Vacuum forming device for decorative plate of environment-friendly instrument

Abstract

The invention relates to the technical field of instrument decorative plate processing, and discloses an environment-friendly instrument decorative plate vacuum forming device which comprises an upper box body and a lower box body, the upper box body is vertically and movably arranged over the lower box body, the upper box body and the lower box body are closed to form a processing cavity, and a lifting unit used for bearing an instrument decorative plate is arranged at the bottom of the lower box body; an ultrasonic welding assembly is arranged in the upper box body, the ultrasonic welding assembly is provided with a profiling welding head matched with the surface of the instrument decorative plate, and a heating unit is installed in the upper box body. According to the vacuum forming device for the environment-friendly instrument decorative plate, firstly, the membrane is pre-attached to the instrument decorative plate, then the membrane is accurately welded to the area, needing to be coated, of the instrument decorative plate through the ultrasonic welding assembly, the bonding strength of the membrane and the instrument decorative plate is enhanced, the instrument decorative plate is convenient to take down, and the working efficiency is improved. And the film covering efficiency and the film covering quality of the instrument decorative plate are greatly improved.

Description

Technical Field

[0001] This invention relates to the field of instrument panel processing technology, and more specifically, to an environmentally friendly instrument panel vacuum forming device. Background Technology

[0002] The dashboard trim panel is a core component of the car interior that combines functionality and aesthetics. Located between the front seats and the windshield, it is typically a thin-walled, large-span curved surface structure. It is one of the most eye-catching design elements in the cockpit, directly affecting the driving experience and the overall style of the vehicle. The surface of the dashboard trim panel is usually covered with a decorative film to enhance its visual appeal.

[0003] A Chinese patent with publication number CN113414975A ​​discloses a TOM molding device for automotive interior parts. By changing the pressure inside the upper and lower chambers and keeping the two ends of the decorative film taut, it heat-coats the film under a set pressure to ensure the adhesion of the decorative film. However, during the heat-coating process, the decorative film may stick to the fixture (the loading mold used to fix the instrument panel), making it difficult to remove the coated instrument panel, and may even cause the decorative film on the instrument panel to be torn or peeled off. Summary of the Invention

[0004] The purpose of this invention is to overcome the defects in the prior art and provide an environmentally friendly vacuum forming device for instrument panel decorative panels that uses ultrasonic welding components to precisely coat the parts of the instrument panel that require coating.

[0005] To achieve the above objectives, the technical solution of the present invention is to provide an environmentally friendly instrument panel vacuum forming device, comprising: an upper box and a lower box, the upper box being movably positioned above the lower box, the upper box and the lower box being closed to form a processing cavity, a lifting unit for supporting the instrument panel being provided at the bottom of the lower box, an ultrasonic welding assembly being provided inside the upper box, the ultrasonic welding assembly being provided with a conformal welding head that mates with the surface of the instrument panel, and a heating unit being installed inside the upper box; An upper membrane assembly is connected to the outside of the lower housing. The upper membrane assembly is used to transport and cut the membrane. The membrane is sandwiched between the upper housing and the lower housing. When the upper housing and the lower housing are closed, the membrane divides the processing chamber into an upper chamber and a lower chamber. The upper chamber is connected to a first air pressure regulating unit, and the lower chamber is connected to a second air pressure regulating unit.

[0006] By using the environmentally friendly instrument panel vacuum forming device described in this invention, the diaphragm is first pre-attached to the instrument panel, and then the diaphragm is precisely welded to the area of ​​the instrument panel to be coated by an ultrasonic welding assembly. The bonding strength between the diaphragm and the instrument panel is enhanced, the instrument panel is easy to remove, and the coating efficiency and coating quality of the instrument panel are greatly improved.

[0007] Preferably, the lifting unit includes a hydraulic cylinder fixedly connected to the lower housing and a fixture driven by the output end of the hydraulic cylinder. The fixture is provided with a contoured protrusion that mates with the instrument panel trim. A negative pressure channel is provided inside the fixture, with the top opening of the negative pressure channel located on the upper surface of the contoured protrusion, and the bottom opening of the negative pressure channel connected to a negative pressure pump via a flexible hose. This design facilitates the secure fixing of the instrument panel trim to the fixture.

