KR20210051426A - Efficient Manufacturing Method Of Vehicle Parts - Google Patents

Abstract

Disclosed are vehicle parts and a manufacturing method thereof. The method comprises: a step of providing a first mold section (22), a second mold section (24), and a blocking member (26) movable between first and second positions; a step of providing a flexible element (121); a step of positioning the flexible element (121) in the vicinity of the first mold section or the second mold section; a step of providing a first cavity formed by the first mold section (22), the second mold section (24), and the blocking member (26) when in the first position; a step of injecting a first resin into the first cavity; a step of providing a second cavity (23) formed by the first mold section (22), the second mold section (24), the first resin (18), and the blocking member (26) when in the second position; a step of moving the blocking member (26) from the first position to the second position; and a step of injecting a second resin (20) into the second cavity (23). A trim panel comprises a piece of a molded member having a first base portion made of the first resin (18), a second base portion made of the second resin (20), and a buffer layer (112) at least partially covering one of the first base portion and the second base portion. Accordingly, the advantage of the panel is that materials and manufacturing costs can be reduced.

Description

Efficient Manufacturing Method Of Vehicle Parts

It is generally known to provide padded or cushioned vehicle interior parts. Vehicle interior parts that are padded or cushioned, such as trim panels (e.g., instrument panels, door panels, etc.), include a substrate made of a relatively rigid material, a relatively soft core (e.g., a foam core), And an external surface or skin.

For example, the vehicle door panel may be buffered to provide increased comfort to the driver of the vehicle when a part of the driver's body contacts the door panel.

Various methods of providing such cushions are known in the art, but these known methods do not provide for any particular advantageous trait and/or combination of traits. For example, one difficulty in producing a panel with a cushioning portion is that it can be difficult to optimize the position of the cushioning portion so that the cushioning portion is provided only in areas to which it is directly connected (e.g., contacted) by an individual. . Also, certain areas of the vehicle interior trim panel do not come into contact with passengers, such as the position above the door panel near the vehicle floor. There is little reason to provide a cushioning portion of the door panel in these areas. In addition, providing cushioning parts or areas in areas where it is not necessary to do so can add unnecessary costs (i.e., materials, labor and equipment) and add excess weight to the vehicle.

In order to provide a localized cushioning portion to an interior vehicle component, one known method involves bonding the cushioning component to a rigid component. For example, a relatively rigid panel (eg, a door panel) can be bonded to a component including a relatively rigid substrate, a relatively soft skin, and a foam interior portion. The difficulty with these methods is that these methods require the use of additional components (e.g., additional substrates, bolts or other fasteners to secure the panel substrate to the substrate in the cushioning section), and weight on the finished product. And add cost.

Accordingly, there is a need to provide a method for producing parts such as trim panels or other structures for vehicle interiors comprising relatively soft parts or sections. There is a need to provide a component with a local buffer zone that is optimized based on a location that is likely to be contacted by the vehicle driver or others. There is a need to provide a component with a localized buffer zone that has a reduced mass and requires less material than conventional components with a buffer zone. There is a need to provide an integrally formed vehicle part comprising a local buffer zone. There is a need to provide parts and methods for making parts that can be manufactured in a relatively simple and effective manner with reduced manufacturing and material costs. There is a need to provide a manufacturing method for producing parts having one or more cushioning parts using existing equipment.

It is generally known to provide a vehicle trim panel composed of multiple colors or multiple materials by connecting multiple pieces. These known trim panels are typically joined together in one assembly by conventional methods such as ultrasonic welding, heat staking or mechanical fastening. Another way to produce multi-colored trim panels is to cover certain areas and paint them with a certain color.

However, such multi-piece trim panels have several disadvantages including poor fit and finish due to component and assembly variations.

Accordingly, it may be desirable to provide a molded article that is molded into multiple colors, materials, fabrics, and the like. It is desirable to provide vehicle trim parts (eg, door panels, feet, instrument panels, consoles, etc.) having multiple colors and/or multiple materials. It is desirable to provide a multi-colour/multi-material trim panel that does not require a secondary bonding operation and is molded as a (fragmented) product that is not covered or painted. While aesthetically good, it would be desirable to provide a piece of multi-color/multi-material panel that creates unique styling opportunities that are not usually done because of the high cost of conventional methods, and poor fit and finish results. It is desirable to provide a trim panel having one or more of these or other desirable features. Providing a low-cost, reliable and versatile trim panel that avoids the above mentioned problems represents a significant advance in the art.

The present invention relates to a method for efficiently manufacturing vehicle parts. The method comprises the steps of providing a flexible element, providing a first mold section, a second mold section, and a first blocking member movable between the first and second positions, the first mold section, the second Providing a first cavity formed by the mold section and the obstruction member when in a first position, and by the first mold section, the second mold section, the first material and the obstruction member when in the second position. Providing a second cavity to be formed, placing a flexible element in the first cavity or the second cavity, injecting a first resin into the first cavity, and blocking from the first position to the second position. And moving the member, and injecting a second resin into the second cavity.

The present invention relates to a vehicle interior trim panel. The trim panel includes a first substrate portion made of a first resin, a second substrate portion made of a second resin, and a buffer layer at least partially covering one of the first substrate portion and the second substrate portion. It includes a piece molded member. In the piece molding member, the buffer layer is positioned into at least one of a first cavity and a second cavity, the first resin is injected into the first cavity, the retractor member is moved to form a second cavity, and the second cavity 2 The resin is formed by the process of being injected into the second cavity.

Other embodiments relate to various configurations and combinations of configurations shown and described in the disclosed embodiments.

