CN112297545B - 一种热塑性汽车内饰件及其制备模具和制备方法 - Google Patents

一种热塑性汽车内饰件及其制备模具和制备方法 Download PDF

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CN112297545B
CN112297545B CN202011107584.4A CN202011107584A CN112297545B CN 112297545 B CN112297545 B CN 112297545B CN 202011107584 A CN202011107584 A CN 202011107584A CN 112297545 B CN112297545 B CN 112297545B
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automotive interior
preparation
skin
thermoplastic
mold
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CN112297545A (zh
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袁瑞建
汪洋
陈蓬勃
杨蕾
杨正高
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Guangdong Jushi composite material Co.,Ltd.
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Polyrocks Chemical Co ltd
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Abstract

本发明公开了一种热塑性汽车内饰件及其制备模具和制备方法，其中，制备模具包括上模板和下模板，所述上模板和所述下模板对置形成内模腔，所述下模板上设有伸缩式气针、以及与所述内模腔连通的真空吸塑孔，所述伸缩式气针可伸入至内模腔内。本发明可一次模压成型制备热塑性汽车内饰件成品，制备工序简单，生产效率高，制备过程环保，无需使用胶黏剂。热塑性汽车内饰件的芯材为发泡芯材或热塑性蜂窝结构芯材，达到轻量化效果。热塑性汽车内饰件的内部结构可自由设计，可根据需要生产等厚产品或不等厚产品，并能一步模压实现产品翻折功能。热塑性汽车内饰件可回收再利用，质量轻，隔音效果好，承载力大。