[0008] Preferably, the heating unit includes multiple mounting brackets installed inside the upper housing, with the brackets spaced apart along the circumferential inner wall of the upper housing, and each bracket equipped with an infrared heating plate. This design improves the heating efficiency of the diaphragm, which is beneficial for increasing the coating efficiency of the instrument panel.

[0009] Preferably, the first pressure regulating unit includes a first vacuum pump connected to the upper chamber via a first connecting pipe, and the second pressure regulating unit includes a second vacuum pump connected to the lower chamber via a second connecting pipe. This design allows the upper and lower chambers to be evacuated separately using the first and second vacuum pumps.

[0010] Preferably, the first pressure regulating unit further includes a pressure pump connected to the upper cavity via a third connecting pipe. This design allows the pressure pump to pressurize the upper cavity.

[0011] Preferably, the ultrasonic welding assembly includes a servo motor fixedly installed on the upper housing, the output end of the servo motor extending into the upper housing driving a rotating disk, and a first welding unit, a second welding unit and a third welding unit installed on the rotating disk; Two contouring protrusions are provided, and the two contouring protrusions are arranged in a circumferential array around the axis of the rotating disk. Instrument panel A and instrument panel B are respectively placed on the two contouring protrusions. Instrument panel A has a first top surface and a first side, a second side, a third side and a fourth side connected end to end. Instrument panel B has a corresponding second top surface, a fifth side, a sixth side, a seventh side and an eighth side. The first side and the fifth side are the sides of instrument panel A and instrument panel B that are close to each other. The first welding unit welds the diaphragm on the first and second top surfaces, the second welding unit welds the diaphragm on the first and fifth sides, and the third welding unit welds the diaphragm on the remaining sides. This design improves the coating efficiency of the instrument panel trim.

[0012] Preferably, the first welding unit includes a first driving member fixedly connected to the rotating disk, a first oscillator assembly fixedly connected to the output end of the bottom of the first driving member, and a first contour welding head fixedly connected to the output end of the bottom of the first oscillator assembly, the first contour welding head cooperating with the first top surface. This design allows the first driving member to move the first contour welding head, facilitating the welding of diaphragms on both the first and second top surfaces.

[0013] Preferably, the second welding unit includes a first linear module fixedly connected to the rotary disk, a second driving member fixedly connected to the output end of the first linear module, a second oscillator group fixedly connected to the output end of the second driving member, and a second contour welding head fixedly connected to the output end of the second oscillator group, the second contour welding head cooperating with the first side. This design allows the first linear module and the second driving member to move the second contour welding head, facilitating the welding of diaphragms on the first and fifth sides.

[0014] Preferably, the third welding unit includes a second linear module fixedly connected to the rotary disk, a third driving member fixedly connected to the output end of the second linear module, a third vibrator group fixedly connected to the output end of the third driving member, a mounting base fixedly connected to the output end of the third vibrator group, and a third, fourth, and fifth contour welding heads fixedly connected to the mounting base. The fourth and fifth contour welding heads are located at the same height and are both below the third contour welding head. The third contour welding head mates with the seventh side, the fourth contour welding head mates with the second side, and the fifth contour welding head mates with the eighth side. This design, using the second linear module and the third drive unit, moves the third, fourth, and fifth contour welding heads to facilitate the welding of diaphragms onto the second, third, fourth, sixth, seventh, and eighth sides.

[0015] Preferably, the fixture is equipped with a cooling channel, the inlet of which is connected to an inlet pipe, and the outlet of which is connected to an outlet pipe. This design facilitates the cooling of the coated instrument panel, ensuring a firm bond between the diaphragm and the panel.

