KR20070073334A - Al-insert injection molding method using al-sheet for multi-pattern parts and ashtray - Google Patents

Abstract

A method for injection-molding an aluminum insert for manufacturing a multi-pattern part by using an aluminum sheet and an ashtray for a vehicle which is manufactured by the same are provided to forming the shape of the aluminum sheet by performing a blanking process and a forming process. A method for injection-molding an aluminum insert for manufacturing a multi-pattern part by using an aluminum sheet includes the steps of: blanking the aluminum sheet to which a protective tape is attached(S100); producing a semi-product by forming the aluminum sheet(S102,S104); washing and drying the semi-product(S106); coating an adhesive to the inner side of the semi-product(S108,S110), heating and fusing the coated semi-product(S112); and integrally injection-molding a clip boss section for mounting a connected article.

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);

Manufacturing a variety of automotive parts using a multi-pattern aluminum sheet, including the step (S116) of integrally molding a synthetic resin molding material including a clip boss portion for mounting on the ashtray body at the same time as molding injection into the resin to the semi-finished part. can do.

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)

In the manufacturing method for manufacturing automotive interior parts insert injection molding Blanking the aluminum sheet to which a protective tape is attached on one surface to match the shape of a component to be manufactured; Forming a semi-finished product by forming 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 molded semi-finished product before molding; Molding injection molding method for manufacturing a multi-pattern part using an aluminum sheet, including molding injection molding of a resin into the adhesive portion of the semi-finished product, which is heated on one side, and integrally molding injection of a clip boss for mounting an object to be connected. . Blanking the overall shape for injection molding an aluminum sheet with a protective tape applied to the molded resin contact portion and leaving the other side with a tape or scratch; Forming a bent portion to enhance resin bonding and appearance in molding the end of the entire circumference of the press-blanked aluminum sheet; Insert injection molding of polypropylene resin on the inner surface of the shaped aluminum sheet to which the adhesive is applied; When the insert injection molding for forming a multi-pattern part, comprising forming the aluminum sheet integral molding, including the process of finishing the finishing process to the end finish by integrally molding the clip boss to facilitate mounting on the main body Method of manufacturing aluminum insert molding injection molding parts. The method according to claim 1, The resin is a polypropylene resin or a polypropylene equivalent series having strength or durability, and the bond applied to the back side of the blanked aluminum sheet is melted by the temperature of the resin injected through the heating and melting process, thereby integrally molding injection. Aluminum insert molding injection method for manufacturing a multi-pattern part using an aluminum sheet. An ashtray for automobiles manufactured using an aluminum insert molding injection method for producing a multi-pattern part using the aluminum sheet according to claim 1.

Images