KR102459136B1 - Adhesion mold of skin for car interior components and manufacturing method for car interior components using the same - Google Patents

Abstract

The present invention relates to a bonding mold for a skin for an automobile interior material and a method for manufacturing an automobile interior material using the same. It includes an upper mold, an IMG molded foam-attached TPO skin or PVC skin and a lower mold in which a foam skin with real stitches is located, and a pair of sliding cores positioned on both sides of the lower mold, the sliding core described above When the upper and lower molds are joined, they slide in the horizontal direction or diagonally to the outer chamber and return to their original position after joining. As the sliding core slides again in the outer horizontal direction or the outer trauma chamber diagonal direction, there is little risk of defects such as foam bursting and rubbing of the foam skin due to undercut shape and morphological interference, and demolding is also safe and easy, due to this It has advantages of not only cost reduction, but also rapid molding time and mass production.

Description

Bonding mold of skin for automobile interior material and manufacturing method of automobile interior material using the same

The present invention relates to a bonding mold for a skin for an automobile interior material and a method for manufacturing an automobile interior material using the same, and more particularly, to a predetermined three-dimensional shape IMG (In Mold Graining) molding and real stitch sewing In manufacturing an automobile interior material by compression-bonding a foam skin to a substrate injection molded into a predetermined three-dimensional shape that matches it, an undercut shape and It relates to a bonding mold for a skin for automobile interior material, which can effectively prevent surface defects such as foam bursting and rubbing of foam skin fabric due to morphological interference, and a method for manufacturing an automobile interior material using the same.

In general, various interior materials such as automobile dashboard, glove box, console, lower cover, pillar, door interior panel, airbag cover panel, etc. have been made by injection molding synthetic resin.

The design and surface texture that can satisfy consumers' luxurious aesthetic sensibility are emerging as important factors for these automotive interior materials.

Conventionally, natural leather is sewn and wrapped or artificial leather is wrapped in order to improve the quality of automobile interior parts, but this is done manually, so it is unreasonable as an industrial large-scale production method.

Conventionally, the IMG (In Mold Graining) molding method that enables automation and mass production that enables the surface treatment of luxurious interior materials by using an electric pole mold that has a pattern with a sophisticated natural leather texture and a fake stitch is common, and such IMG molding It consists of inserting a skin having a natural leather texture and pattern and an injection-molded substrate (core) into a mold to bond them together.

In recent years, an attempt has been made to manufacture skins by IMG molding, sew real stitches on a specific part of the skin surface using a real sewing machine, and rejoin them with a substrate to promote high quality and mass production of products and cost reduction. come.

In other words, the formation of the real stitch is to fold the ends of the two foam skins so that a fold line is formed between the butt bars formed and sew the skins on both sides of the fold line to each other, and slightly spaced apart from the fold line on one side or both sides. By sewing a stitch line separately at one location and forming it, it is formed to express a luxurious and natural aesthetic and texture similar to that fixed by sewing real leather.

A typical method of manufacturing an automobile interior material applying real stitch is to use a female mold to mold TPO (ThermoPlastic Olefin) or PVC skin, sew the real stitch to the molded skin, and install the skin and substrate on the mold for foam molding. , it is only applied to some automobile interior materials due to problems such as foam molding by putting a urethane foam resin in between, or a large manufacturing cost of a foaming mold and a long molding time.

As a typical prior art using such a foaming mold, there may be mentioned Korean Patent Publication No. 10-2165285 (registered on 10.06.2020).

In addition, Registration Patent Publication No. 10-2203654 (registered on 11/11/2021) discloses that the first fabric for skin molding, the second fabric for core molding, and the above-described first fabric and second fabric for forming a foam layer are disposed between the first fabric and the second fabric. A first step of preparing a third fabric; a second step of preheating the first fabric, the second fabric, and the third fabric using a fabric heater; A third step of forming an IMG fabric by heat-sealing the first fabric, the second fabric, and the third fabric; a fourth step of forming a skin by pressing the IMG fabric while cutting it with an IMG mold device in a state in which heat remains in the IMG fabric; a fifth step of forming a core by pressing the IMG fabric with a compression mold device; and a sixth step of taking out the interior material consisting of the skin, the foam layer and the core from the above-mentioned compression mold apparatus, by proposing a method for manufacturing an interior material using an IMG fabric, simultaneously molding the skin and the core, and improving the foaming rate of the foam layer However, this method also relates to the use of a foaming mold.