[0016] The beneficial effects of this invention are as follows: By using the environmentally friendly instrument panel vacuum forming device described in this invention, the diaphragm is first pre-attached to the instrument panel, and then the diaphragm is precisely welded to the area of ​​the instrument panel to be coated by an ultrasonic welding assembly. The bonding strength between the diaphragm and the instrument panel is enhanced, the instrument panel is easy to remove, and the coating efficiency and coating quality of the instrument panel are greatly improved. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall structure of the vacuum forming device for environmentally friendly instrument decorative panels; Figure 2 This is a front sectional view of the vacuum forming device for environmentally friendly instrument decorative panels (S2 has just been completed). Figure 3 This is a front sectional view of the vacuum forming device for environmentally friendly instrument decorative panels (S3 has just been completed). Figure 4 This is a front sectional view of the vacuum forming device for environmentally friendly instrument decorative panels (S41 has just been completed). Figure 5 This is a front sectional view of the vacuum forming device for environmentally friendly instrument decorative panels (S42 has just been completed). Figure 6 This is a front sectional view of the vacuum forming device for environmentally friendly instrument decorative panels (S43 has just been completed). Figure 7 This is a first three-dimensional structural disassembly diagram of the fixture and instrument panel; Figure 8 This is a schematic diagram showing the second type of three-dimensional structure disassembly of the fixture and instrument panel; Figure 9 This is a three-dimensional structural diagram of the jig; Figure 10 This is a three-dimensional structural diagram of the heating unit; Figure 11 This is a bottom view of the structure above the diaphragm; Figure 12 This is a top view of the structure beneath the diaphragm; Figure 13 yes Figure 8 Enlarged view of the structure at point A in the middle; Figure 14 This is a three-dimensional structural diagram of an ultrasonic welding assembly; Figure 15 This is a three-dimensional structural diagram of the first welding unit; Figure 16 This is a three-dimensional structural diagram of the second welding unit; Figure 17 This is a three-dimensional structural diagram of the third welding unit.

[0018] In the diagram: 1. Upper housing; 2. Lower housing; 3. Machining cavity; 31. Upper cavity; 32. Lower cavity; 100. Lifting unit; 110. Hydraulic cylinder; 120. Fixture; 121. Contouring protrusion; 122. Negative pressure channel; 123. Cooling channel; 200. Ultrasonic welding assembly; 210. Servo motor; 220. Rotary disk; 230. First welding unit; 231. First driving component; 2311. First cylinder; 2312. First drive plate; 232. First vibrator assembly; 233. First contour welding head; 240. Second welding unit; 241. First linear module; 242. Second driving component; 2421. Drive frame; 2422. Second cylinder; 243. Second vibrator assembly; 244. Second contour welding head; 245. Connecting seat; 250. Third welding unit; 251. Second linear module; 252. Third driving component; 2521. Second drive plate; 2522. Third cylinder; 2523. Third drive plate; 253. Third vibrator assembly; 254. Mounting seat; 255. Third contour welding head; 256. Fourth contour welding head; 257. Fifth contour welding head; 300. Heating unit; 310. Mounting bracket; 320. Infrared heating plate; 400. Upper membrane assembly; 510. First air pressure regulating unit; 511. First connecting pipe; 512. First vacuum pump; 513. Third connecting pipe; 514. Pressure pump; 520. Second air pressure regulating unit; 521. Second connecting pipe; 522. Second vacuum pump; 610. Hose; 620. Negative pressure pump; 630. Inlet pipe; 640. Outlet pipe; 7. Instrument panel trim; 71. Instrument panel A trim; 711. First top surface; 712. First side edge; 713. Second side edge; 714. Third side edge; 7141. Inner slope; 715. Fourth side edge; 72. Instrument panel B trim; 721. Second top surface; 722. Fifth side edge; 723. Sixth side edge; 724. Seventh side edge; 725. Eighth side edge; 8. Membrane. Detailed Implementation

[0019] The subject matter described herein will now be discussed with reference to exemplary embodiments. It should be understood that these embodiments are discussed to enable those skilled in the art to better understand and implement the subject matter described herein. Changes may be made to the function and arrangement of the elements discussed without departing from the scope of this specification. Various processes or components may be omitted, substituted, or added as needed in the examples. Furthermore, features described in some examples may be combined in other examples.

[0020] To better understand this invention, the following is combined with... Figures 1-17 The present invention provides a detailed description of an environmentally friendly instrument panel vacuum forming device.

