Patent Application
20240051200
The present application claims priority to Korean Patent Application No. 10-2022-0149944, filed Nov. 10, 2022, the entire contents of which is incorporated herein for all purposes by this reference.
The present disclosure relates to an apparatus and method for manufacturing automotive interior materials in which skins are integrated with base materials.
Automotive interior materials include dashboards, door trims, glove boxes, etc.
In recent years, automotive interior materials have been manufactured in a form in which a hard base material is finished with a soft skin due to the increasing demand for high-quality products. Skins may express luxury through elaborate patterns, textures, or decorations on the surface.
Manufacturing of automotive interior materials composed of a base material and a skin may be carried out in the following order: obtaining a semi-finished product with a skin attached to a base material, and wrapping the peripheral portion of the base material in the obtained semi-finished product with the edge portion of the skin. Such automotive interior material manufacturing process has the following problems:
In the process of obtaining a semi-finished product, wrinkles may occur in the skin due to slight movement of the skin, pressure acting on the skin, etc.
In order to wrap the peripheral portion of the base material with the edge portion of the skin, trimming needs to be performed to remove the excess portion of the skin (i.e., the remaining part of the edge portion of the skin that wraps the peripheral portion of the base material) from the skin, and then the edge portion of the skin needs to be adhered to the peripheral portion of the base material. Thus, the overall process is inevitably complicated and difficult, and an increase in equipment and resulting cost increases cannot be avoided. Moreover, the use of adhesives may generate large amounts of environmental pollutants such as volatile organic compounds (VOCs).
Meanwhile, during the manufacturing process of automotive interior materials, high temperature and high pressure may be applied to skins, and the skins may be damaged by high temperature and pressure acting thereon. For example, a defect may occur where the skins become hard.
Accordingly, the present disclosure has been made keeping in mind the above problems occurring in the related art, and the present disclosure is intended to provide an apparatus and method for manufacturing automotive interior materials that are eco-friendly and advantageous in terms of productivity improvement.
An objective of the present disclosure is to provide an apparatus and method for manufacturing automotive interior materials that prevent defects such as wrinkles on skins.
Another objective of the present disclosure is to provide an apparatus and method for manufacturing automotive interior materials that are more advantageous in preventing damage to skins.
The objectives to be achieved are not limited to those mentioned above, and other objectives can be clearly understood by those skilled in the art from the following description.
In order to achieve the above objectives, according to an embodiment of the present disclosure, there is provided an apparatus for manufacturing automotive interior materials. The apparatus includes: a first mold unit provided with a first molding surface and a gate disposed on the first molding surface, wherein a skin is set on the first molding surface; a second mold unit provided with a second molding surface facing the first molding surface, and configured to provide an opening exposing an edge of an edge portion of the set skin along a periphery between the first molding surface and the second molding surface when the second mold unit is combined with the first mold unit; and a sealing block provided with a tip portion disposed along the opening when the first mold unit and the second mold unit are combined, wherein the tip portion may include: a pressurizing tip that presses the edge portion to bring the edge of the skin into full contact with the first molding surface; and a wrapping molding surface that closes the opening to form an enclosed molding space between the first molding surface and the second molding surface, wherein the enclosed molding space is configured to shape a molten resin injected through the gate into a base material, and integrate the base material with the skin; and the wrapping molding surface is configured to guide the skin to wrap a peripheral portion of the base material.
The sealing block may be provided in the first mold unit and composed of a plurality of unit blocks arranged around the first molding surface, wherein each of the plurality of unit blocks may be capable of moving back and forth with respect to an edge section of the first molding surface where the edge of the skin is positioned by a block drive module, thereby pressing the edge of the skin when moving forward and releasing pressure on the edge of the skin when moving backward.
The block drive module may include: a forward operation member capable of moving back and forth with respect to each of the plurality of unit blocks, and advancing each of the plurality of unit blocks toward the edge section by a tapered surface when moving forward; and a backward operation member providing elastic force in a backward direction to each of the plurality of unit blocks so as to move each of the plurality of unit blocks away from the edge section when the forward operation member moves backward.
The backward operation members may be composed of an elastic member interposed between each of the plurality of unit blocks and the first mold unit.
The first mold unit may include: a central mold and a peripheral mold coupled to each other to enable sliding back and forth with respect to the second mold unit; and a mold drive module that moves the central mold or the peripheral mold, wherein the central mold may provide a central portion of the first molding surface and have the gate, the peripheral mold may provide a peripheral portion of the first molding surface around the central mold, the mold drive module may switch a state of the central mold and the peripheral mold between a first state, in which the central mold and the peripheral mold are aligned to provide the first molding surface, and a second state, in which the central mold and the peripheral mold are misaligned to provide an injection space surrounded by the peripheral mold in front of the gate, and the central mold and the peripheral mold may be maintained in the second state when the molten resin is injected, and after an injection of the molten resin is completed, the central mold and the peripheral mold may be switched to the first state, reducing the injection space and compressing the injected molten resin in the injection space.
