KR20010073715A - Forming device and method for wallboard of vehicle - Google Patents

Abstract

PURPOSE: An interior material forming method and a device thereof for a vehicle are provided to reduce cost for a mold equipment by performing forming of a base material and bonding of a surface material simply with upper and lower molds, to improve productivity by shortening a manufacturing process, and to improve quality. CONSTITUTION: A base material(10) of an interior material for a vehicle is molded by injecting base material injecting liquid to the molding faces of upper and lower molds(30,40) via a nozzle with a hot wire. When heat generated from the hot wire remains in the base material, a surface material(20) is put into the mold by opening the upper mold. By attaching the surface material on the base material, uneven side edge of the base material leaks as much as the thickness of the surface material. Then, the leaked base material liquid is stuck on the bottom of an edge(21) of the surface material. After the leaked base material liquid is hardened, the edge is trimmed. Therefore, an interior material of uniform quality is obtained in a reduced manufacturing time. Additionally, an environmental pollution is restrained by attaching the surface material to the base material without using an adhesive agent.

Description

Forming method of automobile interior materials and forming apparatus thereof {Forming device and method for wallboard of vehicle}

The present invention relates to a method for forming a vehicle interior material and a molding apparatus thereof, and in particular, the base molding that forms the interior material of the vehicle with only one pair of upper and lower molds by mixing only the advantages of the low-pressure injection method and the advantages of the high-pressure injection method; The present invention is to provide a method for forming a car interior material and a molding apparatus that can significantly reduce the cost by improving the productivity by reducing the mold cost burden and speeding up the production process, so that the bonding of the skin can be performed well.

Generally, interior materials of automobiles include door trims, pillars, trunk mats, package trims, and headliners. Among these interior materials, injection molding is performed using only hard materials based on cheap national cars, small cars, and medium / large luxury cars. Alternatively, the surface material may be bonded to the surface of the substrate, but trimming of the edges may be used.In order to form a hard substrate, the skin may be bonded to the surface of the substrate in order to improve touch. It can also be used to wrap things around.

The materials of the hard substrate include PP, PE, PP PP, POLY-PROPYLENE BOARD, ABS, WOOD STOCK, and the like. RESIN FELT is mainly used, and soft skin material is film on PE FOAM, PP FOAM, PU FOAM on the back of non-woven fabric, fabric or skin paper made of PVC. This attached is mainly used.

The injection molding of the base material of the automotive interior material and the skin material are attached to the low pressure injection method and the high pressure injection method, the low pressure injection method of the injection molding of the substrate injection liquid to the molding surface of the lower mold, and then the molding surface When the injection liquid is put on the skin material and the injection liquid is pressed into the upper mold with the high-pressure press pressure, the injection liquid is formed into a substrate of a predetermined type, and the skin material is simultaneously bonded to the surface of the substrate to be molded.

This low-pressure injection method is a good productivity because the base molding and the skin material adhesion is made at the same time. However, if the surface skin paper material of the skin material is fabric or non-woven fabric, the quality is lowered, such as when the injection of the base material is oozed out to the surface of the skin material when pressed by the upper mold with high press pressure. Therefore, there is a problem that the material is limited.

As the material of the base material, an expensive low pressure type should be used, and the foam layer of the skin material should use a low magnification foam. Because the press pressure acts as the foam layer of the skin material is severely pressed and thinned, the touch when the surface of the interior material is poor, resulting in poor texture, resulting in poor quality for use in medium / large luxury vehicles.

In addition, the low-pressure injection machine as described above is quite expensive (about 2 to 3 billion won), so domestic parts manufacturers producing and supplying various interior materials of automobiles have a considerable cost burden to equip their facilities. .

In the high pressure injection method, injection of the substrate injection liquid into the molding surface between the upper and lower molds is carried out to cool the substrate first, and then transfer the matured substrate to the skin coating mold and adhere the skin to the substrate. That's the way it is. In other words, the first production of the base material, and then the method of producing the interior material by the process of bonding the skin material in a later process.

Since the high pressure injection method uses a general press and an injection machine, the cost of constructing the equipment is lower than that of the low pressure injection method, but when the skin material is adhered to the surface of the substrate, the adhesive material is manually bonded after spraying the adhesive bond. There is a problem that productivity is poor due to poor workability, each time the spray of the adhesive bond is severely polluted air in the workplace has a lot of environmental pollution.