As an economical method to solve the problems of the foaming mold, a foam skin fabric in which a foam is bonded to a TPO skin is manufactured, and a foam skin having a predetermined three-dimensional shape is manufactured using the IMG mold, and then the same three-dimensional A method of re-bonding with a substrate having a shape has been attempted, but there is a problem in that surface defects and foam breakage easily occur due to the rubbing of the foam skin when the upper and lower molds are combined.

As a typical prior art for overcoming the problem of surface defects and foam bursting due to the rubbing of the foam skin during the combination of the upper and lower molds, the following may be mentioned.

Registered Patent Publication No. 10-2033647 (registered on October 11, 2019) describes the first core forming area formed along the periphery of the core forming surface where the core of the interior material for molding is disposed, and the inside of the above-mentioned core forming surface. a first mold in which a second core forming region protruding from the first core forming region to have a step difference and a third core forming region connecting the first core forming region and the second core forming region are formed; A first skin forming area facing the core forming surface and formed along the periphery of the skin forming surface on which the skin of the interior material is disposed, and having a step difference from the first skin forming area within the skin forming surface a second mold in which a second skin forming region formed by being recessed so as to be formed and a third skin forming region connecting the first and second skin forming regions are formed; a slide mold operated by a driving device coupled to the second mold and capable of folding the skin in the direction of the core by moving inside the second mold while in contact with the first skin forming region; and a vibrating device coupled to the first mold so as to vibrate the core when the core and the skin are compressed using the first mold and the second mold, wherein the vibration device is coupled to the slide mold and There is proposed a mold apparatus having a vibrating device further comprising a wrapping tube that increases in volume when a fluid is supplied so that the skin folded in the direction of the core can be folded to wrap the end of the core.

However, the above-described mold device is not only very complicated in its configuration, but also requires a lot of additional cost because molding molds must be manufactured according to the shape and type of automobile interior materials. If the vibration is too severe, the foam skin may be damaged. Conversely, if the vibration is too weak, the problem of surface defects and foam bursting due to the rubbing of the foam skin may still occur. There is a problem that it is difficult to control.

Registered Patent Publication No. 10-2165285 (Registered on 10.06.2020) Registered Patent Publication No. 10-2203654 (Registered on 11/11/2021) Registered Patent Publication No. 10-2033647 (Registered on October 11, 2019)

Therefore, the first object of the present invention is to press-bond a foam skin fabric molded with IMG into a predetermined three-dimensional shape and sewn with real stitches to a substrate injection molded into a predetermined three-dimensional shape matching it to manufacture an automobile interior material. An object of the present invention is to provide a bonding mold for skin for automobile interior materials that can effectively prevent surface defects such as foam bursting and rubbing of foam skin fabric due to undercut shape and morphological interference.

The second object of the present invention is to minimize the risk of defects by locating the foam skin fabric, which is IMG molded into a predetermined three-dimensional shape and sewn with real stitches, in the exact position of the substrate injection molded into a predetermined three-dimensional shape. An object of the present invention is to provide a bonding mold for skins for automobile interior materials.

A third object of the present invention is to provide an economical and efficient method for manufacturing an automobile interior material using the bonding mold of the skin for automobile interior material described above.

The first and second objects of the present invention described above include: an upper mold for fixing an injection-molded three-dimensional substrate by vacuum suction; A lower mold comprising IMG-molded three-dimensional foam-attached TPO skin or PVC skin, and on which a real-stitched foam skin is positioned; A pair of sliding cores positioned on both sides of the lower mold are included: the sliding core slides in an outer horizontal direction or a diagonal direction outside the outer chamber when the upper and lower molds are combined, and returns to their original positions after the upper and lower molds are combined. After the bonding of the foam skin to the substrate is completed by thermal compression of Foam bursting and abrasion of the fabric can be minimized, and it can be smoothly achieved by the bonding mold of the skin for automobile interior materials.

On the other hand, the sliding core may be mounted to be capable of tilting motion or hinge motion.

A plurality of locking wells are formed on the upper surface of the sliding core, a plurality of downward recesses are also formed on the edge of the foam skin, the downward recesses are located in the locking well, and an interlocker is installed in the upper mold to form the upper mold. An interlocker engages and fixes one of the downward recesses, and the sliding core may slide in a diagonal direction of the trauma chamber.