In general, the part or molded article described herein is a molded article having one or more local or separate cushioning areas or portions. In one embodiment, the molded product is comprised of trim panels used in vehicles such as automobiles, airplanes, boats, etc., for example passenger cars, trucks, buses, and the like. By providing the trim panel with one or more local or separate cushioning areas or portions, the trim panel can optionally include compressible areas in areas that are likely to be touched by passengers or others without the need to provide cushioning to the entire trim panel. There will be. In this way, the buffer zone can be optimized based on the usual passenger experience. The advantage of such panels is that material and manufacturing costs can be reduced, and the relatively inefficient implementation of providing cushioning in areas not normally contacted by passengers can be eliminated.

The molded products described herein can be used in a variety of products, and can be applied generally to a variety of products where it is advantageous to provide a molded product having one or more local or separate cushioning areas or portions. As mentioned above, in one embodiment, the molded article is a trim panel for the interior of a vehicle. Such trim panels are particularly suitable for use in the interior cabin of a vehicle and may be useful in the form of door panels, dashboards, instrument panels, consoles, sidewall trims, overhead liners, other vehicle parts or portions thereof. While the disclosed embodiments may be described as vehicle trim panels such as door panels, the configurations of the disclosed embodiments include other panels, molded products and parts, offices using local compressible zones, home or educational, industrial, commercial or consumer products. Likewise can be applied to.

1 is a perspective view of an interior of a vehicle including a door panel and an instrument panel.
2 is a perspective view of a door panel according to the embodiment.
Fig. 3 is a perspective cross-sectional view of the door panel shown in Fig. 2 along line 3-3.
Fig. 4 is a detailed view of the door panel shown in Fig. 3;
Fig. 5 is an enlarged view of the door panel shown in Fig. 4;
Fig. 6 is a schematic cross-sectional side view of a mold having a slide member in an extended position and a resin injected into the first cavity.
Fig. 7 is a schematic cross-sectional side view of the mold of Fig. 3 with the slide member in a pulled position to form a second cavity.
Fig. 8 is a schematic cross-sectional side view of the mold of Fig. 3 with a slide member in a pulled position and a resin injected into the second cavity.
Fig. 9 is a schematic cross-sectional side view of the product molded in Figs. 6 to 8;
Fig. 10 is a schematic cross-sectional side view of a mold having a slide member in an extended position and a first shot of polymer material injected into a first cavity.
Fig. 11 is a schematic cross-sectional side view of a mold having a slide member in a pulled position and a second shot of polymer material injected into a second cavity.
Fig. 12 is a side cross-sectional view of the molded plastic product shown in Figs. 10 and 11;
13 is a side cross-sectional view of a plastic product molded with varying blocking shapes and angles.
Fig. 14 is a schematic cross-sectional side view of a mold with a slide member in an extended position.
Fig. 15 is a cross-sectional view of the interlocking interface of the first and second molding parts of Fig. 14 taken along line 15-15;
Fig. 16 is a cross-sectional view of the interlocking interface of Fig. 14 according to an alternative embodiment.
Fig. 17 is a schematic cross-sectional side view of a mold with a molded instrument panel and a slide member in a pulled position.
Fig. 18 is a schematic cross-sectional side view of a mold with a slide member in an extended position.
Fig. 19 is a schematic cross-sectional side view of the mold of Fig. 18 with a slide member in a pulled position.
Fig. 20 is a cross-sectional view of the mold with the elongated slide member of Fig. 15 taken along line 20-20.
Fig. 21 is a cross-sectional view of the mold with the pulled slide member of Fig. 18 taken along line 21-21.
Fig. 22 is a cross-sectional view of the mold with the elongated slide member of Fig. 18 taken along line 22-22.
Fig. 23 is a cross-sectional view of the mold with the pulled slide member of Fig. 19 taken along lines 23-23;
Fig. 24 is a cross-sectional view of the mold with the elongated slide member of Fig. 19 taken along line 24-24.
Fig. 25 is a cross-sectional view of the mold with the pulled slide member of Fig. 19 taken along line 25-25;
Fig. 26 is a cross-sectional side view of a mold configured to form a product from three materials using a first polymer material injected into a first cavity and two slide members in an extended position according to an alternative embodiment.
Figure 27 is a schematic cross-sectional side view of the mold of Figure 26 with a slide member in a pulled position.
Fig. 28 is a schematic cross-sectional side view of the mold of Fig. 27 having a second polymer material injected into a second cavity and a third polymer material injected into a third cavity.

Prior to describing various embodiments of the present invention in detail, the present invention is not limited to the details or methods described in the following description or shown in the drawings. The present invention may be in other embodiments and may be carried out in a variety of ways.

The terms used herein are for the purpose of description and should not be regarded as limiting.

In general, the part or molded article described herein is a molded article having one or more local or separate cushioning areas or portions. In one embodiment, the molded product is comprised of trim panels used in vehicles such as automobiles, airplanes, boats, etc., for example passenger cars, trucks, buses, and the like. By providing the trim panel with one or more local or separate cushioning areas or portions, the trim panel can optionally include compressible areas in areas that are likely to be touched by passengers or others without the need to provide cushioning to the entire trim panel. There will be. In this way, the buffer zone can be optimized based on the usual passenger experience. The advantage of such panels is that material and manufacturing costs can be reduced, and the relatively inefficient implementation of providing cushioning in areas not normally contacted by passengers can be eliminated.

The molded products described herein can be used in a variety of products, and can be applied generally to a variety of products where it is advantageous to provide a molded product having one or more local or separate cushioning areas or portions. As mentioned above, in one embodiment, the molded article is a trim panel for the interior of a vehicle. Such trim panels are particularly suitable for use in the interior cabin of a vehicle and may be useful in the form of door panels, dashboards, instrument panels, consoles, sidewall trims, overhead liners, other vehicle parts or portions thereof. While the disclosed embodiments may be described as vehicle trim panels such as door panels, the configurations of the disclosed embodiments include other panels, molded products and parts, offices using local compressible zones, home or educational, industrial, commercial or consumer products. Likewise can be applied to.