The second mold unit may include: a first split mold in which a core mold having the second molding surface is slidably coupled; a second split mold disposed behind the first split mold; a core mold rod with a first end thereof is connected to the core mold and a second end thereof is connected to the second split mold; and at least one pressure-reducing elastic member interposed between the first split mold and the second split mold, and retracting, in a state in which the first mold unit and the second mold unit are combined, the core mold by a core-back distance by which the second split mold is retracted from the first split mold. The molten resin may contain a forming agent.
The second mold unit may further include: a stop unit that limits a retraction distance of the second split mold with respect to the first split mold.
The stop unit may include at least one core-back suppression cylinder connected to the first split mold and the second split mold, and may be configured to limit the retraction distance of the second split mold with respect to the first split mold through adjustment of a movement distance of the core-back suppression cylinder.
The second split mold may include: a second front split mold disposed behind the first split mold; and a second rear split mold disposed behind the second split mold. The second end of the core mold rod may be connected to the second front split mold, the pressure-reducing elastic member may be interposed between the first split mold and the second front split mold, and the core-back suppression cylinder may be connected to the first split mold and the second rear split mold.
The second mold unit may further include: a core-back correction module connected to the first split mold and the second rear split mold, and providing elastic force to the first split mold. The elastic force provided by the core-back correction module may be greater than the elastic force provided by the pressure-reducing elastic member.
The stop unit may further include at least one core-back suppression cylinder connected to the first split mold and the second split mold.
the second mold unit may comprise a first split mold in which a core mold having the second molding surface is slidably coupled; a second split mold disposed behind the first split mold; a core mold rod with a first end thereof is connected to the core mold and a second end thereof is connected to the second split mold, and a pusher that retracts, in a state in which the first mold unit and the second mold unit are combined, the core mold by a core-back distance by which the second split mold is retracted from the first split mold.
The molten resin may contain a foaming agent.
In order to achieve the above objective, according to an embodiment of the present disclosure, there is provided a method for manufacturing automotive interior materials using the apparatus for manufacturing automotive interior materials. The method includes: setting the skin on the first molding surface of the first mold unit; bringing the edge of the edge portion of the set skin into full contact with the first molding surface by pressurizing a tip of the tip portion of the sealing block; and combining the first mold unit and the second mold unit; forming, as a result of the combining, the enclosed molding space between the first molding surface and the second molding surface by closing the opening with the wrapping molding surface of the sealing block, wherein the opening is provided along the periphery between the first molding surface and the second molding surface to expose the edge of the skin; molding the base material that is integrated with the skin in the enclosed molding space by injecting molten resin into the enclosed molding space through the gate of the first mold unit; and guiding, by the wrapping molding surface, the edge portion of the skin into a shape that wraps the peripheral portion of the base material.
According to an embodiment of the present disclosure, molding of a base material and wrapping the peripheral portion of the base material with the edge portion of a skin can be accomplished in one step without generating environmental pollutants such as volatile organic compounds (VOCs). Thus, productivity can be greatly improved and manufacturing costs can be greatly reduced.
In addition, in the process of molding a base material by injecting molten resin, the position of a skin is maintained in an accurately fixed state (i.e., the skin is prevented from moving), thereby preventing wrinkles from forming on the skin.
In an apparatus for manufacturing automotive interior materials according to an embodiment of the present disclosure, a sealing block (see 310) is configured (see
According to an embodiment of the present disclosure, during the injection process of molten resin, damage to the back surface of a skin due to the injection pressure of the molten resin can be minimized by injecting molten resin at a location away from the skin.
In addition, since mold parts on opposite sides are separated from each other by a small distance (core back) after injection and compression of molten resin, damage to the skin (deterioration, hardening of a foam layer on the back, etc.) caused by high pressure and temperature in the molding space can be prevented, and if the molten resin contains a foaming agent, foaming can be clearly induced.