A third object of the present invention, (A) forming a foam skin of a three-dimensional shape by IMG molding TPO skin or PVC skin and foam; (B) sewing a single or double real stitch on a predetermined portion of the molded foam skin; (C) As described above, the injection-molded three-dimensional substrate is fixed to the upper mold of the bonding mold for the skin for automobile interior material by vacuum suction under reduced pressure, and the above-described foam skin is located in the lower mold, and the upper and lower molds During this molding, the sliding core slides in the horizontal direction on the outside or in the diagonal direction of the outer chamber, and returns to its original position after molding. At the time, the sliding core slides in the horizontal direction or the diagonal direction of the outer chamber again, so that there is little risk of defects such as foam bursting and rubbing of the foam skin fabric due to undercut shape and morphological interference. It can be smoothly achieved by a method of manufacturing an automobile interior material comprising the steps.

In addition, it goes without saying that the sliding core may be operated in a tilting motion or a hinge motion.

In the forming step (A) of forming the foam skin by IMG molding, a plurality of locking wells are formed in the lower mold of the IMG mold, and an interlocker is installed in the upper mold so that the interlockers are engaged with the locking wells during compounding. It is possible to form a plurality of downward recesses in one foam skin.

In addition, a plurality of locking wells are formed on the upper surface of the sliding core so that a plurality of downward recesses formed in the foam skin are positioned in the locking well, while an interlocker is installed in the upper mold of the bonding mold, An interlocker is engaged and fixed to the downward recessed portion of the foam skin located within one locking well, and the sliding core may slide in a diagonal direction of the trauma chamber.

According to the bonding mold of the skin for an automobile interior material of the present invention and a method for manufacturing an automobile interior material using the same, the foam skin fabric formed by IMG molding into a predetermined three-dimensional shape and sewing real stitches is injection molded into a predetermined three-dimensional shape matching it. It is possible to effectively prevent surface defects such as foam bursting and rubbing of the foam skin fabric due to undercut shape and morphological interference in manufacturing automobile interior materials by compression bonding to the substrate. By positioning it in the position, it is possible to minimize the risk of occurrence of defects, and even molded products having a bad demolding gradient can be safely and easily taken out, which has the advantage of not only reducing the cost, but also enabling rapid molding time and mass production accordingly.

1 to 3 are sequential schematic explanatory views sequentially illustrating a method of manufacturing an automobile interior material of the present invention using a bonding mold for a skin for automobile interior material according to the present invention, and FIG. 4 is a schematic cross-sectional view of the manufactured molded article.
5 is another sequential schematic explanatory diagram.
6 is a partial cross-sectional view illustrating an interlocker and a locking well respectively formed in an In Mold Graining (IMG) upper and lower mold.
7 is a partial cross-sectional view showing that a fixing recess is formed in the foam skin fabric molded by the IMG mold shown in FIG. 6 .
8 and 9 are partial cross-sectional views illustrating a closed state and a sliding state in an oblique direction of a slide core having a locking well formed in a lower mold of a bonding mold for a skin for an automobile interior according to the present invention, respectively.

First, the term 'foam skin (11)' used throughout this specification refers to TPO (ThermoPlastic Olefin) skin 12 or PVC skin and foam 13 by IMG (In Mold Graining) molding. It is defined as referring to a molded article molded to have a predetermined three-dimensional shape, and unless otherwise stated, means a state in which real stitches are sewn.

In addition, the shape and dimensions of the 'substrate 14' are such that the above-described foam skin 11 can be bonded to the outer surface, and the shape and dimensions of the above-described foam skin 11 are the above-described substrates. It is necessary to understand that the shape and dimensions of (14) are almost identical.

Hereinafter, the present invention will be described in more detail with reference to the accompanying drawings.

The bonding mold 1 of the skin for an automobile interior material according to the present invention will be described with reference to FIGS. 1 to 3 and 5 and FIGS. 8 and 9 .

The bonding mold 1 for a skin for an automobile interior according to the present invention includes an upper mold 2 and a lower mold 3 having a sliding core 3c.

A substrate 14 as a core of an automobile interior material having an injection-molded three-dimensional shape is fixed to the upper die 2 by vacuum suction under reduced pressure.

On the other hand, in the lower mold (3), IMG molded three-dimensional foam 13 attached TPO skin 12 or PVC skin made of a real stitch (not shown) is sewn foam skin 11 is located.

A pair of sliding cores 3c are mounted on both upper sides of the lower mold 3, and the sliding core 3c slides upward or outward when the upper mold 2 and the lower mold 3 are combined. And after consolidation, it is returned to its original position.

The bonding of the foam skin 11 to the substrate 14 is completed by thermocompression of the upper mold 2 and the lower mold 3, and when the upper mold 2 and the lower mold 3 are released, the sliding core ( 3c) again slides outward or upwards, so that there is little risk of defects such as bursting and rubbing of the foam skin 11 due to undercut shape and morphological interference, and demolding can also be done safely and easily.