[0021] Example 1: like Figures 1-8 As shown, an environmentally friendly instrument panel vacuum forming device includes: an upper box 1 and a lower box 2. The upper box 1 is movably positioned above the lower box 2. The upper box 1 and the lower box 2 are closed to form a processing cavity 3. The bottom of the lower box 2 is provided with a lifting unit 100 for supporting the instrument panel 7. An ultrasonic welding assembly 200 is provided inside the upper box 1. The ultrasonic welding assembly 200 is provided with a conformal welding head that matches the surface of the instrument panel 7. A heating unit 300 is installed inside the upper box 1. The lower housing 2 is connected to the outer side of the upper membrane assembly 400, which is used to transport and cut the membrane 8. The membrane 8 is sandwiched between the upper housing 1 and the lower housing 2. When the upper housing 1 and the lower housing 2 are closed, the membrane 8 divides the processing chamber 3 into an upper chamber 31 and a lower chamber 32. The upper chamber 31 is connected to a first air pressure regulating unit 510, and the lower chamber 32 is connected to a second air pressure regulating unit 520.

[0022] It should be noted that both the upper housing 1 and the lower housing 2 have openings on their adjacent sides. When the upper housing 1 and the lower housing 2 are closed, the diaphragm 8 separates the upper housing 1 and the lower housing 2. The space formed by the diaphragm 8 and the upper housing 1 is the upper cavity 31, and the space formed by the diaphragm 8 and the lower housing 2 is the lower cavity 32. The lower housing 2 is mounted on a mounting frame (not shown in the figure), and the upper housing 1 is adjusted up and down by a vertical position adjustment structure (such as a cylinder, not shown in the figure) on the mounting frame. The upper mold assembly is existing technology, and its specific structure will not be described in detail here. For example, the upper mold assembly can be a film feeding mechanism disclosed in CN218966157U. By using the combination of the film pulling device, displacement device, leveling and conveying assembly, film pressing device, guide assembly, cutting blade and cutting drive in the prior art, the film sheet 8 is conveyed and cut.

[0023] The film coating process for the instrument panel trim 7 includes the following steps: S1. Fix the instrument panel 7 to the lifting unit 100, and the lifting unit 100 drives the instrument panel 7 to descend into the lower housing 2; S2, the upper membrane assembly 400 conveys the membrane 8, and the membrane 8 is laid above the opening of the lower box 2; S3. The upper housing 1 moves down and clamps the diaphragm 8 together with the lower housing 2. Then, the heating unit 300 heats the diaphragm 8. S4, the first air pressure regulating unit 510 and the second air pressure regulating unit 520 respectively regulate the air pressure of the upper cavity 31 and the lower cavity 32, and the lifting unit 100 drives the instrument decorative panel 7 to rise into the upper housing 1. The diaphragm 8 is tightly pre-attached to the surface of the instrument decorative panel 7 to be covered under the action of pressure difference. S5. The ultrasonic welding assembly 200 uses a contour welding head to attach and extrude the membrane 8 of the required coating area of ​​the instrument panel 7, and welds the membrane 8 of that area onto the instrument panel 7. S6. Stop heating, depressurize the upper chamber 31 and lower chamber 32, and cut the diaphragm 8. Then, move the upper housing 1 upward and take out the instrument decorative panel 7 after the film is applied. S7. Trim the excess edges and remove the excess film 8 from the instrument panel 7 after it has been coated.

[0024] It should be noted that S4 specifically includes the following steps: S41, the first pressure regulating unit 510 and the second pressure regulating unit 520 respectively evacuate the upper cavity 31 and the lower cavity 32 until the pressure in the upper cavity 31 is the first preset pressure and the pressure in the lower cavity 32 is the second preset pressure, and the first preset pressure is less than the second preset pressure. Under the action of the pressure difference, the diaphragm 8 is stretched and bulges upward. S42, The lifting unit 100 drives the instrument panel 7 to rise into the upper housing 1, and the top part of the instrument panel 7 contacts the diaphragm 8. S43. The first air pressure regulating unit 510 pressurizes the upper cavity 31 until the air pressure in the upper cavity 31 is the third preset air pressure. The third preset air pressure is positive pressure. Under the action of pressure difference, the diaphragm 8 is further stretched, tightly and completely adhering to the surface of the instrument decorative panel 7 that needs to be covered with film.