According to an embodiment of the present disclosure, the retraction distance of a second split mold with respect to a first split mold can be limited by adjusting the movement distance (controlling the transition between released and fixed states) of a core-back suppression cylinder (see 270) connected to the first split mold (see 210) and the second split mold (see 220 and 230) of the second mold unit (see 200). In a core-back state, the movement of a mold is limited by the core-back suppression cylinder, so the core-back distance can be stably and accurately maintained at the required level, and thus the compressed skin can be more accurately restored to the required shape. That is, due to the core-back suppression cylinder, in order to accurately restore the skin, the second split mold that has retracted by the core-back distance can be suppressed from further retracting by adjusting the movement distance of the core-back suppression cylinder (adjusting the travel distance of a cylinder rod by controlling the transition between the released and fixed states). Furthermore, depending on the process conditions, such as the material of the skin, the core-back suppression cylinder can also be involved in precise control of the core-back distance according to the retraction of the second split mold.
The advantageous effects are not limited to this, and other effects not mentioned can be clearly understood by those skilled in the art from the present specification and the attached drawings.
The above and other objectives, features, and other advantages of the present disclosure will be more clearly understood from the following detailed description when taken in conjunction with the accompanying drawings, in which:
Hereinafter, embodiments of the present disclosure are described in detail with reference to the accompanying drawings to enable those skilled in the art to easily implement the present disclosure. However, it is important to note that the present disclosure may be embodied in many different forms and is not limited to the embodiments described herein.
When describing the embodiments of the present disclosure, if it is determined that a detailed description of a known related function or configuration may unnecessarily obscure the subject matter of the present disclosure, the specific description will be omitted, and parts with similar functions and actions will be denoted by the same reference numerals throughout the drawings.
Since at least some of the tams used in the specification are defined in consideration of functions within the present disclosure, they may vary according to user, operator intention, custom, and the like. Therefore, the terms should be interpreted based on the context provided throughout the specification. In addition, in this specification, the inclusion of a certain component implies that other components may also be included, unless explicitly stated otherwise. Additionally, when a part is said to be connected (or coupled) with another part, this includes not only the case of being directly connected (or coupled), but also the case of being indirectly connected (or coupled) with another part in between.
Meanwhile, in the drawings, the size or shape of components, and thickness of lines may be somewhat exaggerated for convenience of understanding.
An apparatus and method according to an embodiment of the present disclosure may perform insert injection molding for manufacturing automotive interior materials, and provide an automotive interior material including a skin and a base material integrated with the skin by insert injection molding. In addition, in the process of molding the base material by insert injection molding, it is possible to wrap the peripheral portion of the base material with the edge portion of the skin.
An automotive interior material manufactured according to an embodiment of the present disclosure may be used for, for example, armrests, console boxes, crash pads, dashboards, door panels, door trims, glove boxes, headliners, and headrests.
The skin used in manufacturing automotive interior materials according to an embodiment of the present disclosure may consist of a soft skin comprising a skin layer and a foam layer, and may include actual stitches. The foam layer may be positioned between the base material and the skin layer. For clarification, actual stitches may be created through a sewing process using a sewing machine, and similar equipment. The skin used in manufacturing automotive interior materials according to an embodiment of the present disclosure may be preformed beforehand and shaped to a size suitable for wrapping the peripheral portion of the base material with the edge portion of the skin.
The material of the skin layer may be PVC or olefin-based thermoplastic elastomer (TPO), which is a type of thermoplastic elastomer (TPE), and thermoplastic polyurethane (TPU), and the material of the foam layer may be polypropylene foam, polyurethane foam, ethylene vinyl acetate foam, etc., but embodiments of the present disclosure are not limited thereto.
The material of the base material may be acrylonitrile butadiene styrene, acrylonitrile styrene, polyamide, polycarbonate, polyethylene, polyphenylene sulfide, polypropylene, polystyrene, PVC, but embodiments of the present disclosure are not limited thereto.
The configuration and operation of an apparatus for manufacturing automotive interior materials according to the first embodiment of the present disclosure are shown in
Referring to
The position of the first mold unit 100 may be fixed, and the second mold unit 200 may be moved back and forth with respect to the first mold unit 100 by an injection molding machine. Accordingly, the first mold unit 100 and the second mold unit 200 may approach or be spaced apart from each other depending on the moving direction of the second mold unit 200, and may be joined according to the distance at which they approach each other. Alternatively, for the joining process, the second mold unit 200 may be fixed in position, and the first mold unit 100 may be moved forward or backward relative to the second mold unit 200. Of course, for the joining process, it is also possible to configure the first mold unit 100 and the second mold unit 200 to approach or be spaced apart from each other, as needed.
