KR20160040933A - Method for manufacturing luggage board of vehicle - Google Patents

Abstract

The present invention provides an interior material, such as a luggage board, for a vehicle. The method for molding an interior material for a vehicle includes the steps of: disposing a heated lower sheet (36) on the top of a core (24) installed on the top of a lower mold (30), and allowing the lower sheet (26) to be in close contact with the core (24) by using an external vacuum pump made of an air-permeable metal or through a plurality of air flow paths; disposing a solid foam body (38) on the top of the lower sheet attached to the core from the preceding step: disposing a heated upper sheet (34) on the top of the solid foam body and disposing a skin material (32) on the top of the upper sheet; and allowing the upper mold (10) to be in close contact with the lower mold, followed by compression. In addition, a rib structure (36b) is formed on the cavity molding surface (24a) which forms the top of the core so that the corresponding rib structure (36b) may be formed on the lower sheet (36). On the bottom surface of the solid foam body, the shape corresponding to the rib structure is molded preliminarily.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention [0002] The present invention relates to a method and an apparatus for molding an interior material of an automobile, and more particularly, to a method and an apparatus for molding an interior material for an automobile which are configured to have a sufficient strength and to realize an easier manufacturing process.

Various types of interior materials are installed in the interior of the vehicle, such as a luggage board or a back plate called a rear parcel shelf (interior material) is installed behind the rear seat. Such a rugby board can be said to be a part which is installed inside the automobile and one side is exposed to the user, and it can be said that a certain strength is required. Therefore, it can be said that the portion exposed to the user is required to have aesthetic aesthetics, and the strength that can be supported when the object is placed is also required.

Korean Patent Laid-Open Publication No. 10-2014-0015569 discloses an apparatus and a method for molding such an automobile interior material. According to this conventional technique, a core material is placed between a pair of molten resin sheets to form a resin molded article. However, according to this conventional technique, since the resin molded article is molded using the molten sheet, the following problems are pointed out.

First, since a resin sheet in a molten state is used, a certain limit is pointed out in the deformation of the molten resin. For example, since a sheet for forming a resin molded article is provided in a molten state, there is a disadvantage that it is impossible to form a structure for reinforcing the resin sheet. That is, according to this conventional technique, since a sheet in a molten state is used, it is pointed out that the surface to be formed by the resin can not be realized only in the form of a flat resin molded article.

In order to use the resin in the molten state as described above, it is necessary to include a device for melting the resin. This causes a disadvantage in terms of economics because it increases the overall size of the equipment and increases the facilities. In other words, the above-mentioned conventional technique has a disadvantage in that the apparatus for manufacturing a resin molded article is not only expensive but also large-sized, and thus it is economically disadvantageous to apply it.

It is an object of the present invention to provide a method for molding an automobile interior material which can further reinforce the structural strength of a resin sheet.

Another object of the present invention is to provide a molding method of an automobile interior material which can be implemented in a place-like environment and an economical environment more easily by simplifying the facilities.

A method for molding an automotive interior material according to the present invention is characterized in that a heated lower sheet is placed on an upper portion of a core placed on an upper portion of a lower mold and is made of a breathable metal or is made to contact the lower sheet with an external vacuum pump through a plurality of air passages ; A second step of placing a solid foam on an upper portion of the lower sheet adhering to the core in a first step; A third step of putting the skin material on the upper sheet and the upper sheet heated on the upper part of the solid foam; And a fourth step of pressing and bonding the upper mold to the lower mold. Here, a bead structure is formed on the cavity forming surface forming the upper portion of the core, and a bead structure corresponding to the bead structure is formed on the lower sheet, and a shape corresponding to the bead structure is previously formed on the bottom surface of the solid foam .

According to another aspect of the present invention, there is provided a molding apparatus comprising: an upper mold having a concave cavity forming surface on a bottom surface; A core having a bead structure on its upper surface and formed of a breathable metal or having a plurality of air passages is seated on an upper portion of the core and connected to an external vacuum pump between the core and the core, And a lower mold capable of being opened and closed. Here, the bead structure corresponding to the bead structure of the core is molded in the lower sheet, and the solid is foamed between the lower sheet and the upper sheet.

As described above, according to the present invention, a solid foaming agent is interposed between an upper sheet and a lower sheet, and a bead structure for reinforcing structural strength is formed on one side (bottom surface of the lower sheet and the foaming material) It is possible to provide an automobile interior material having strength, for example, a luggage board.