[0025] In S41, the pressure difference between the first preset air pressure and the second preset air pressure is related to the unevenness of the instrument panel surface. The greater the unevenness of the instrument panel surface, the greater the pressure difference, and the greater the bulging of the diaphragm 8. In this way, the stretching deformation of the diaphragm 8 is more uniform. In S42, when the lifting unit 100 drives the instrument decorative panel 7 to rise into the upper housing 1, the instrument decorative panel 7 is less likely to break the diaphragm 8. Compared with the Chinese patent with publication number CN113414975A ​​in the background art, when the pressure of the upper and lower cavities of the decorative film is the same, the loading mold drives the product to be coated onto the film. The lifting of the decorative film causes it to stretch and deform. On the one hand, if the top of the product to be coated has a sharp point, the decorative film is easily broken. On the other hand, when the product to be coated touches the decorative film, the top part of the product to be coated contacts the decorative film, and the degree of stretching deformation of the decorative film at the contact part is the greatest, resulting in uneven stretching of the decorative film. However, in this application, under the condition of heating the diaphragm 8, the pressure difference causes the diaphragm 8 to stretch and bulge upward, resulting in more uniform stretching of the diaphragm 8. Furthermore, during the process of the lifting unit 100 driving the instrument decorative panel 7 to rise into the upper housing 1, the instrument decorative panel 7 will not break the diaphragm 8.

[0026] In step S43, the diaphragm 8 initially adheres to a portion of the top of the instrument panel 7 and is stretched. As the air pressure in the upper cavity 31 gradually increases, the diaphragm 8 is further stretched and completely and tightly adheres to the surface of the instrument panel 7 that needs to be coated. By completing the pre-coating of the diaphragm 8 in this way, the probability of air bubbles appearing between the diaphragm 8 and the instrument panel 7 can be greatly reduced, so that the conformal welding head can adhere to the diaphragm 8 in step S5, thereby welding the diaphragm 8 onto the instrument panel 7, which is beneficial to improving the coating quality of the instrument panel 7.

[0027] In this embodiment, the instrument panel 7 is made of PC / ABS alloy (a blend of PC and ABS), and the diaphragm 8 is made of PET / TPU co-extruded film. In S3, the heating unit 300 heats the diaphragm 8 to 140±5℃. In S41, the first preset air pressure is set to -75±5kPa, the second preset air pressure is set to -55±5kPa, and in S43, the third preset air pressure is set to +80±10kPa. The TPU layer is in contact with the instrument panel 7, and the PET layer with decorative effect is located on the side of the TPU layer away from the instrument panel 7. In S5, after the conformal welding head completes the bonding, the pressure between the conformal welding head and the diaphragm 8 is 0.3±0.05MPa. The ultrasonic welding assembly 200 controls the conformal welding head to generate high-frequency vibration, causing the TPU layer of the diaphragm 8 to generate intense friction with the contact surface of the instrument panel 7. The TPU layer melts and forms a viscous flow state, while the PET layer and the instrument panel 7 remain solid. Under the action of mechanical vibration and pressure, the molten TPU penetrates into the micro-gap on the surface of the instrument panel 7. After cooling, it forms a mechanical interlock, and the diaphragm 8 is firmly welded to the instrument panel 7. Because the conformal welding head bonds to and squeezes the diaphragm 8 in the area of ​​the instrument panel 7 that needs to be coated, the diaphragm 8 can be precisely welded to the area of ​​the instrument panel 7 that needs to be coated during welding. There will be no situation where the diaphragm 8 sticks to the lifting unit 100, and the instrument panel 7 can be easily removed from the lifting unit 100.

[0028] By using the environmentally friendly instrument panel vacuum forming device of the present invention, the diaphragm 8 is first pre-attached to the instrument panel 7, and then the ultrasonic welding assembly 200 precisely welds the diaphragm 8 to the area of ​​the instrument panel 7 that needs to be coated. The bonding strength between the diaphragm 8 and the instrument panel 7 is enhanced, the instrument panel 7 is easy to remove, and the coating efficiency and coating quality of the instrument panel 7 are greatly improved.