The apparatus for manufacturing automotive interior materials according to the first embodiment of the present disclosure further includes a sealing block 310. The sealing block 310 is configured to have a tip portion consisting of wrapping molding surface 311 and a pressurizing tip 312, and disposed along the opening OP (see
Referring to
Referring to
Referring to
The first mold unit 100 includes: a central mold 110 and the peripheral mold 120 coupled to each other so as to be able to slide back and forth with respect to the second mold unit 200; and a mold drive module 130 that moves the peripheral mold 120. The mold drive module 130 may be configured to move the central mold 110 rather than the peripheral mold 120. The central mold 110 and the peripheral mold 120 are tightly coupled to each other so as to slide back and forth to prevent leakage of the molten resin 10. The central mold 110 is configured to provide a central portion 101c of the first molding surface 101 and to have a gate 105. The peripheral mold 120 is configured to provide a peripheral portion 101b of the first molding surface 101 around the central mold 110.
The mold drive module 130 may switch the state of the central mold 110 and the peripheral mold 120 between a first state (see
The central mold 110 and the peripheral mold 120 are maintained in the second state that the central portion 101c of the first molding surface 101 and the peripheral portion 101b of the first molding surface are misaligned (see
The second mold unit 200 includes: a first split mold 210 combined with a core mold 215 equipped with a second molding surface 201 to enable the core mold 215 to slide back and forth relative to the first mold unit 100; second split mold comprising a second front split mold 220 and a second rear split mold 230 and disposed behind the first split mold 210; and a core mold rod 250 whose opposite ends are connected to the core mold 215 and the second split mold, respectively. In addition, the second mold unit 200 further includes: at least one pressure-reducing elastic member 240 interposed between the first split mold 210 and the second split mold. The pressure-reducing elastic member 240 is responsible for retracting the core mold 215 by an amount equivalent to the predetermined core-back distance G1 at which the second split mold is retracted from the first split mold 210 under the action of elastic force (see
After compression of the molten resin 10, when the core mold 215 is retracted by the core-back distance G1, the molding space, formed by the opening OP being closed by the wrapping molding surface 311 of the sealing block 310, between the first molding surface 101 and the second molding surface 201 is expanded, and thus the pressure and temperature in the molding space decrease. At this stage, when the molten resin 10 contains a foaming agent, foaming may occur due to a drop in pressure and temperature in the molding space. Consequently, due to the pressure and temperature drop in the molding space, damage (deterioration, hardening of the foam layer on the back side, etc.) caused by the high temperature of the molten resin 10 may be prevented.
The second split mold includes the second front split mold 220 disposed behind the first split mold 210; and the second rear split mold 230 disposed behind the second split mold 220. Both ends of the core mold rod 250 are fixed to the core mold 215 and the second front split mold 220, respectively. The pressure-reducing elastic member 240 is interposed between the first split mold 210 and the second front split mold 230.
Referring to
The second mold unit 200 may further include a stop unit that limits the retraction distance of the second split mold with respect to the first split mold 210. The stop unit may include at least one core-back suppression cylinder 270 connected to the first split mold 210 and the second rear split mold 230. When the excess core-back distance is absorbed by the core-back deviation correction module 260, the core-back suppression cylinder 270 is activated to switch from the released state to the fixed state, preventing the second rear split mold 230 from retracting further due to remaining pressure, etc., of the injection molding machine. This ensures the precise maintenance of the core-back distance G1 at the required level, and accordingly, the compressed skin 20 may be more accurately restored to the required form.
Meanwhile, the core-back suppression cylinder 270 may be used as a pusher to retract the core mold 215 by the distance of the core-back G1 by which the second split mold is retracted with respect to the first split mold 210. Accordingly, depending on the implementation conditions, etc., except for the pressure-reducing elastic member 240, retracting the core mold 215 by the core-back G1 distance and limiting the retraction distance of the second split mold may be implemented by the core-back suppression cylinder 270.
Referring to
As described above, in the apparatus for manufacturing automotive interior materials according to the first embodiment of the present disclosure, the first mold unit 100 is configured to have the central mold 110 and the peripheral mold 120 that are slidably coupled to each other, and to switch the combined state of the central mold 110 and the peripheral mold 120 between different first and second states. Of the two states, the second state is a state in which the injection space 50 surrounded by the peripheral mold 120 is provided in front of the gate 105 of the central mold 110 (see
In the first mold unit 100, when the molten resin 10 is injected through the gate 105, the state of the central mold 110 and the peripheral mold 120 is maintained in the second state providing the injection space 50 of a predetermined volume, so that the molten resin 10 is introduced into the injection space (see
An automotive interior material may be manufactured by the apparatus for manufacturing automotive interior materials according to the first embodiment of the present disclosure as follows.