Referring to a preferred embodiment, FIG. 1 is a perspective view of an interior of a vehicle having a door panel 110 and an instrument panel 111. Referring to Fig. 2, the door panel 110 is a local or separate cushioning area in an area or portion (relatively padded or denoted by a compressible or cushioning layer or area 112) that is likely to be contacted by a passenger or another person. Includes. For example, the door panel 110 is an area where a part of the passenger's body is likely to come into contact with a door panel, for example, an armrest 114, an adjacent window sill 116, etc. It includes a buffer area 112 on. This configuration allows areas that are typically not contacted by the passenger, shown by one or more portions 118, to be made of a relatively hard plastic or other material. For the sake of description, reference is made only to the door panel 110, but those skilled in the art will understand that the description applies to other trim panels, such as instrument panels and the like.

The method of providing a localized buffer zone in the manner described herein can be used to provide molded articles having a wide variety of shapes. For example, one or more portions 118, such as rigid plastic on the door panel 110, e.g., bezels, aacents, appliques, pull cups, etc. For example, regions, zones, isolated portions, and the like may be provided. In another example, the door panel 110 may be formed in a complex shape, for example, ball armrests, x, y, z boundaries, or the like. In yet another example, door panel 110 may include raised (eg, raised) or recessed cushioning areas for improved aesthetics.

According to an embodiment, the door panel 110 comprises a member or element in the form of a relatively rigid substrate, a base, a layer (referred to herein as “substrate 120” for simplicity) and a buffer zone 112. Generally includes. The buffer zone 112 is disposed adjacent or proximate to at least a portion of the substrate 120 and includes a flexible element 121. The flexible element 121 comprises, for example, a coverstock, a skin 122, such as a cover material, and a filler or compressible material ( 124) may be optionally included. In accordance with various embodiments, some or all of the substrate 120 may have a buffer zone 112 provided adjacent thereto.

Further, according to various embodiments, another portion of the skin 122 may be separated from the substrate by the compressible material 124, while a portion of the skin 122 may be in direct contact with the substrate 120. In this way, one or more localized areas are provided with selectively varying amounts or degrees of cushioning while retaining the look and feel of the skin even in those areas where no additional cushioning of compressible material 124 is provided. According to the specific embodiment shown in FIG. 3, the cushioning zone 112 includes a first compressible zone 152 disposed in an area where the skin 122 directly contacts the substrate 120, and the compressible material 124 is a skin. 122 and a second compressible zone 154 disposed in a region provided between the substrate 120.

According to an embodiment, the cushioning zone 112 is disposed to cover at least a portion or a portion of the substrate 120. The skin 122 forms at least a portion of the exterior surface of the part (eg, the portion visible in the cabin commonly referred to as the “A” surface, etc.). According to an embodiment, portion 126 of substrate 120 forms part of an outer surface. The boundary 128 between the substrate and the skin may be provided as a recess 36 such as a seam, interface or joint, for example. This boundary 128 may be visible on the exterior surface or may be filled with a material to provide a "even" appearance for the part. The formation and shape of the recess portion 36 is described below.

According to an embodiment, the skin 122 is made of a relatively soft or flexible material, that is, a flexible sheet, including a polymer material such as, for example, thermoplastic olefin (TPO), polyurethane, polyvinyl chloride (PVC), etc. do. According to another embodiment, the skin 122 may be made of other materials and includes a fabric such as a cloth, leather, a composite material, for example a layered material such as a layer of leather applied over a layer of polymer material, and the like.

According to a preferred embodiment, the skin 122 is provided on the substrate 120 in such a way that the compressible material 124 (if present) is disposed between or intermediate at least a portion of the skin 122 and the substrate 120. According to an embodiment, a portion of the skin 122 may be provided in direct contact with the substrate 120, such that the compressible material 124 is disposed in one or more specific areas between the skin 122 and the substrate 120. . The particular selected structure may depend on a variety of factors including the desired look and feel of the exterior surface of the part, material cost, ease of manufacture, and the like.

According to an embodiment, the skin 122 may be manufactured or produced using any one of various processes. According to a preferred embodiment, the skin 122, for example a TPO sheet, is heat formed (eg, vacuum formed, press formed, etc.) and then trimmed into a predetermined shape or shape. In the vacuum forming process, a pre-cut or formed sheet of polymeric material is provided to a mold and heated to soften the material. A vacuum is applied to the mold, and the softened polymer material is drawn out to the wall of the mold. Thereafter, the polymeric material is cooled and retains the shape formed by the mold wall. The formed sheet can be trimmed to a predetermined size.

According to an alternative embodiment, the skin 122 is formed by a slush shaping process. For example, a thermoplastic material in liquid or powder form is introduced into a temperature controlled mold to form a viscous skin adjacent to the mold wall. Once the skin is formed, the excess material is removed from the mold and the skin is cured and cooled, and then separated from the mold. According to another alternative embodiment, the skin 122 may be manufactured according to a variety of different methods. For example, the skin can be formed in a spray molding process to form a polymer skin, an extrusion process, for example a casting process such as gravity casting, or other suitable process.

According to an embodiment in which the skin 122 is made of a polymeric material, the skin has a thickness of between about 0.1 and 2.0 mm, most preferably between about 0.8 and 1.0 mm.

The skin 122 may have a size, shape, and shape configured according to a shape included in the substrate 120. The size, shape, and shape of the skin 122 and the substrate 120 may have various shapes, and a relatively complex shape may be formed.