[0029] Example 2: As an optimization of Example 1, such as Figure 1 , Figure 2 , Figure 3 , Figure 7 , Figure 8 and Figure 9 As shown, the lifting unit 100 includes a hydraulic cylinder 110 fixedly connected to the lower housing 2, and a fixture 120 drivenly connected to the output end of the hydraulic cylinder 110. The fixture 120 is provided with a contoured protrusion 121 that cooperates with the instrument panel 7. A negative pressure channel 122 is provided inside the fixture 120. The top opening of the negative pressure channel 122 is located on the upper surface of the contoured protrusion 121, and the bottom opening of the negative pressure channel 122 is connected to a negative pressure pump 620 through a hose 610.

[0030] It should be noted that the cylinder body of the hydraulic cylinder 110 is located below the lower housing 2 and is fixedly connected to the lower housing 2. The output end of the hydraulic cylinder 110 extends into the lower housing 2. The fixture 120 is fixedly connected to the output end of the hydraulic cylinder 110. The hydraulic cylinder 110 drives the fixture 120 to rise or fall through the extension and retraction of the output end. The negative pressure channel 122 is provided with multiple top openings, which are spaced apart on the upper surface of the contoured protrusion 121. In S1, after the instrument panel 7 is placed on the contoured protrusion 121, the instrument panel 7 covers and seals all the top openings of the negative pressure channel 122. Then, the negative pressure pump 620 is started. The negative pressure pump 620 generates negative pressure in the negative pressure channel 122 through the hose 610, thereby firmly adsorbing the instrument panel 7 onto the contoured protrusion 121. This prevents the instrument panel 7 from lifting or even shifting during the pre-lamination of the diaphragm 8 in S4, which would affect the normal lamination process. A sealing gasket can be set at the top opening of the negative pressure channel 122 to improve the reliability of the negative pressure adsorption. In S42, the output end of the hydraulic cylinder 110 extends, driving the fixture 120 and the instrument panel 7 to rise into the upper housing 1.

[0031] Example 3: As an optimization of Example 2, such as Figure 1 , Figure 10 and Figure 11 As shown, the heating unit 300 includes a plurality of mounting brackets 310 installed inside the upper housing 1. The plurality of mounting brackets 310 are spaced apart along the circumferential inner sidewall of the upper housing 1, and each mounting bracket 310 is equipped with an infrared heating plate 320.

[0032] It should be noted that the infrared heating plate 320 is equipped with heating elements (such as infrared lamps, carbon fiber heating elements, ceramic plates, etc.). After being powered on, the heating elements emit infrared rays. After the diaphragm 8 absorbs the infrared rays, the molecular vibration intensifies and is converted into heat energy, thereby completing the heating of the diaphragm 8. The heating efficiency of the diaphragm 8 is higher, which is beneficial to improving the coating efficiency of the instrument decorative panel 7.

[0033] In this embodiment, in S3, the infrared heating plate 320 emits infrared rays with a wavelength range of 3-10μm to heat the film 8 to 110±10℃, so as to ensure that the film 8 is fully softened, which is conducive to the uniform stretching of the film 8. The PET / TPU co-extruded film has high absorption efficiency for infrared rays with a wavelength range of 3-10μm, which is conducive to improving the heating efficiency of the film 8. In S4 and S5, the infrared heating plate 320 intermittently emits infrared rays within this wavelength range to maintain the temperature of the diaphragm 8. Maintaining the temperature of the diaphragm 8 through intermittent heating helps to reduce the impact on the ultrasonic welding assembly 200 in S5.

[0034] Example 4: As an optimization of Example 3, such as Figure 1 As shown, the first pressure regulating unit 510 includes a first vacuum pump 512 connected to the upper chamber 31 via a first connecting pipe 511, and the second pressure regulating unit 520 includes a second vacuum pump 522 connected to the lower chamber 32 via a second connecting pipe 521.

