin inlet in the mold for injection molding. The mold is molded, and the resin molding material including the clip boss portion is molded integrally with the semi-finished product by injection molding the resin into a mold in which the movable side mold and the fixed side mold are combined.

After the resin insert molding process (S116) is completed, the protective sheet removal and inspection process (S118) of the aluminum sheet;

Attaching a scratch prevention tape to a surface (S120);

The finished product may be shipped further including the step of assembling the clip (S122).

It is preferable that the surface protection tape is attached to the surface of the aluminum sheet before the blanking process (S100) so that scratches do not occur on the surface during the press working process.

In addition, the edge of the semi-finished product after the forming process (S102) (S104) is preferably formed with a bent portion so that the resin can be seated well, so that the appearance problem due to the occurrence of a gap with the other adjacent relative assembly in appearance The bending blanking radius should be minimized, and the curved part should be shaped into a beautiful style line during mold making to prevent the bending and stretching.

In addition, after seating the aluminum sheet coated with the adhesive bond to the injection mold, the mold should be shaped so that the polypropylene resin (FIG. 3-30) flows smoothly on the inner surface of the aluminum sheet. Make sure to have a mold model so that the bosses are also integrally molded.

Bonding of the aluminum sheet and the resin is caused by melting the bond by the temperature (about 195 ℃ ~ 245 ℃) of the resin to be injection-molded is bonded to the injection product resin which is a release material.

Hereinafter, an ashtray for an automobile will be described as an embodiment manufactured by the method of the present invention.

2 is an aluminum sheet on the surface of the ashtray which is an embodiment of the present invention can be designed in an infinite form by processing a variety of patterns and colors, contrast, sharpness, etc. in a special processing process, which is possible due to the material properties of the aluminum sheet The core of the present invention can be said.

By changing the type of sheet patterned on the same mold, any object can respond to customer's needs.

The resin material to be used may contain glass fiber, talc, natural rubber, or the like in the resin when strength and adhesion are required in consideration of the marketability of the required product.

3 is a cross-sectional view taken along the line A-A of FIG.

In the resin ashtray for automobiles completed in other processes, heating and melting of the bonding part before washing, bonding, drying, and molding the rear part of the shaped aluminum sheet 20 which has undergone sheet blanking and forming with the protective tape attached to the surface of the aluminum sheet. It consists of the resin 40 which was insert-molded and injected integrally through the bonding adhesive via the process, the adhesive 30 of the molding main body, the ashtray main body 50, etc.

4 is a cross-sectional view taken along the line C-C of FIG.

As shown in FIG. 4, the finished semi-finished product is at least 5 mm at the edge of the polypropylene resin injected at a high temperature (195 ° C. to 245 ° C.) at least 5 mm at the edge (possibly 3 mm due to the development of mold technology). A bend of ˜6 mm or more is formed. This bending part has a direct effect on the defective rate and appearance when forming, and should be well reflected in the design of the forming mold.

5 is a cross-sectional view taken along line B-B in FIG. 2.

The semi-finished product 20 and the semi-finished product that have been subjected to the aluminum sheet forming process on the surface thereof are shown by the resin layer 40 and the bent part 60 which are molded by injection molding due to the heat of the resin through the adhesive material 30.

When injection molding the resin, it is possible to minimize the deformation of the product by medium and low-speed injection rather than high-speed injection, and to minimize the sink (flow mark) by uniformizing the water flow of the molten resin.

The injection time is suitable for 5 ~ 7 seconds, and the resin cooling time in the state of injection equipment after injection should be maintained for a certain time (35 ~ 45 seconds for this ashtray) to prevent natural post-deformation by resin heat after injection molding. do

The molding body 70 is a clip boss portion for attaching to the automobile ashtray body 50.

The clip boss portion should be equipped with a mold shape by the side slide insertion method so that the clip can be easily installed with one touch.

FIG. 7 is for explaining a process chart of forming an aluminum sheet in which a blanking process is completed.

Although the ashtray for automobiles has been described as an example, it is well-known that the application of the present invention is not limited thereto and is used throughout automotive interior electrical and electronic exterior products.

According to the present invention, the bad characteristics of a material having weak ductility and scratchability due to the characteristics of aluminum are solved in a press forming mold, thereby simplifying the forming process of forming a mold several times, thereby shortening the manufacturing process. By using the processed aluminum sheet, it is possible to select the pattern, color, and yin-embossed specifications that meet the various needs of customers, and to bring out the impression as much as possible due to the characteristics of natural materials to make high-quality finished products. It is effective to produce by simple method.

Claims (4)

What is claimed is: 1. A manufacturing method for manufacturing an automotive interior interior part insert injection molding. Blanking the aluminum sheet; Forming a semi-finished product by forming a bent portion having a depth of 5 to 6 mm at an edge of the aluminum sheet after the blanking process; Washing and drying the semifinished product; Applying and drying an adhesive on the inside of the semifinished product; Heating and melting the dried adhesive of the semi-finished product before inserting it into a mold; Mounting the semifinished product on a mold; Injection molding the resin of 195 ~ 245 ℃ at a medium speed or low speed for 5-7 seconds to the adhesive portion of the semi-finished product to melt the adhesive by the temperature of the injected resin to integrally mold the semi-finished product and resin, but to mount the object to be connected An aluminum insert molding injection method for manufacturing a multi-pattern part using an aluminum sheet including a process of integrally molding a clip boss part. delete The method according to claim 1, The resin is a polypropylene resin or an aluminum insert molding injection method for producing a multi-pattern part using an aluminum sheet, characterized in that the resin is a polypropylene equivalent series that has enhanced strength or durability. delete

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