Also, optionally, the sliding core 3c may be mounted to be capable of tilting motion or hinge motion.

A plurality of, specifically, 4 to 16 locking wells 3e are formed on the upper surface of the sliding core 3c, and an interlocker (not shown) is installed in the upper mold 2 , so that the interlocker forms the above-described form when combined. It is fastened to the above-described locking well 3e via the skin 11 .

On the other hand, also at the edge of the foam skin 11, a plurality of downward recesses (reference numerals not assigned) are formed in advance at the position of the locking well 3e during IMG molding, and the downward recesses are formed in the locking well 3e. It is positioned in the upper mold (2) to be accurately fixed in place by the interlocker.

Next, a method for manufacturing an automobile interior material of the present invention using the above-described bonding mold 1 for a skin for automobile interior material according to the present invention will be described.

The method for manufacturing an automobile interior material according to the present invention includes the following steps.

(1) Design and mock-up model making stage:

This is a step of designing a product shape and manufacturing a mock-up model accordingly, and processing is performed using a CNC milling machine, etc., based on a typical design.

(2) Nping step:

TPO skin 12 or PVC skin having a predetermined natural leather texture and pattern (embossing pattern) formed by applying an adhesive to the surface of the mock-up model and having a thickness of 0.5 to 0.7 mm, specifically 0.6 mm, is manually N ping.

(3) Model cloning steps:

After replicating the N-pinned mockup model in the first negative state using silicone, the same positive model as the original model, that is, the mandrel, is made using epoxy resin on the silicone model.

(4) conduction phase of the mandrel:

Conductivity is given by forming a thin film of silver by spray coating using silver reduction reaction so that the surface of the duplicated mandrel can be energized.

(5) Nickel shell electroforming step:

A mandrel with a thin silver film is immersed in a nickel sulfamic acid plating bath, and a direct current of 0.6 to 3 A is supplied to electro-electrode nickel until the thickness of the nickel plating becomes 4 to 5 mm.

On the inner surface of the electroformed nickel shell, the natural leather texture and pattern are negatively formed, while a protruding line with a '∧' cross-section is formed, and a number of fine vacuum holes are formed during the electroforming process.

When the nickel plating goes up to a thickness of 4-5 mm, the mandrel is put in a heating furnace and heated to 300-400°C to remove the epoxy mandrel and separate the manufactured nickel shell.

(6) pole mold assembly steps:

Attach the separated nickel shell (electroforming mold) to the mold box (mold base) to assemble the vertical IMG vacuum mold.

The above-mentioned upper and lower molds are provided with ejector pins as utility devices, cooling and heating lines, and vacuum suction lines.

(7) Forming the three-dimensional shape of the foam skin by IMG:

After mounting the IMG vacuum mold assembled as described above in the vacuum molding machine, vacuum molding is performed to form a TPO skin 12 or PVC skin with a thickness of about 3 mm with a natural leather texture and pattern positively formed on the surface ( 3) is IMG-molded to form the three-dimensional foam skin 11 .

On the other hand, as shown in FIGS. 6 and 7 , in molding the foam skin 11 by IMG molding, a plurality of locking wells 3e are formed in the lower mold 2 of the IMG mold, and the upper mold 3 is By installing the interlocker 2b so that the interlocker 2b is engaged with the locking well 3e during mating, a plurality of downward recesses (reference numerals not assigned) can be formed in the foam skin 11 described above. have.

(8) Real stitch sewing steps:

A single or double real stitch is sewn on the surface of the IMG molded foam skin 11 in a predetermined area using a desired predetermined sewing thread based on the fold line.

At this time, if a V-groove line is formed on the surface of the foam skin to allow the stitch thread to settle naturally and guide the placement of the real stitch, it will be arranged beautifully and neatly to improve the aesthetic quality, and even if it is a curved shape, there is not much directional distortion. By offsetting the excessively prominent stitching phenomenon, the risk of breakage is reduced and stain resistance is improved.

(9) bonding step (see FIGS. 1 to 3):

As described above, the injection-molded three-dimensional substrate 14 is fixed to the upper mold 2 of the bonding mold 1 of the skin for automobile interior material according to the present invention by vacuum suction under reduced pressure, and the lower mold 3 is Place the IMG molded foam skin 11 .

A pair of sliding cores 3c are positioned to face each other on the lower mold 3 as described above.