In addition, since the high-pressure injection method is to completely remove the substrate from the injection mold and harden immediately when the injection molding the substrate, the shrinkage (strain) of the substrate is severe, in particular, because the injection mold equipment of the substrate and the adhesive mold equipment of the skin material must be provided separately There is a problem in that it costs a lot of cost and takes up a lot of installation place. Since the base material is moved to another mold after the base material is formed, the skin is adhered to the mold, so that the process is long and the working time is long, thus the productivity is considerably reduced.

And, in order to solve the above problems, it can be said that it is preferable to carry out the skin material adhesion process with a base injection mold. However, in the method of attaching the skin material in the state that the injection-molded substrate is completely cured, the spacer layer is inserted between the upper and lower molds, and only the plane portion gap is corrected by the thickness of the skin material, so that the plane portion layer is not deformed. Although bonded, the upper mold portion forming the edge side vertical portion of the base material cannot correct the gap as much as the thickness of the skin material, so that the texture of the side portion of the interior material becomes very poor as the foam layer is severely pressed and thinned.

Therefore, in the related art, a first upper mold for forming a substrate and a second upper mold for attaching a skin material (an upper mold having a side surface gap corrected by the thickness of the skin material) are separately provided on the lower mold for injection of the substrate. When the first mold is combined with the lower mold, and then the skin material is bonded onto the molded substrate, the second mold is bonded to the lower mold so that the skin foam layer on the plane and the side portion is bonded almost uniformly. It was.

However, this is also equipped with two sets of upper molds, the mold cost and equipment cost burden to install alternately operating, and the two upper molds must be moved to work alternately work time takes a long time to reduce productivity There are many problems with the cost increase.

When the base material and the skin material are adhered to each other, most of the skin material is wider than the base material so that the edge of the skin material is exposed to the outside of the base material, and the automobile interior material is formed of the skin material adhered to the surface of the base material according to the specification of the product. The trimming area is different depending on the products that need to be wrapped around the inner edge of the substrate and the products that do not.

In other words, the product that wraps the edge of the skin material on the inner surface of the substrate is trimmed at intervals as much as the portion to be wrapped in the substrate edge, and the product that does not need to wrap the edge of the skin material on the inner surface of the substrate is trimmed to a width that matches the edge of the substrate. The site is visible from the outside.

By the way, when cut and trimming only the skin material with the cutting blade, the skin material is soft, so even if the cutting blade is sharp, the cutting part is trimmed uncleanly. Therefore, even if the product that wraps the skin edges on the inner surface of the base material is trimmed so that the edges of the skin material are not clean as described above, if the trimming area is wrapped and attached to the inner surface of the base material, the trimming part is not seen from the outside. It doesn't matter.

However, in the case of trimming the skin material with the same width as the base frame, if the trimming part of the skin material is not clean, the trimming part is visible from the outside. Could not be presented.

The present invention is to solve the conventional problems as described above, the object of the present invention is to mix the advantages of the low-pressure injection method and the advantages of the high-pressure injection method to form a base material constituting the interior material of the automobile only a pair of inexpensive upper and lower molds Forming method of automobile interior material and its molding apparatus which can reduce the cost burden of mold equipment by improving adhesion between the skin and skin, and reduce the cost and quality by improving productivity by speedy production process To provide.

Another object of the present invention is to perform the injection molding of the base material and the bonding material of the skin material in a single upper / lower mold, but according to the product and the product that need to wrap the edge of the skin material on the inner surface of the base material It is an object of the present invention to provide a molding method and a molding apparatus in which the bonding process between the skin material and the substrate is performed differently.

1 is a cross-sectional view schematically showing a state in which the upper mold is opened and the skin material is supplied after injection molding the substrate into the upper and lower molds in the present invention.

FIG. 2 is a partial cross-sectional view of the substrate and the skin when the upper and lower molds of FIG.