According to the present invention, since the upper sheet and the lower sheet sheared in a predetermined size and the solid foam finished in a separate process are used, the entire facility for molding the automobile interior material can be implemented more simply. Other and further advantages of the present invention will become more apparent from the following description.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a cross-sectional view of a molding apparatus for providing a molding method according to the present invention; FIG.
2 is a cross-sectional exemplary view of an automotive interior material to be molded according to the present invention;
Fig. 3 is an exemplary explanatory view showing a molding method of an automobile interior material according to the present invention in sequence; Fig.

Hereinafter, the present invention will be described in detail with reference to the drawings. First, the structure of the molding apparatus according to the present invention will be described based on FIG. An automotive interior material molding apparatus according to the present invention includes a pair of molds, that is, an upper mold 10 and a lower mold 20, for forming a cavity for molding an interior material therebetween.

One of the upper mold 10 and the lower mold 20 is composed of a movable mold and the other is composed of a fixed mold. In the illustrated embodiment, the lower mold 20 is composed of a fixed mold connected to the vacuum pump 28. On the lower surface of the upper mold 10, the cavity forming surface 12 is formed concavely. The cavity forming surface 12 is for substantially forming the upper surface of the interior material 30 shown in Fig. 2, and has a shape corresponding thereto.

The lower mold 20 includes a detachable core 24. The core 24 is formed to cooperate with the cavity forming surface 12 of the upper mold 10 to form an overall cavity . That is, the automobile interior material 30 shown in Fig. 2 is pressed and molded between the cavity forming surface 12 of the upper mold 10 and the upper surface (cavity forming surface) 24b of the core 24 can do.

The core 24 is seated inside the lower mold 20. It is preferable that the cavity forming surface 24b which is the upper surface of the core 24 has a size capable of forming a whole cavity. Therefore, it is preferable that the core 24 has a larger size on the plane than the cavity forming surface 12 of the upper mold 10. The lower mold 20 on which the core 24 is mounted is formed so that the air discharge portion 26 for connecting the core 24 and the vacuum pump 28 is entirely communicated.

The lower mold 20 is vacuum-molded so as to have a predetermined shape by sucking the lower sheet 36 which is placed on the upper surface thereof in a vacuum. The air discharging portion 26 is formed by vacuum- And the core 24 is discharged to the outside, which will be described later. Therefore, the core 24 should be substantially breathable. In the present invention, the core 24 is formed with a plurality of air passages 24a for vacuum. As another embodiment, it is also possible to form the core 24 with a breathable metal.

When the vacuum pump 28 is operated, the air is sucked into the upper portion of the core 24 through the air discharging portion 26, The lower sheet 26 mounted on the upper portion of the core 24 can be brought into close contact with the cavity forming surface 24b which is the upper surface of the core 24. [

Next, the vacuum forming method according to the present invention will be described in detail with reference to FIG. The molding apparatus shown in Fig. 3 will be described while giving only reference numerals of the parts that are related to each process. The upper mold 10 and the lower mold 20 are prepared in an open state and the lower mold 20 is fitted with the core 24 as shown in FIG.

In this state, a lower sheet 36 heated by a separate heat source Ha from the outside is lifted onto the lower mold 20 corresponding to the upper surface of the core 24, as shown in (b) . This process can be done by hand, but it is more preferable to proceed in an automated facility.

Next, as shown in (c), the vacuum pump 28 operates in a state in which the lower sheet 36 is placed on the core 24. The lower sheet 36 is brought into close contact with the core 24 by the operation of the vacuum pump 28 which is in communication with the air discharge portion 26. That is, since the core 24 is formed with a breathable metal or a plurality of air passages 24a, the lower sheet 36 is brought into close contact with the upper surface of the core 24 by the action of the vacuum pump 28 will be.

Here, the upper sheet 34 and the lower sheet 36 in the present invention can be formed into various materials. For example, a synthetic resin, a reinforced synthetic resin containing an additive, a synthetic resin containing wood powder and the like, and may also include a fiber material. The lower sheet 26 adhered to the upper surface of the core 24 is deformed into a shape corresponding to the upper surface of the core 24. The upper surface of the core 24 may have various structures to form the outer shape of the lower sheet 26. In the illustrated embodiment, the core 24 has a constant width in one direction with respect to the upper surface 24b And has a bead structure 24c that is concavely formed. The lower sheet 36 has a reference surface 36a corresponding to the upper surface 24b of the core 24 and a bead structure 36b having a constant width downward from the reference surface 36a and continuing in one direction .