The compressible material 124 may be bonded (eg, bound, melted, bonded, fixed, attached, etc.) to the skin 122 and disposed between the skin 122 and the substrate 120 to act as a filler. Such a material is relatively soft or acts as a cushioning material, and at least partially provides a cushioning member having a relatively soft or cushioning property. In a preferred embodiment

According to this, the material is a polymeric material such as a foam material (eg, upethane foam over open cell foam, closed cell foam, etc.).

Substrate 120 may be made of a suitable material including any one of a variety of polymers such as polypropylene, polyethylene, copolymer, and the like, for example. The substrate 120 can be formed in a wide variety of shapes, sizes and shapes (see, for example, FIG. 1 showing a door panel 110 according to an embodiment having a zone of local buffering), and various other shapes. (For example, door locks and openings for handles, internal molding structures, etc.) may be included. The substrate 120 may be a standalone part or a part within a larger assembly (e.g., the substrate may be an entire door panel or a portion thereof, etc.) According to an embodiment, the substrate 120 may be described in detail below. Can be made from a process that allows multiple materials and/or multiple colors to be assigned (position, placement, molding, etc.) in different parts of the substrate.

As shown in Figure 3, a visible boundary (e.g., a seam or joint) is formed or provided between the skin 122 and the substrate 120, so that the substrate 120 forms a frame around the skin 122. do. The size, shape, and shape of the border may vary in various embodiments. The boundary can be removed or reduced in size using a material for at least partially filling within the boundary, such as a caulk, adhesive, liquid polyper, or other material. According to another embodiment, the skin 122 and the substrate 120 may be provided in a manner that minimizes the visible boundary. Figure 5 shows an embodiment that initiates the bonding between the skin and the substrate.

Any of a variety of shapes can be used for the interface of the skin and the edge of the substrate. According to an embodiment, the flange 130 shown in FIG. 4 is formed over the skin 122 by forming a vacuum mold to form a protrusion, for example by providing the edge of the skin having a "fold back" shape. Thereafter, the substrate 120 is molded around the flange 130 of the skin 122. According to a preferred embodiment, the skin 122 and the substrate are bonded together to provide a relatively airtight and/or watertight seal. In one example, the skin includes a flange 130 extending substantially completely around the periphery of the skin 122 and the substrate 120 (e.g., substantially around the periphery of the area on which the skin 122 is provided. Is molded around the flange 130) to form a channel or groove that extends completely to accommodate the flange 130. Various sizes, shapes, and shapes may be used for the protrusions or flanges and openings or grooves to couple the skin 122 to the substrate 120.

According to an embodiment, the door panel 110 is disclosed with an integral support and armrest. The present invention uses a die-cut compressible material 124 such as a die-cut hermetic cell foam that is attached (via a pressure sensitive adhesive or similar process) to the vacuum-shaped skin 122. The part is then placed into the tool so that the plastic is molded around the assembly to form the substrate 120. If compressible material 124 (and skin 122) is present, there is a soft compressible feel to the part. If there is no compressible material 124 behind the skin 122, the part has a tighter feel. Using this innovative process, door trim panels can be manufactured to have multi-colored or woven or soft parts.

According to an embodiment, a method of forming a molded product or part includes forming the skin 122, bonding the compressible material 124 to the skin 122, molding the skin 122 and the compressible material 124 Positioning within and forming a rigid substrate around skin 122 and compressible material 124, wherein compressible material 124 is disposed between skin 122 and substrate 120. The method provides a first compressible zone in which the compressible material 124 is disposed between the skin 122 and the substrate 120, and includes a second compressible zone in which the skin 122 is directly bonded to the substrate 120. I can. The substrate 120 may comprise a molded polymer material. The skin 122 may be formed by forming a vacuum and trimming the sheet. The sheet can be a thermoplastic olefin. The compressible material 124 may be a foam material such as a closed cell foam. The foam can be coupled to the skin 122. The skin 122 may include a flange 130, and the substrate 120 may be molded to at least partially surround the flange 130. According to an embodiment, the molded product or component may be the door panel 110. Skin 122 may be formed first, then compressible material 124 is bonded to skin 122 and then substrate 120 is molded from skin 122 and compressible material 124. Forming the substrate 120 includes spray molding a plastic material.

According to one embodiment, the substrate is formed from a single material as a single jet. In other embodiments, the substrate may be formed by a process that allows multiple materials to be assigned to different portions of the substrate. According to an exemplary embodiment, the process of making such a substrate involves multiple injections into a mold that is reconstituted during the molding operation. As used herein, the terms "multi-color", "multi-material", "multi-color", "multi-shot" and "other" polymer (or "plastic", "polymer material", "polymer resin "Etc.) is a broad term and is not a limiting term. The specific materials used to construct the embodiments are exemplary. The resin may be various colors of the same polymer, different polymers having the same color, different polymers having different colors, and the like. Any of a variety of materials can be used and include polymers such as thermoplastic, thermoset, elastomer, and the like. For example, polypropylene, polyethylene, high concentration polyethylene, acrylonitrile butadiene styrene ("ABS"), polycarbonate, vinyl, polyester, polyurethane, thermoplastic elastomer (TPE), thermoplastic elastomer polyolefin (TPO), thermoplastic vulcanizates (TPV), polyvinyl chloride (PVC), nylon, homopolymer plastics, copolymer plastics, plastics containing special additives, filled plastics, and the like may be used. One of a variety of thermosetting resins such as phenolic resins, thermosetting polyesters, silicones, polyurethane elastomers, and the like can be used.