Description

一种热塑性汽车内饰件及其制备模具和制备方法
技术领域
本发明属于汽车内饰件制造技术领域，具体涉及一种热塑性汽车内饰件及其制备模具和制备方法。
背景技术
模压是压缩模塑的简称，又称压塑，是一种塑料或橡胶胶料在闭合模腔内借助加热、加压而成型为制品的加工方法。模压具有加工成本低，制品重复性较好，便于实现自动化生产，能一次成型结构复杂的制品等诸多优点，目前已被广泛应用于衣帽间、顶棚、脚踏板等产品的加工中。
现今，高承重汽车的行李箱盖板主要以PHC湿法纸蜂窝板为主，后序需要喷胶包边，制备工序复杂，气味大，VOC容易超标，玻纤存在外漏风险，玻纤外漏容易引起皮肤过敏，而且材料无法回收再利用，对于翻折功能无法一次加工完成。如PP蜂窝板、六角蜂窝玻纤板、圆孔蜂窝玻纤板等其它发泡芯玻纤增强复合板，则通过复合板材经烘烤软化压制成型，这种产品的内部结构无法自由设计，不适用于车体空间复杂、要求不等厚的产品制备。
发明内容
为解决上述现有技术中存在的不足之处，本发明的目的在于提供一种热塑性汽车内饰件及其制备模具和制备方法。
为达到其目的，本发明所采用的技术方案为：一种热塑性汽车内饰件的制备模具，其包括上模板和下模板，所述上模板和所述下模板对置形成内模腔，所述下模板上设有伸缩式气针、以及与所述内模腔连通的真空吸塑孔，所述伸缩式气针可伸入至内模腔内。由此，本发明的模具可通过真空吸塑和吹塑原理实现一次模压成型制备热塑性汽车内饰件，大大简化了汽车内饰件的制备工序。
优选地，所述下模板包括至少两个区段，相邻所述区段的高度不等。由此，本发明的模具可一次模压成型制备不等厚的热塑性汽车内饰件。
优选地，相邻所述区段之间设有弯折的连接部。由此，可使热塑性汽车内饰件的不同厚度部位之间预留翻折线，使汽车内饰件实现翻折功能。
优选地，各个所述区段上均设有所述伸缩式气针和所述真空吸塑孔。
优选地，所述上模板和所述下模板的内部设有冷却水通路。由此，可向上模板和下模板的内部通入冷却水冷却。
本发明还提供了一种热塑性汽车内饰件，其采用所述热塑性汽车内饰件的制备模具制备而成，所述热塑性汽车内饰件包括芯材和包裹所述芯材的表皮，所述表皮由上表皮和下表皮组成。
优选地，所述上表皮的表面上还设有装饰面料层。
优选地，所述热塑性汽车内饰件为不等厚的夹芯结构，所述热塑性汽车内饰件设有至少两个芯材，相邻所述芯材的厚度不等。
优选地，相邻所述芯材之间设有金属支撑架。金属支撑架可提高汽车内饰件的承重能力。
优选地，所述芯材由热塑性材料制成，所述热塑性材料可选自聚烯烃材料。如采用聚烯烃材料经塑化挤出成型蜂窝结构的芯材或发泡成型相应结构的芯材，该结构的芯材的质量轻，可使汽车内饰件实现轻量化。
优选地，所述上表皮和所述下表皮可选用聚烯烃材质的挤塑表皮、纤维增强聚烯烃材质的挤塑表皮、或丙纶与玻纤混纺的压制表皮等制成。优选地，所述上表皮和所述下表皮的厚度分别为1～5mm。
优选地，所述热塑性汽车内饰件的厚度为5～30mm。
优选地，所述装饰面料层选用无纺布、针织布、皮革等可实现热复合的材料制成。由此，后续无需喷胶加工，一次模压成型。
优选地，所述热塑性汽车内饰件为行李箱盖板、备胎盖板、顶棚或脚踏板等。
本发明还提供了一种所述热塑性汽车内饰件的制备方法，其包括使用所述热塑性汽车内饰件的制备模具模压成型，具体步骤如下：
(1)将上表皮和下表皮进行加热烘烤；
(2)将下表皮放在下模板上，抽真空，使下表皮紧贴下模板的模腔，然后打开伸缩式气针穿透下表皮；
(3)根据产品的厚度要求，将相应厚度的芯材放在下表皮上；
(4)将上表皮放在芯材上，装饰面料层置于上表皮上；
(5)合模，吹气，冷却定型，切除边料，退真空，停吹气，退气针，开模取件，即得所述热塑性汽车内饰件。
优选地，所述步骤(1)中，采用红外非接触式烘箱对上表皮和下表皮进行烘烤加热，加热温度为200～300℃，加热时间为30～60s。
优选地，所述步骤(2)中，抽真空的真空压力为0.1～0.5Mpa。
优选地，所述热塑性汽车内饰件为不等厚的夹芯结构时，所述步骤(3)还包括如下操作：将金属支撑架置于相邻的芯材之间。
优选地，所述步骤(5)中，合模的保压压力为18～25MPa，保压时间为30～180s；吹气的压力为0.5～0.8Mpa，吹气时间为30～180s。
与现有技术相比，本发明的有益效果为：本发明可一次模压成型制备热塑性汽车内饰件成品，制备工序简单，生产效率高，制备过程环保，无需使用胶黏剂。热塑性汽车内饰件的芯材为发泡芯材或热塑性蜂窝结构芯材，达到轻量化效果。热塑性汽车内饰件的内部结构可自由设计，可根据需要生产等厚产品或不等厚产品，并能一步模压实现产品翻折功能。热塑性汽车内饰件的内部可增加金属支撑架，提高产品的承重能力，取代现有的高承重PHC湿法纸蜂窝。本发明制备的热塑性汽车内饰件可回收再利用，质量轻，隔音效果好，承载力大。
附图说明
图1为本发明所述热塑性汽车内饰件的结构示意图；
图2为本发明所述热塑性汽车内饰件模压中的状态示意图。
图中，1.上模板；2.下模板；3.连接部；21.真空吸塑孔；22.伸缩式气针；a.装饰面料层；b.上表皮；c.下表皮；d.前端芯材；e.后端芯材；f.金属支撑架；g.翻折线。
具体实施方式
下面将结合实施例及附图对本发明的技术方案作进一步描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。本发明中，所用材质和连接方式如无特别指明，均为现有材料或现有常规连接，本领域技术人员根据所需的产品型号和规格，可以直接从市面购买或订做。
实施例1
一种热塑性汽车内饰件，其包括芯材和包裹芯材的表皮，表皮由上表皮和下表皮组成，上表皮的表面上设有装饰面料层。本实施例的热塑性汽车内饰件为不等厚的夹芯结构，热塑性汽车内饰件设有至少两个不等厚的芯材，相邻芯材之间可设置金属支撑架。芯材由热塑性材料制成，热塑性材料可选自聚烯烃材料，如采用聚烯烃材料经塑化挤出成型蜂窝结构的芯材或发泡成型相应结构的芯材，该结构的芯材的质量轻，可使汽车内饰件实现轻量化。上表皮和下表皮可选用聚烯烃材质的挤塑表皮、纤维增强聚烯烃材质的挤塑表皮、或丙纶与玻纤混纺的压制表皮等制成；上表皮和下表皮的厚度分别为1～5mm；热塑性汽车内饰件的总厚度为5～30mm。装饰面料层选用无纺布、针织布、皮革等可实现热复合的材料制成；由此，后续无需喷胶加工，一次模压成型。本实施例的热塑性汽车内饰件为行李箱盖板、备胎盖板、顶棚或脚踏板等。
实施例2
一种热塑性汽车内饰件的制备模具，如图2所示，其包括上模板1和下模板2，上模板1和下模板2对置形成内模腔。下模板设有至少两个区段，相邻区段的高度不等，且相邻区段之间设有弯折的连接部3。由此，可实现一次模压成型制备不等厚的热塑性汽车内饰件，并通过连接部3在热塑性汽车内饰件的不同厚度部位之间预留翻折线，使汽车内饰件实现翻折功能。此外，各个区段上均设有伸缩式气针22和真空吸塑孔21，真空吸塑孔21与内模腔连通，伸缩式气针22可伸入至内模腔内。上模板1和下模板2的内部设有冷却水通路，由此，可向上模板1和下模板2的内部通入冷却水冷却。
实施例3
采用实施例2的制备模具制备实施例1的热塑性汽车内饰件的方法，步骤如下：
(1)将上表皮和下表皮放在红外非接触式烘箱内，200～300℃加热烘烤30～60s；
(2)将下表皮放在下模板上，抽真空至真空压力为0.1～0.5Mpa，使下表皮紧贴下模板的模腔，1～2s后打开伸缩式气针穿透下表皮；
(3)根据产品的厚度要求，将相应厚度的芯材放在下表皮上，将金属支撑架置于相邻的芯材之间；
(4)将上表皮放在芯材上，装饰面料层放在上表皮上；
(5)合模，吹气，冷却定型，切除边料，退真空，停吹气，退气针，开模取件，即得所述热塑性汽车内饰件；合模的保压压力为18～25MPa，保压时间为30～180s；吹气的压力为0.5～0.8Mpa，吹气时间为30～180s。
实施例4
一种不等厚热塑性汽车备胎盖板的制备方法，包括使用实施例2的制备模具进行模压成型，如图1～2所示。该备胎盖板的芯材为20倍PP发泡芯，前端芯材d的厚度为12mm，后端芯材e的厚度为20mm，前端芯材d与后端芯材e之间设有H型铝合金支撑架f；上表皮b和下表皮c为PP-TD20材质，厚1.2mm；覆盖在上表皮b表面上的装饰面料层a为200g/m2 PET无纺布。制备方法的步骤如下：
(1)将上表皮和下表皮放在红外非接触式烘箱内，260℃加热烘烤30s；
(2)将下表皮放在下模板上，抽真空至真空压力为0.3Mpa，使下表皮紧贴下模板的模腔，2s后打开伸缩式气针穿透下表皮；
(3)将20mm厚的芯材放在后端的下表皮上，12mm厚的芯材放在前端的下表皮上，H型铝合金支撑架放于翻折线处；
(4)将上表皮放在芯材上，装饰面料层放在上表皮上；
(5)上下合模，吹气，10℃冷却水冷却定型，切除边料；合模的保压压力为18MPa，保压时间为60s；吹气的压力为0.6Mpa，吹气时间为60s；
(6)退真空，停吹气，退气针，开模取件，即得备胎盖板。
最后所应当说明的是，以上实施例仅用以说明本发明的技术方案而非对本发明保护范围的限制，尽管参照较佳实施例对本发明作了详细说明，本领域技术人员应当理解，可以对本发明的技术方案进行修改或者等同替换，而不脱离本发明技术方案的实质和范围。