First, a preformed skin 20 is mounted on the first molding surface 101 so that the skin 20 is set on the first molding surface 101. For mounting the skin 20, a skin transport unit 30 that inserts the skin 20 between the first mold unit 100 and the second mold unit 200 may be used.
Then, the edge 22 of the edge portion 21 of the set skin 20 is entirely brought into close contact with the first molding surface 101 by a pressurizing tip 312 of the sealing block 310. The peripheral mold 120 of the first mold unit 100 is advanced toward the second mold unit 200 to maintain the central mold 110 and the peripheral mold 120 in the second state. At this time, an injection space 50 is formed in front of the gate 105 of the central mold 110.
Next, the first mold unit 100 and the second mold unit 200 are joined. That is, as shown in
Next, the molten resin 10 is injected through the gate 105. At this time, depending on implementation conditions, etc., a foaming agent may be included in the molten resin 10.
When the injection of the molten resin 10 is completed, the second mold unit 200 is advanced by the injection molding machine and moved to the injection position. Then, the peripheral mold 120 of the first mold unit 100 is pushed and retracted by the second mold unit 200, and the state of the central mold 110 and the peripheral mold 120 change from the second state to the first state. In this process, the injection space 50 is reduced in volume, the injected resin is compressed as the volume of the injection space 50 is reduced, and enters and fills the molding space and is molded into the base material. In addition, the peripheral portion of the molded substrate is wrapped with the edge portion of the skin 20. Depending on the implementation conditions, etc., the core-back suppression cylinder 270 operated in a fixed state during the injection process of the molten resin 10 may be maintained in a released state during the compression process of the injected molten resin 10.
Next, after completion of compression of the molten resin 10, the second rear split mold 230 is retracted by the core-back distance G1 to retract the core mold 215. At this time, when the molten resin 10 contains a foaming agent, foaming may occur. In addition, as the pressure and temperature of the molding space decrease, damage to the skin 20 due to the high temperature of the molten resin 10 may be prevented. Furthermore, the compressed skin 20 may be more accurately restored to the required form.
When the injection molding machine retracts the second mold unit 200 beyond the core-back distance G1, as shown in
Finally, the first mold unit 100 and the second mold unit 200 may be completely opened, and the molded product, that is the base material with the skin 10 integrated, may be taken out.
According to the second embodiment shown in
According to the second embodiment of the present disclosure, the second mold unit 200A is advanced to the injection position to form the injection space 50A, and then molten resin 10 is injected through a gate 105A. Then, when the injection of the molten resin 10 is completed, the second mold unit 200A is further advanced to the compression position to compress the molten resin 10 in the injection space 50A. At this time, the volume of the injection space 50A is reduced. Accordingly, the injection space 50A may be volume variable. When the compression of the molten resin 10 is completed, the second mold unit 200A is moved backwards by a predetermined distance G2A. Reference numeral 10A is a molded base material.
According to the third embodiment shown in
According to the third embodiment of the present disclosure, after the skin 20 is mounted, each of the plurality of unit blocks of the sealing block 310A is advanced to push the edge portion 21 of the skin 20 entirely inward, so that the edge portion 21 of the skin 20 is transformed into a wrapping-like shape (a shape bent inward). Then, the second mold unit 200A is advanced to the injection position and each of the plurality of unit blocks of the sealing block 310A is further advanced. At this time, the injection space 50A is formed, the edge 22 of the skin 20 is entirely in close contact with the first molding surface 101A by a pressurizing tip 312A, and an opening OP1 is closed by a wrapping molding surface 311A. Then, the molten resin 10 is injected through the gate 105A. When the injection of the molten resin 10 is completed, the second mold unit 200A may be retracted a predetermined distance for core back operation without compressing the injected molten resin 10.
Although the present disclosure has been described above, the present disclosure is not limited to the disclosed embodiments and the accompanying drawings, and various modifications may be made by those skilled in the art without departing from the technical spirit of the present disclosure. In addition, the technical ideas described in the embodiments of the present disclosure may be implemented independently or in combination of two or more.
10: molten resin, 20: skin, 21: edge portion, 30: skin transport unit, 50 injection space, 100: first mold unit, 101: first molding surface, 105: gate, 110: central mold, 120: peripheral mold, 200: second mold unit, 201: second molding surface, 210: first split mold, 215: core mold, 220: second front split mold, 230: second rear split mold, 240: pressure-reducing elastic member, 250: core mold rod, 260: core-back deviation correction module, 270: core-back suppression cylinder, 280: core-back correction module, 310: sealing block, 311: wrapping molding surface, 312: pressurizing tip, 320: forward operation member, 330: drive source, 340: backward operation member.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10-2022-0149944 | Nov 2020 | KR | national |