[0035] It should be noted that in S3, when the diaphragm 8 is horizontal, the upper chamber 31 and the lower chamber 32 have the same volume. Valves are installed on both the first connecting pipe 511 and the second connecting pipe 521. In S41, the valves on the first connecting pipe 511 and the second connecting pipe 521 open simultaneously. The vacuum pump 512 pumps vacuum at a rate greater than that of the second vacuum pump 522. The first vacuum pump 512 and the second vacuum pump 522 complete vacuuming simultaneously. That is, when the first vacuum pump 512 pumps the air pressure in the upper chamber 31 to the first preset air pressure, the second vacuum pump 522 also pumps the air pressure in the lower chamber 32 to the second preset air pressure. The valves on the first connecting pipe 511 and the second connecting pipe 521 close simultaneously. The first vacuum pump 512 and the second vacuum pump 522 stop vacuuming simultaneously. By controlling the vacuuming rate, the upper chamber 31 and the lower chamber 32 complete vacuuming simultaneously. The stretching of the diaphragm 8 per unit time is small, which is beneficial to the uniform stretching of the diaphragm 8 and ensures the stretching quality of the diaphragm 8.

[0036] Example 5: As an optimization of Example 4, such as Figure 1 As shown, the first air pressure regulating unit 510 also includes a pressure pump 514 connected to the upper cavity 31 via a third connecting pipe 513.

[0037] It should be noted that a valve is also installed on the third connecting pipe 513. In S43, the valve on the third connecting pipe 513 is opened, and the pressure pump 514 pressurizes the upper chamber 31 until the air pressure in the upper chamber 31 reaches the third preset air pressure. Then the valve on the third connecting pipe 513 is closed, and the pressure pump 514 stops pressurizing.

[0038] Example 6: As an optimization of Example 5, such as Figure 1 , Figure 2 , Figure 3 , Figure 7 , Figure 8 , Figure 11 , Figure 12 and Figure 13 As shown, the ultrasonic welding assembly 200 includes a servo motor 210 fixedly installed on the upper housing 1. The output end of the servo motor 210 extends into the upper housing 1 and drives a rotating disk 220. A first welding unit 230, a second welding unit 240 and a third welding unit 250 are installed on the rotating disk 220. Two contouring protrusions 121 are provided, and the two contouring protrusions 121 are arranged in a circular array around the axis of the rotating disk 220. Instrument decorative panel A 71 and instrument decorative panel B 72 are respectively placed on the two contouring protrusions 121. Instrument decorative panel A 71 has a first top surface 711 and a first side 712, a second side 713, a third side 714 and a fourth side 715 connected end to end. Instrument decorative panel B 72 has a corresponding second top surface 721, a fifth side 722, a sixth side 723, a seventh side 724 and an eighth side 725. The first side 712 and the fifth side 722 are the sides of instrument decorative panel A 71 and instrument decorative panel B 72 that are close to each other. The first welding unit 230 welds the diaphragm 8 on the first top surface 711 and the second top surface 721, the second welding unit 240 welds the diaphragm 8 on the first side 712 and the fifth side 722, and the third welding unit 250 welds the diaphragm 8 on the remaining sides.

[0039] It should be noted that the A instrument panel trim 71 and the B instrument panel trim 72 have the same shape, structure, and size. In a clockwise direction, the first side 712, the second side 713, the third side 714, and the fourth side 715 are connected end-to-end. In a clockwise direction, the fifth side 722, the sixth side 723, the seventh side 724, and the eighth side 725 are connected end-to-end. S5 includes the following steps: S51, the first welding unit 230 welds the diaphragm 8 on the first top surface 711, then the second welding unit 240 welds the diaphragm 8 on the first side 712, and then the third welding unit 250 welds the diaphragm 8 on the seventh side 724. S52, servo motor 210 drives the other structures of ultrasonic welding assembly 200 to rotate 90° in the clockwise direction; S53, the third welding unit 250 welds the diaphragm 8 on the second side 713 and the eighth side 725; S54. Repeat S52 once. The first welding unit 230 welds the diaphragm 8 on the second top surface 721. Then, the second welding unit 240 welds the diaphragm 8 on the fifth side 722. After that, the third welding unit 250 welds the diaphragm 8 on the third side 714. S55, repeat S52 once, the third welding unit 250 welds the diaphragm 8 on the fourth side 715 and the sixth side 723; S56. Repeat S52 once to reset the ultrasonic welding assembly 200.