Claims (3)

1.一种热塑性汽车内饰件的制备方法，其特征在于，所述热塑性汽车内饰件为行李箱盖板、备胎盖板、顶棚或脚踏板；所述制备方法包括使用热塑性汽车内饰件的制备模具模压成型；所述制备模具包括上模板和下模板，所述上模板和所述下模板对置形成内模腔，所述下模板上设有伸缩式气针、以及与所述内模腔连通的真空吸塑孔，所述伸缩式气针可伸入至内模腔内；所述下模板包括至少两个区段，相邻所述区段的高度不等，相邻所述区段之间设有弯折的连接部，各个所述区段上均设有所述伸缩式气针和所述真空吸塑孔，所述上模板和所述下模板的内部设有冷却水通路；所述热塑性汽车内饰件包括芯材和包裹所述芯材的表皮，所述芯材由热塑性材料制成，所述表皮由上表皮和下表皮组成，所述上表皮的表面上还设有装饰面料层，所述热塑性汽车内饰件为不等厚的夹芯结构，所述热塑性汽车内饰件设有至少两个芯材，相邻所述芯材的厚度不等，相邻所述芯材之间设有金属支撑架；
所述制备方法的具体步骤如下：
(1)将上表皮和下表皮进行加热烘烤；
(2)将下表皮置于下模板上，抽真空，使下表皮紧贴下模板的模腔，然后打开伸缩式气针穿透下表皮；
(3)根据产品的厚度要求，将相应厚度的芯材放置于相应的内模腔上；
(4)将上表皮置于芯材上，装饰面料层置于上表皮上；
(5)合模，吹气，冷却定型，切除边料，退真空，停吹气，退气针，开模取件，即得所述热塑性汽车内饰件。
2.如权利要求1所述的制备方法，其特征在于，所述步骤(1)中，采用红外非接触式烘箱对上表皮和下表皮进行烘烤加热，加热温度为200～300℃，加热时间为30～60s。
3.如权利要求1所述的制备方法，其特征在于，所述步骤(5)中，合模的保压压力为18～25MPa，保压时间为30～180s；吹气的压力为0.5～0.8MP a，吹气时间为30～180s。
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