3 is an enlarged cross-sectional view showing a state in which the edges of the substrate and the skin material bonded by FIG. 2 are trimmed to the same width;

Figure 4 is a cross-sectional view showing another embodiment of the apparatus for performing the injection molding and the skin material bonding process of the substrate only a pair of upper and lower molds according to the present invention

Figures 5a to 5d is a partial cross-sectional view showing the skin forming process from the substrate molding to the apparatus of the present invention shown in Figure 4

FIG. 6A is an enlarged view of portion “A” of FIG. 5D

Figure 6b is a partial cross-sectional view showing an enlarged state of trimming the edge of the skin material and the leakage of the substrate in the present invention;

6C is an enlarged partial cross-sectional view showing a state in which a trimmed edge of the skin material is wrapped around the inner surface of the edge of the substrate;

Explanation of symbols for the main parts of the drawings

10: base material 11: leakage part

20: skin 21: border

30: upper mold 40: lower mold

60: pad 61: elastic means

62: crevice

Hereinafter, a molding method capable of effectively achieving the features of the present invention and its technical configuration and operation will be described in detail with reference to the accompanying drawings for a preferred embodiment.

Example 1 (Product Forming Process No Need to Cover the Skin Material on the Inner Surface)

1 is a cross-sectional view schematically showing a process of bonding the skin material to the mold after injection molding the substrate with the upper / lower mold in the present invention, Figure 2 is the upper and lower molds of Figure 1 bonding the substrate and the skin material 3 is an enlarged cross-sectional view showing a state in which the edges of the base material and the skin material adhered by FIG. 2 are trimmed to the same width.

Referring to the configuration of the mold apparatus for achieving Example 1 (molding process of the product that does not need to wrap the skin material on the inner surface of the base material) by the drawings as described above through the nozzle 50 provided with the heating wire 51 The injection liquid is supplied to the molding surfaces of the upper and lower molds 30 and 40, and the molding surface edge portion 31 of the upper mold 30 and the molding surface edge portion 41 of the lower mold 40 are matched with each other. In the drawing, the molding surface is sealed, and reference numeral 70 in the drawing is a clamp for supplying the skin 20 to the base 10 while being lifted to the cylinder 71.

In the present invention, the constituent device may be referred to as a general constituent device, but the present invention is characterized by a method of making the product of Example 1 by the above mold apparatus, which will be described below step by step.

1st process (substrate injection molding process): Injecting the base material injection liquid into the molding surface of the upper / lower molds 30 and 40, injection molding the base material 10 into a predetermined shape, which is a conventional substrate injection molding method Same as

Second process (skin material adhesion process): When injection molding the substrate 10 by the first process, the heat of injection is substantially retained in the substrate 10, and when the state is leaked out, the upper mold 30 is immediately opened and clamped. After supplying the skin material 20 held by the 70, it presses the skin material 20 with the upper mold 30, and adhere | attaches it to the base material 10. FIG.

Then, the lamellar side of the base material 10 is pushed by the thickness of the skin material 20, and the leaked liquid leaks to the bottom surface of the edge 21 of the skin material 20 and is buried as much as the thickness of the skin material 20. Since the molding surface spacing between the lower molds 30 and 40 is corrected, the portion of the skin material 20 attached to the side surface of the substrate 10 is bonded without being damaged.

Third step (border trimming step): When the bottom surface of the edge 21 of the skin material 20 is hardened by the leaked injection leakage by the second process, the edge 21 of the skin material 20 is subsequently processed. Trimming the blade with a cutting blade allows the product of the first embodiment to be obtained while trimming the edge of the skin material 20 easily and easily.

The present invention is carried out between the upper and lower molds 30 and 40 like a conventional mold apparatus when performing the second process of inserting and bonding the skin material 20 after performing the first process of injection molding the substrate 10. When the spacer (not shown) is inserted, the upper and lower molds 30 and 40 have a spacing between the upper and lower molds 30 and 40 even if the upper mold 30, which is the injection molding of the base material 10, is used as it is. Since the thickness of the material 20 is corrected, the flat horizontal portion of the skin 20 may be smoothly adhered to the substrate 10 without being damaged as in the prior art.

However, when the edge side portion of the base material 10 and the skin material 20 are bonded to each other, the present invention provides that the upper mold 30 is the skin material 20 when the injection-molded base material 10 is laid out by injection residual heat. ) Is pushed to the side of the base material 10, the loose base material 10 is pushed down by the thickness of the skin material 20 as shown in Figure 2 and the thickness correction while the molding surface of the upper and lower molds 30, 40 Since the leakage between the edge portions 31 and 41 may be adhered without damaging the side thickness of the skin 20.