In addition, one of various elastomer resins such as rubber, butyl, synthetic elastomer (SBR), and the like may be used. One or more molded together or molded sequentially may be polymers. Although the molding operation is preferably injection molding, one of a variety of molding operations can be used, such as reactive injection molding (RIM), transport molding, and the like. Descriptions or claims using or reciting "first resin" and "second resin", "first polymer material" and "second polymer material", or "first color" and "second color" are terms in a broad sense. And is not limited to one or more resins, materials, or colors (ie, cover products having three, four, etc. resins, materials and colors, or combinations thereof).

The method is further disclosed and described below, but for example, a multi-color/multi-material trim panel of pieces is generally using multi-shot molding techniques such as injection molding, spin molding, conveying molding, overmolding, etc. To produce. The mold comprises a second mold section shown as core 24, a first mold section shown as cavity 22 and a blocking member or retractor 26. A first "shot" of a polymer resin material (representing the first portion 18 of the trim panel 110 or 111) is in the first cavity formed by the retractor 26, the core 24 and the cavity 22. It is constrained within the mold corresponding to a specific area of the trim panel. When the first cavity is filled with a polymer resin, the retractor 26 is displaced (preferably approximately by the thickness of the part) by the displaced retractor 26, the cavity 22, the core 24 and the first polymer resin. It provides a second cavity to be formed. A portion related to the first cavity and the second cavity among the portions of the first mold section is referred to as a first portion and a second portion of the first mold section, respectively, and a portion related to the first and second cavities among the portions of the second mold section Are referred to as the first part and the second part of the second mold section, respectively. Thereafter, a second “shot” (representing the second portion 20 of the trim panel 110 or 111) flows to the first material boundary and fills the second cavity with a polymer resin that binds it. According to an embodiment, the second shot is provided by a secondary injection unit. Preferably, the retractor 26 provides a barrier to the polymer resin from contacting the mold so that there is a gap or gap between the retractor and the opposite mold section, whereby the resin fills the first space. Vents are provided to allow air to exit the first cavity. Thus, the retractor does not need to actually contact the cavity surface in the first position to prevent the flow of material to the second cavity. Instead, depending on the viscosity of the molten resin, the retractor may be offset from the second mold section (ie, the core) (eg, may not be in contact with the second mold section).

Thus, the retractor can be blocked relative to the core or offset relative to the core. According to a preferred embodiment, when the second material is injected, the first material is at least partially solidified.

Compared to conventional multi-piece substrates, there are many excellent opportunities to be implemented with multi-shot substrates (substrates formed by a process involving multiple jetting of plastic into a mold). For example, a two-colored color boundary can pass through an aperture or other part (eg, transition, pass, etc.). The isolated color dispersion, which makes one configuration appear separate, can be implemented in trim panels in pieces, such as speaker grilles or map pocket borders, molded in different colors.

The multi-colored column trim allows flow from the front to the rear of the interior without the need to disassemble the trim into multiple pieces.

Lock can be provided. Accents in scarf plates and other trims can be produced within the copper fragment. Part separation does not need to indicate the location of the color decay. Specific details and features may be emphasized in different colors.

1 is a perspective view of a door panel 110 and an instrument panel 111 according to a preferred embodiment. The instrument panel 111 and the door panel 110 are shown according to a preferred embodiment, which is a single tool injection molded substrate by adding a partial mold behind a soft covering layer such as a skin or cover stock, for example. The unity of the two colors is shown within. The addition of a partial mold back (PMB) skin 122 is intended to reduce manufacturing costs, as well as flexibility (e.g. design and manufacturing) and finesse ( For example, less fitting parts, fasteners, and additional manufacturing steps that can degrade quality) increase. The process is intended to be fluid in that the laminate or substrate can be of a wide variety of materials, colors and fabrics. The color of the injection molded substrate can be varied without changing to the tool.

The material injected behind the substrate may be translucent in nature, and an LED or conventional lamp (or one of a variety of light sources) is placed at the rear of the panel to illuminate the exposed edge of the material (see border 156 in Fig. 2) from the rear. To be positioned or attached.

In addition, this process eliminates the assembly of various parts that can lead to non-small gaps, mechanical noise and other technical problems.

In contrast, conventional methods of manufacturing trim panels require multiple tools to create a separate dark color on the substrate and separate tools to create a backing with a stack. When these pieces are created, there is an assembly process for the bonding of the three separate substrates, which requires additional capital, labor and manufacturing area. The disclosed invention combines all of these into one injection molding tool. The skin 122 is placed into the tool, and the tool is sealed. The first color is sprayed behind the skin 122 and forms a trim ring around the edge of the skin 122 on the "A" side of the part. Thereafter, the second color is sprayed onto the tool and combined with the first color. The part exits the molding machine in complete condition as an auxiliary part to be added later in the molding machine. This significantly reduces the molding, capital and assembly costs for trim manufacturing.

According to an embodiment, a process for forming an integral molded trim panel having one or more cushioning zones 112 and a multicolored and/or materialized substrate 120 is provided in a single mold or tool. The mold includes a core, a cavity and a retractor. A skin 122 (which may be a preformed three-dimensional shape or a flat sheet, etc.) is loaded into a mold and placed within a first cavity (ie, one of the color or material zones). The skin 122 may be one of a variety of materials, and includes an epitaxial material such as a cloth with a foam support, polyvinyl chloride (PVC) with a foam support, TPO with a foam support, wood metal, etc. It is not limited. The skin 122 is fixed in position by any one of a variety of means, such as, for example, by a preformed shape conforming to the mold, pins, vacuum assistance, or the like. Thereafter, the mold is partially closed in preparation for a low pressure molding operation. The amount of gap provided by the partially enclosed mold will depend on the type of skin used. (According to an alternative embodiment, the mold is completely sealed.) The inner surface of the core 24 at least partially accommodates the first protrusion 29 extending from the cavity 22 by forming a recess. The first protrusion 29 can be one of a variety of members extending from the surface of the core, such as, for example, a blade, a pin, or the like, and is configured to position and/or hold the end of the coverstock or skin in place.