When the upper mold (2) and the lower mold (3) are combined, the sliding core (3c) slides in an outer horizontal direction or a diagonal direction outside the outer chamber, and is returned to its original position after the union.

It goes without saying that the sliding core 3e may be operated in a tilting motion or a hinge motion.

After bonding the foam skin 12 to the substrate 14 by curing the adhesive by thermocompression of the upper mold 2 and the lower mold 3, the upper mold 2 and the lower mold 3 are released. One sliding core (3c) again slides in the outer horizontal direction or the outer chamber diagonal direction, whereby thermal compression without bursting and rubbing of the foam skin fabric due to undercut shape and morphological interference is possible.

The thermal compression is performed by a hot water or electric heating line installed in the upper mold 2 and the lower mold 3, and cooling is performed by a cooling line.

On the other hand, as shown in FIGS. 8 and 9, a plurality of locking wells 3e are formed on the upper surface of the sliding core 3c, and a plurality of downward recesses (reference numerals) formed in the foam skin 11 are formed. On the other hand, an interlocker (not shown) is installed in the upper mold 2 of the bonding mold 1 described above, and is located in the locking well 3e when combined. An interlocker (not shown) may be engaged and fixed to the downward recessed portion (reference numeral not provided) of the foam skin 11 .

In the illustrated example, as indicated by the arrow A, the sliding core 3c slides in the diagonal direction of the trauma chamber, so that almost no interference occurs.

(10) Trimming and Nping steps:

After the bonded molded product 10 is demolded (refer to FIG. 4), the unnecessary end of the foam skin 11 is removed using a trimming mold or mechanical trimming equipment, and the remaining excess end is removed by automatic Nping equipment or manual operation. The final automobile interior material is manufactured by wrapping it inside the substrate 14 .

1: Bonding mold according to the present invention
2: hieroglyph
2a: vacuum vacuum suction hole 2b: interlocker
3: Ha Hyung
3a: mold base 3b: inner surface
3c: sliding core 3d: decompression vacuum suction hole
3e: locking well
10: molded article
11: Foam skin 12: TPO skin
13: foam (foam material) 14: substrate

Claims (7)

an upper mold for fixing an injection-molded three-dimensional substrate by vacuum suction;
In Mold Graining (IMG) Formed three-dimensional form-attached TPO (ThermoPlastic Olefin) skin or PVC skin, real stitch is sewn, and a foam skin with a plurality of downward recesses formed in advance at the edge. The lower type is located;
It includes a pair of sliding cores located on both sides of the lower mold:
A plurality of locking wells are formed on the upper surface of the sliding core, and an interlocker is installed on the upper mold, so that the above-described downward recessed portion of the foam skin located within the locking well when combined. Interlocker engages and secures,
When the upper and lower molds are combined, the sliding core slides in the direction of the outer chamber diagonally and returns to its original position after bonding. The sliding core slides again in the direction of the trauma chamber diagonally, thereby minimizing foam bursting and abrasion of the foam skin fabric due to undercut shape and morphological interference.
A bonding mold for skins for automobile interior materials. delete delete A method of manufacturing an automobile interior material comprising the steps of:
(A) In IMG (In Mold Graining) molding of TPO (ThermoPlastic Olefin) skin or PVC skin and foam, a plurality of locking wells are formed in the lower mold of the IMG mold, and an interlocker is installed in the upper mold to lock the above-mentioned locking during merging. forming a three-dimensionally shaped foam skin with a plurality of downwardly recessed portions formed in advance at edges thereof by engaging an interlocker in the well;
(B) forming a V groove line on a predetermined surface of the molded foam skin and sewing a single or double real stitch along the V groove line;
(C) The injection-molded three-dimensional substrate is fixed to the upper mold of the bonding mold for the skin for automobile interior according to claim 1 by vacuum suction under reduced pressure, and the above-described foam skin is positioned on the lower mold, and sliding A plurality of downward recesses formed in the foam skin are placed in a plurality of locking wells formed on the upper surface of the core, while an interlocker formed in the upper mold is disposed in the downward recesses of the foam skin located in the locking wells during mating. One interlocker is engaged and fixed,
When the upper and lower molds are combined, the sliding core slides in the diagonal direction of the outer chamber and returns to its original position after joining, and after bonding the foam skin to the substrate by thermocompression of the upper and lower molds, the upper and lower molds At the time of release, the sliding core slides again in the direction of the external chamber diagonally, so that the bonding step by thermocompression without the foam bursting and rubbing of the foam skin fabric due to the undercut shape and morphological interference. delete delete delete

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