And, as described above, when the leaked liquid thinly deposited on the bottom of the edge 21 of the skin 20 is hardened, the edge of the skin 20 is hardened, so the present invention describes the edge 21 of the skin 20. In order to make a product that does not need to wrap around the inner surface of the frame (10) as shown in Figure 3 when trimming the edge 21 of the skin material 20 with a cutting blade can be cut more clean and easy to improve quality In addition, the ease of operation can significantly improve productivity.

Example 2 (Product Forming Process in which the Skin Material Needs to Be Wrapped Inside the Substrate)

Figure 4 is a cross-sectional view showing another embodiment of the apparatus for performing the injection molding and the skin material bonding process of the substrate with only a pair of upper and lower molds according to the present invention, Figures 5a to 5d is the apparatus of the present invention shown in Figure 4 This is a partial cross-sectional view showing the process from substrate molding to skin material bonding process.

Referring to the configuration of the molding apparatus for achieving the second embodiment of the present invention (molding process of the product that should cover the skin material on the inner surface of the substrate) by the above drawings the present invention through the nozzle 50 is provided with a heating wire 51 In forming the apparatus in which the substrate injection liquid is supplied to the molding surface of the upper and lower molds so that the substrate 10 is injection molded, the width of the lower mold 40 is formed only to the size of the molding surface of the upper mold 30. As the frame of the lower die 40, the pad 60, which is in contact with the edge 31 of the upper die 30, has elasticity such as a spring or a cylinder in the state of the lower die 40 and a slight gap 62. It is characterized by being installed elastically by the means 61, the reference numeral 11 in the drawing is a leaking portion formed by pushing the edge side of the base material 10 by the thickness of the skin material 20.

Cooling holes are provided in a zigzag form in the constituent devices of the first and second embodiments, in which the molding surfaces of the upper mold 30 and the lower mold 40 are formed at a predetermined interval from the molding surface, as in a conventional injection mold. However, the accompanying drawings are shown in a state omitted.

Referring to the process of making the product of Example 2 by the present invention as follows.

1st process (substrate injection molding process): Even if the width | variety of the lower mold | type 40 was formed in the size of the shaping | molding surface of the upper mold | type 30, when the upper mold | type 30 and the lower mold | type 40 are engaged, as shown in FIG. Since the edge of the mold 40 is surrounded by the edge 31 of the upper mold 30, the sealing of the molding surface is well maintained, so even when the injection of the base material is injected through the nozzle 50, the injection liquid leaks to the outside. Injection molding of the substrate is performed smoothly without fear.

Second process (skin material adhesion process): When injection molding the substrate 10 by the first process, the heat of injection is substantially retained in the substrate 10, and when the state is leaked out, the upper mold 30 is immediately opened and clamped. The skin material 20 put on 70 is supplied. At this time, even if the upper mold 30 is opened to supply the skin material 20, as shown in FIG. 5B, the pad 60 rises slightly by the elastic means 61, thereby blocking the edge of the molding surface of the lower mold 40. There is no fear that the base material 10 formed in the stacked state will flow down, and in this state, the skin material 20 is pressed by the upper mold 30 to adhere to the base material 10.

Then, the lagging side of the base material 10 is pushed by the thickness of the skin material 20 as shown in FIG. 6A, and the leaked liquid leaks into the gap 62 formed between the edge of the lower mold 40 and the pad 60. As shown in FIG. 6B, the leakage part 11 is formed in a state in which the edge portion 21 of the skin material 20 is separated from each other, and the side surface of the base material 10 leaks as described above. Since the gap between the lower molds 30 and 40 is corrected, the skin material 20 can be adhered to the foam layer without being damaged when bonded to the side surface of the substrate 10.

Third Step (Trimming Step): Simultaneously or immediately after performing the second step, the edge 21 of the skin material 20 is appropriately sized by a cutting blade (not shown in the drawing) provided at the edge of the upper die 30. Trimming, and the leaking part 11 of the leaked substrate 10 is cut and then trimmed. In this case, since the leaking part 11 of the base material 10 is formed in a state in which it is separated from the edge 21 of the skin material 20, the trimming operation of only the leaking part 11 can be performed more quickly and simply.