Thereafter, molten plastic for the first member part, for example a first color and/or a first material, is injected or sprayed behind the cover stock. Thereafter, the mold is completely sealed with the plastic being injected. The injection of plastic and sealing of the mold is configured to press the skin 122 against the mold. The first shot of plastic material is constrained in the mold corresponding to a specific area on the trim panel by means of a retractor or slider mechanism. The retractor, core and cavity provide a first cavity.

When the first cavity is filled with plastic, the retractor is displaced (preferably approximately the thickness of the part). According to a preferred embodiment, the retractor is displaced to provide a second cavity (formed by the displaced retractor, cavity, core and first material). Then, the second shot fills the second cavity and the plastic flows to the first material boundary and is joined.

Thereafter, the mold is opened and the finished part is separated. According to an embodiment, the second shot is provided by a secondary injection unit. The retractor provides barrier for the plastic by contacting the opposite side of the mold. According to a preferred embodiment, the first material is at least partially solidified when the second material is injected.

Preferably, this may be an alternative, but the part of the trim panel with the skin 122 is first molded so that the mold does not open during the operating cycle. The amount of gaps left in the partially enclosed mold depends on a variety of factors including the type of cover stock or skin 122 used, the shape of the part, and the like. According to an alternative embodiment, the first and second materials are the same color and material and the retractor is not used so that both the primary and secondary cavities are filled at the same time. The process of integrating the multiple colors of the material substrate with the partial mold back is to lower costs and eliminate area, assembly capital investment and increased craftsmanship. The material used for the substrate is one of a variety of polymers and includes, but is not limited to, polypropylene, TPO, filled plastic, polycarbonate ABS blend, ABS or various other materials.

For example, different "materials" used in the disclosed methods may be different colors of the same plastic resin, and are configured to provide different fabrics and the like. The different materials may be different plastic resins of the same or different colors. The disclosed process can be used for one of a variety of molded plastic products, including vehicle parts.

The molded member of the piece further comprises "A", that is, a surface of the molded product visible to the vehicle driver and a surface of "B" The "A" surface is generally formed by a portion of the polymer resin injected first, a portion of the polymer resin injected second, and an interface between two polymer materials (eg, in a recess or groove).

Some of the overlapping two impregnated polymer resins are generally not visible. The recess is located above the "A" surface. When portion 18 or portion 20 provides a “A” surface, a rigid surface may be provided, and the skin 122 or a stack of skins 122 and filler or compressible material 124 may be “ When providing an A" surface, a smooth or compressible surface may be provided.

The retractor forming part of the block may be perpendicular or angled to the direction of the die (mold, tool, etc.) withdrawal. According to the embodiment shown in Figures 6-9, the vertical retractor surface is configured to provide a "square" recess (eg, ditch, recess, etc.) at the boundary of the two shots. According to another embodiment shown in Figs. It is configured to provide an angled recess 36 for concealing.

This angular block 28 creates an apparent geometric gap or transition that may be more desirable for some molded products than a square mechanical recess because it can hide the material joint. Such a shape may be used to hide the interface between the skin 122 and the substrate 120 and/or hide the interface between the boundaries of two shots.

Referring to FIGS. 14 to 16, in order to improve the strength of the boundary between two shots, a geometry to be coupled to each other is generated to provide mechanical fixation in addition to the existing chemical bonds.

17 shows another exemplary molded article shown as part of the instrument panel 111. The instrument panel 111 includes an upper or first portion 18 molded into a first shot and a second or lower portion 20 molded into a second shot. The skin 122 is disposed in front of the upper portion 18. Fig. 17 is a side cross-sectional view of a vehicle instrument panel 111 having a square recess 36b separating an upper portion 18 and a lower portion 20. The lower part 20 of the instrument panel 111 comprises a glove box part 20a (which forms the rear wall of the glove box) and an outdoor section (which typically provides a glove box door not shown on a shiny surface). 20b). According to the embodiment, the upper portion 18 of the instrument panel 111 is first molded and then the lower portion of the instrument panel 111 is molded.

The blocking surface on the retractor (perpendicular or angled to the die draw) is designed to withstand the molding pressure and prevent the injected plastic from flowing into other areas of the tool. 20-25 show exemplary cross-sections of a boundary recess or a ditch of two shots of square and angled shape that can be applied to molded products such as trim panels, instrument panels, and the like. For example, the door panel 110 includes a first portion including a first color and a second portion including a second color.

Part of the trim panel is manufactured using a mold that is reconstituted during the molding operation during a process with a blocking step so that different colored plastic resins are injected into the mold at different times.

6 shows an exploded cross-sectional view of a mold during a molding operation for an instrument panel. According to an embodiment, the mold comprises a first mold section or cavity 22, a second mold section or core 24 and a slide blocking member or retractor 26. Preferably, the retractor 26 is disposed at least partially within the core 24. Preferably the "A" surface (or "shown surface") of the molded article is provided by the cavity 22 and the "B" surface is provided by the core 24. According to an alternative embodiment, the retractor is disposed within the cavity and/or the “A” surface is provided by the core. In embodiments, the “A” surface (provided by the substrate as a skin) may be stamped, molded or stamped with one of a variety of markings or mockups, such as, for example, wood grain or the like.

According to an embodiment, the retractor 26 is configured to move between a first position and a second position shown by the broken line during the forming operation. (According to an alternative embodiment, the retractor is configured to move to three or more positions, for example a third position, etc.) The slide or retractor 26 is (when the mold section is open, the slide is It can be moved using a variety of methods including a spring loaded wedge system, hydraulic, pneumatic, mechanical, etc. to move backward).