It is natural that the bead structure 36b has a function of substantially reinforcing the strength, and it will have a sufficient strength to be able to support a constant load in combination with the following components. Thus, when the lower sheet 36 is completely brought into close contact with the upper portion of the core 24 and the lower mold 20, the solid foam 38 as shown in (d) is put on the lower sheet.

Here, the solid-phase foam 38 refers to a foam in a solid state in which foaming is completed, and examples thereof include styrofoam and the like. Such a solid-state foamed article 38 is molded by a separate device from the outside. The bottom surface of the solid foam 38 has the same shape as the cavity forming surface 24b which is the upper surface of the core 24 and is in close contact with the upper surface of the core 24 State.

The upper sheet 34 and the skin material 32 are placed between the upper mold 10 and the lower mold 20 as shown in Fig. The upper sheet 34 is raised to be positioned on the upper portion of the solid foam 38 and the skin material 32 is put on the upper portion of the upper sheet 34. The upper sheet 34 is preferably made of the same material as the lower sheet 36. The skin material 32 can be said to form the outer surface of the actual luggage board and can be said to be substantially a finish material. The skin material 32 may be formed of, for example, nonwoven fabric or fiber.

Here, the upper sheet 34 is heated while being heated by an external heat source Hb like the lower sheet 36. The heated state means that the lower sheet 36 is also the same and is in a state of plastic deformation due to external force (pressing force of the upper mold 10 or suction force of the vacuum pump 28). the upper mold 10 is lowered and brought into close contact with the lower mold 20 in a state in which the upper sheet 34 and the skin material 32 are placed on the upper portion of the solid foam 38 as shown in FIG. As shown in Fig.

In this state, the upper sheet 34 and the lower sheet 36 are heated to a constant temperature, and a constant press pressure is applied between the upper mold 10 and the lower mold 20 as shown in (f) When it is received for a certain period of time, it is plastically deformed as shown in (g). Here, the skin material 32 and the upper sheet 34 and the solid foam 38 and the upper and lower sheets 34 and 36 must be firmly adhered to each other. Of course, it can be bonded by deformation due to high temperature therebetween, but it is also possible to apply an adhesive when solid adhesion does not occur.

For example, in order to make the adhesion between the skin material 32 and the upper sheet 34 stronger, it is also possible to coat the lower surface of the skin material 32 with a predetermined adhesive agent, It will be possible. It is of course also possible to apply an adhesive to each of the surfaces which are bonded to the upper sheet 34 and the lower sheet 36. After completion of the interior material 30 as shown in (g), by trimming the skin material 32, the upper sheet 34, and the edge portion of the lower sheet 36, h) is completed.

It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the inventive concept as defined by the appended claims. It is self-evident that it will do.

10 ..... upper mold
12 ..... cavity forming face
20 ..... lower mold
24 ..... core
24a ..... air passage
24b ..... cavity forming surface (or upper surface)
24c ..... bead structure
28 ..... Vacuum pump
30 ..... interior material
32 ..... skin material
34 ..... top sheet
36 ..... Lower seat
36a ..... reference plane
36b ..... bead structure

Claims (2)

The heated lower sheet 36 is placed on the upper portion of the core 24 seated on the upper portion of the lower mold 20 and the lower sheet 26 is made of a breathable metal or an external vacuum pump through a plurality of air passages A first process for bringing the core 24 into close contact with the core 24;
A second step of placing the solid foam 38 on the upper portion of the lower sheet adhering to the core in the first step;
A third step of placing a heated upper sheet 34 on the upper portion of the solid foam and a skin material 32 on the upper sheet; And
And a fourth step of pressing and bonding the upper mold 10 to the lower mold;
A bead structure 36b is formed on the cavity forming surface 24a forming the upper portion of the core and a bead structure 36b corresponding to the bead structure 36b is formed on the lower sheet 36. On the bottom surface of the solid foam, And the corresponding shape is preformed.
An upper mold (10) having a concave cavity forming surface (12) on its bottom surface;
A core 24 having a bead structure 24c on its upper surface and formed of a breathable metal or having a plurality of air passages is seated on the upper side and a vacuum pump connected to an external vacuum pump is provided between the core 24 and the lower sheet 36) is formed on an upper surface of the core, and an upper mold (20) and an openable lower mold (20);
Wherein a bead structure 36b corresponding to the bead structure 24c of the core is molded in the lower sheet 36 and the solid foam 38 is sandwiched between the lower sheet and the upper sheet 34 Inside molding device.

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