4th process (surface wrapper wrapping process): When trimming of the leaking part 11 of the base material 10 by the said 3rd process is completed, as shown in FIG. 6C, the edge 21 of the skin material 20 is described (10) Wrap the inner surface of the edge of the interior material to complete the production process.

In the present invention, when the injection-molded substrate 10 is pressed by the residual heat of injection, the upper mold 30 pushes the skin material 20 to the side of the substrate 10 so that the loose substrate 10 is pressed. Since the side surface is pushed down by the thickness of the skin material 20 and the thickness is corrected while forming the leaking part 11, the side thickness of the skin material 20 may be adhered without much damage.

As described above, in the present invention, after the injection molding of the base material, the upper mold is opened once, and the injection pressure is first released in the process of supplying the skin material, and then the upper mold is closed again. Since it is performed, there is little shrinkage (strain) of a base material, and quality is uniform.

In addition, since the injection molding of the base material and the bonding process of the skin material are performed only with a single upper / lower mold, the cost burden required to equip the injection mold facility can be minimized, and the workability is quick and simple, which can significantly increase productivity. As a result, there is a cost reduction effect of about 20-25% compared to the existing production method, which can significantly improve the quality and price competitiveness.

In addition, when bonding the base material and the skin material, it is possible to significantly reduce the pollution of the environmental pollution due to the use of the adhesive bond, because only by using the residual heat of the substrate without using the adhesive bond at all as in the prior art.

Claims (3)

In injection molding the substrate 10 by injecting the substrate injection liquid into the molding surfaces of the upper and lower molds 30 and 40 through the nozzle 50 provided with the heating wire 51, A first step of injecting the substrate injection liquid into a molding surface between the upper and lower molds 30 and 40 to inject the substrate 10 into a predetermined shape; When the injection heat in the injection-molded substrate 10 by the first process is considerably in a state of being leaked, the upper mold 30 is opened and the skin material 20 is supplied to the upper mold 30. When the skin material 20 is adhered to the base material 10, the lattice edges of the base material 10 are pushed out by the thickness of the skin material 20, and the leakage of the base material is caused by the edges of the skin material 20. A second step of causing the bottom to be buried; A third step of trimming the edge of the skin material 20 hardened by the leakage after performing the second step with a cutting blade; Molding method of the interior material for cars, characterized in that made of. In injection molding the substrate 10 by injecting the substrate injection liquid into the molding surfaces of the upper and lower molds 30 and 40 through the nozzle 50 provided with the heating wire 51, A first step of injecting a substrate injection liquid into a molding surface between the upper and lower molds 30 and 40 to inject the substrate 10 into a predetermined form; When the injection heat is considerably remaining in the injection molding of the substrate 10 in the first process, the upper mold 30 is opened and the skin material 20 is supplied to the upper mold 30. When the ash 20 is pressed to the substrate 10 and the adhesive is pressed, the loose side of the substrate 10 is pushed out of the molding surface by the thickness of the skin 20 so that the leak is separated from the edge of the skin 20. A second step formed of the part 11; Trimming the edge 21 of the skin material 20 with a cutting blade installed on the edge of the upper mold 30 when performing the second process, and the leaking portion 11 of the leaked substrate 10 is cured and then cut. A third step of trimming by; When the trimming of the edge 21 of the skin material 20 and the leaking part 11 of the base material 10 is completed in the third process, the trimmed edge 21 of the skin material 20 is inner surface of the edge of the base material 10. The fourth step Molding method of a vehicle interior material characterized in that consisting of. In constructing an apparatus in which the substrate injection liquid is supplied to the molding surfaces of the upper and lower molds 30 and 40 through the nozzle 50 provided with the heating wire 51, the substrate 10 is injection molded. The width of the lower mold 40 is formed only by the size of the molding surface of the upper mold 30, and the pad 60 which is in contact with the edge portion 31 of the upper mold 30 is formed as an edge of the lower mold 40. When the base 10 and the skin 20 are adhered to each other by being elastically installed by the elastic means 61 such as a gas spring or a cylinder in a state where the lower die 40 and the slight gap 62 are present, the base 10 Molding apparatus for a vehicle interior, characterized in that the leakage liquid pushed out from the side of the) is formed as a leaking portion 11 in a state separated from the edge 21 of the skin material (20).