The mold shown in Fig. 6 includes a vent 27 between the retractor 26 and the cavity 22. A vent 27 is provided by a retractor 26 that does not block the cavity 22 (i.e., there is a gap or gap) so that the first polymer resin is injected into the first cavity while the air from the first cavity is It can be exited through the vent 27. According to another embodiment, the retractor may be designed to "block" the cavity by contacting the mold (ie, no vent). According to another alternative embodiment, the lower part 20 of the molded article (instrument panel) can be initially molded, for example by rotating the retractor around it for the geometry shown.

10 and 11 show the movement of the retractor 26 to provide a first cavity and a second cavity during a subsequent forming operation. Referring to Fig. 10, for a first shot 30, a retractor 26 seals half the cavity of the mold to prevent the first shot from entering the upper portion of the tool (shown as the second cavity). The first shot is injected into the first cavity.

Referring to Fig. 11, for a second shot of resin forming the second portion 20, the retractor 26 is pulled rearward to open the upper portion of the tool and provide a second cavity. Preferably, the retractor 26 moves approximately the wall stock thickness.

When the second shot is injected and reaches the first material, it stops flowing. Figure 12 shows the finished part.

Referring to Fig. 13, an example of a blocking geometry is shown. The blocking geometry causes the intersection or boundary of the two materials (injection or shot) to be obscured from view. According to an embodiment, this blocking shape provides a recess 36a having an outer surface angled with respect to the major surface of the molded part. According to a preferred embodiment, the recessed portion 36a is angled such that the boundary surface of the two materials is hidden, for example, at least partially, substantially, etc. from the gaze of the vehicle driver. According to an embodiment, the angled recess geometry is provided by an angled blocking surface. Referring to Figure 11, arrow 38 shows the direction of withdrawal of the retractor and mold die.

Referring to Figures 14 to 16, a geometry that engages with each other is created to provide a mechanical lock in addition to a chemical binder, for example a molten polymer resin, which is present to improve the strength of the boundary of the two shots. According to a preferred embodiment, the molded article comprises geometry and angular interlocking interlocking. 14 is an exploded side cross-sectional view of a mold configured to provide a mechanical interlock 40 to a molded article. Mechanical mutual fasteners 40 are provided by one or more (or series) protrusions and/or recesses on the retractor. Fig. 15 shows a section of a square mechanical mutual fastener 42 in which the protrusions and/or recesses on the retractor have a square cross section. FIG. 16 shows a section of a dovetail mechanical interconnect 44 having angled sides with protrusions and/or recesses on the retractor (eg, to provide additional interlocking and directional stability). The first shot of the resin forming the first portion 18 is, for example, a first color, and the second shot of the resin forming the second portion 20 is a second color. Therefore, the fixing direction is vertical.

Figures 18 and 19 illustrate a retractor system that allows a vertical wall (for use in forming at a corner, for example) to be of full material thickness (parallel to the die draw). 18-19 are horizontal sections of a mold with a core 20, a cavity 22, a first retractor 26a, a second retractor 26b and a secondary slide 68. (For example, secondary slide 68 provides internally molded details for a particular molded article (ie, a recess that receives an end cap for an instrument panel).)

As shown, the use of a second retractor 26b is used to provide additional wall thickness.

26 to 28 show a process of molding a molded product (trim panel 10a) with three resin shots. Fig. 26 is a cross-sectional view of a mold configured to form a product having three materials using two slide members in an extended position and a first polymer material injected into a first cavity according to an alternative embodiment. Figure 27 is a schematic cross-sectional side view of a mold with a slide member in a pulled position. Fig. 28 is a schematic cross-sectional side view of a mold having a second polymer material injected into a second cavity and a third polymer material injected into a third cavity.

The method produces a piece of multi-color/multi-material trim panel 10a by integrating three resin materials into a single substrate using a multi-shot molding technique. The mold comprises a cavity 22, a core 24, a first retractor 26a and a second retractor 26b.

The skin 122 is secured in its position by one of a variety of means (eg, by a preformed shape conforming to the mold, pins, vacuum assist, etc.). Thereafter, the mold is completely or partially closed in preparation for the molding operation. The inner surface of the core 24 at least partially receives the first protrusion 29 extending from the cavity 22 by forming a recess. The first protrusion 29 can be one of a variety of members extending from the surface of the core (eg, blades, pins, etc.) and is configured to position and/or secure the end of the coverstock or skin in place.

A first shot of polymeric material 18 is constrained in the mold corresponding to a specific area on the trim panel 10a by retractors 26a, 26b.

The mold shown in Fig. 26 includes a vent 27a between the retractor 26a and the cavity 22, which is a first blocking member, and a vent 27b, between the retractor 26b and the cavity 22, which is a second blocking member. do. According to an alternative embodiment, the retractor is designed to block against the cavity (ie, there is no vent). A portion protruding from the first mold section facing the first blocking member 26a, a portion protruding from the center of the first mold section, and a portion protruding from the first mold section facing the second blocking member 26b, respectively. It is referred to as a first protrusion, a second protrusion, and a third protrusion. The portions of the skin 122 extending past the first protrusion and the second protrusion are referred to as a first edge of the skin and a second edge of the skin, respectively.

When the first cavity is filled with the polymer resin 18, the first retractor 26a is displaced (by the displaced first retractor 26a, the cavity 22, the core 24 and the first material 18). A second cavity 23a is provided, and the second retractor 26b is displaced (preferably approximately by the thickness of the part) to be displaced (displaced second retractor 26b, cavity 22, core 24). ) And a third cavity (23b) formed by the first material (18). A portion of the first mold section that is related to the third cavity is referred to as a third portion of the first mold section, and a portion of the second mold section that is related to the third cavity is referred to as a third portion of the second mold section. The first retractor 26a and the second retractor 26b are configured to move between a first position and a second position during the forming operation (i.e., the mold can be reshaped). The first retractor 26a and the second The retractor 26b may be configured to move simultaneously or at separate times. The second polymer resin 20a and the third polymer resin 20b may be configured to be injected at the same time or at different times. According to an alternative embodiment, the retractor may be configured to move to three or more positions (eg, a third position, etc.) during the forming operation. The retractor 26 can be moved using a variety of methods including a spring loaded system, hydraulic, pneumatic, mechanical, and the like (so that when the mold section is opened, the slide moves backward to one of the mold sections).

Thereafter, a second shot of the polymer material 20a (representing the second portion of the trim panel 10a) fills the second cavity 23a and the polymer flows to the first material boundary to join. The second shot can be provided by a secondary injection unit. According to a preferred embodiment, the first material is at least partially solidified when the second material is injected.

Thereafter, a third shot of the polymer material 20b (representing the third portion of the trim panel 10a) fills the third cavity 23b and the polymer flows to the first material boundary and bonds. The third shot may be provided by a third injection unit. According to a preferred embodiment, the first material is at least partially solidified when the third material is injected.

Referring to Figures 26 to 28, the process may be in one of various orders. For example, the first retractor 26a may be moved before the second retractor 26b, and then the polymer material may be injected simultaneously or sequentially. Alternatively, the first retractor can be moved before (or after) the second retractor and the polymeric material can be injected simultaneously or sequentially (eg, before, during and after the movement of the remaining retractors).

The configuration and arrangement of the elements of the vehicle trim panel as shown in the preferred and other exemplary embodiments are merely exemplary. While only a few embodiments of the invention have been described in detail herein, those skilled in the art reviewing this specification will be able to (see examples)

For example, it will be easy to see that many changes are possible: size, dimensions, structure, shape and ratio of various elements, values of variables, mounting arrangement, material, color, orientation, etc.) For example, a molded product may have several colors in one part, such as a two-tone door exterior and a separately colored sail panel. Separate parts can connect two colors without matching problems. Isolated color dispersion (such as around an internally molded speaker grill and map pocket to make it look separate) can also be used. In addition, such molded products may have separate requirements for parts that are not dictated by the color dispersion location, such as the quarter trim and B pillar trim of the vehicle. Small details can also be achieved that can cause registration or masking problems. Small details such as highlighting of cargo hooks or fixed hooks can also be molded inside. Further, the molded product or part may be provided in a wide variety of sizes, shapes, and shapes according to various exemplary embodiments. Certain materials used to construct the exemplary embodiments are also exemplary. For example, heat such as polypropylene, high concentration polyethylene, other polyethylene, acrylonitrile butadiene styrene ("ABS"), polyurethane, nylon, homopolymer plastics, copolymer plastics, plastics containing special additives, filled plastics, etc. Various materials can be used to form the substrate layer, including plastic resins. “Buffer area”, “local buffer area”, “multi-color”, “multi-shot”, “multi-material” and “multi-colors” are terms in a broad sense and are not limiting terms.

Accordingly, all such modifications will be included within the scope of the present invention as defined in the appended claims.

The order or sequence of any process or method steps may be changed or rearranged according to alternative embodiments. Any means and functional provisions in the claims will encompass the described functions and structural equivalents as well as structures described herein that perform equivalent structures. Other substitutions, changes, changes and/or omissions may be made within the design, operating conditions and arrangements of the preferred and other exemplary embodiments, as expressed in the appended claims, without departing from the spirit of the invention.

Claims (3)

Is a method of manufacturing vehicle parts,
A first mold section, a second mold section, a first protrusion extending from the first mold section, a second protrusion extending from the first mold section, a third protrusion extending from the first mold section, the first protrusion Providing a first blocking member opposite to and movable between a first position and a second position, and a second blocking member opposite to the third protrusion and movable between a first position and a second position. Wow,
The first protrusion, the first part of the first mold section, the first part of the second mold section, the second protrusion, the first blocking member when in the first position and when in the first position Providing a first cavity formed by the second blocking member of,
Providing a skin having a first edge and a second edge, and
The first edge of the skin extends past the first protrusion and the second edge of the skin extends past the second protrusion, between the first protrusion and the second protrusion, in the vicinity of the first mold section. Placing the skin in the first cavity,
Injecting a first resin, wherein the outer surface of the vehicle part is provided by the skin and the first resin, into the first cavity and between the skin and the first portion of the second mold section and the first Injecting the first resin between the first portion of the first mold section and the first portion of the second mold section,
A second portion of the first mold section, a second portion of the second mold section, a first edge of the skin, the first resin, and a first formed by the first blocking member when in the second position Moving the first blocking member from the first position to the second position to provide a 2 cavity,
Injecting a second resin into the second cavity and bonding to the first resin and the first edge of the skin,
A third portion of the first mold section, a third portion of the second mold section, a portion of the first resin disposed between the first mold section and the second mold section, and when in the second position Moving the second blocking member from the first position to the second position to provide a third cavity formed by the second blocking member of,
Injecting a third resin into the third cavity, comprising injecting a third resin so that a part of the third resin is bonded to the first resin. The method of claim 1, wherein the first blocking member includes a recess for receiving the first edge of the skin. The method of claim 1, wherein the second blocking member comprises a front surface, a first side surface, a second side surface sharing an edge with the front surface, and an inclined surface extending between the front surface and the first side surface, ,
The step of injecting the third resin is provided by the inclined surface of the second blocking member so as to hide the interface between the first resin and the third resin from the occupant inside the vehicle, and A method of manufacturing a vehicle part comprising the step of forming an inclined recess in a molded article having an upper surface provided at a flat angle with respect to a vertical plane.

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