[0040] It should be noted that S52 specifically refers to the servo motor 210 driving the rotary disk 220, the first welding unit 230, the second welding unit 240, and the third welding unit 250 to rotate 90° clockwise. After the welding and coating of two instrument panel decoration panels 7 (A instrument panel decoration panel 71 and B instrument panel decoration panel 72) is completed, when welding and coating of the next set of two instrument panel decoration panels 7 is performed, the servo motor 210 drives the other structures of the ultrasonic welding assembly 200 to rotate 90° in the opposite direction to the rotation direction of the previous set of instrument panel decoration panels 7 welding and coating, thereby performing welding and coating to avoid the situation of wire entanglement. By completing the coating of two instrument panel decoration panels 7 at one time, it is beneficial to improve the coating efficiency of the instrument panel decoration panels 7 and to reduce the waste of the film 8.

[0041] In this embodiment, the bottom of the parts of each side of the instrument panel 7 that need to be coated is recessed inward. For example, the third side 714 has an inwardly recessed inner slope 7141, and the other sides have similar structures. Welding coating cannot be completed by a single welding unit. This application completes welding coating by using a first welding unit 230, a second welding unit 240, and a third welding unit 250. On the one hand, it can ensure the accuracy and quality of welding. On the other hand, the number of welding units required is small, which helps to reduce coating costs.

[0042] Example 7: As an optimization of Example 6, such as Figure 2 , Figure 14 and Figure 15 As shown, the first welding unit 230 includes a first driving member 231 fixedly connected to the rotating disk 220, a first oscillator group 232 fixedly connected to the output end of the bottom of the first driving member 231, and a first contour welding head 233 fixedly connected to the output end of the bottom of the first oscillator group 232. The first contour welding head 233 cooperates with the first top surface 711.

[0043] It should be noted that the first contour welding head 233 can also cooperate with the second top surface 721. The first contour welding head 233 is used to weld the diaphragm 8 on the first top surface 711 and the second top surface 721. The first transducer group 232 includes multiple spaced ultrasonic transducers (a combination of transducers and amplitude transformers). The fixed ends of the multiple ultrasonic transducers are all fixedly connected to the output ends of the first drive unit 231, and the output ends of the multiple ultrasonic transducers are all fixedly connected to the first contour welding head 233. The multiple ultrasonic transducers ensure the coordination of vibration through phase synchronization technology. By setting multiple synchronously vibrating ultrasonic transducers, the welding pressure distribution can be uniform, the vibration energy transmission can be uniform and stable, and weak or incomplete welding can be avoided, thus ensuring the welding quality of the diaphragm 8.

[0044] In S51 and S54, the first driving member 231 drives the first oscillator group 232 and the first conformal welding head 233 to move down until the first conformal welding head 233 is in contact with the diaphragm 8. Then, the first oscillator group 232 drives the first conformal welding head 233 to vibrate and weld the diaphragm 8 in the vertical direction at high frequency. After the welding is completed, the first welding unit 230 is reset according to the reverse steps described above. Specifically, in S51, the first contour welding head 233 is attached to the diaphragm 8 on the first top surface 711, and in S54, the first contour welding head 233 is attached to the diaphragm 8 on the second top surface 721.

[0045] In this embodiment, the first driving component 231 includes a plurality of spaced first cylinders 2311 and a first driving plate 2312 fixedly connected to the output ends of the plurality of first cylinders 2311. The first oscillator group 232 is fixedly mounted on the first driving plate 2312. The output ends of the plurality of first cylinders 2311 extend or shorten synchronously, thereby driving the first driving plate 2312, the first oscillator group 232 and the first contour welding head 233 to descend or rise vertically.

[0046] Example 8: As an optimization of Example 7, such as Figure 2 , Figure 14 and Figure 16 As shown, the second welding unit 240 includes a first linear module 241 fixedly connected to the rotary disk 220, a second drive member 242 fixedly connected to the output end of the first linear module 241, a second oscillator group 243 fixedly connected to the output end of the second drive member 242, and a second contour welding head 244 fixedly connected to the output end of the second oscillator group 243. The second contour welding head 244 cooperates with the first side 712.

[0047] It should be noted that the second contour welding head 244 can also be used to cooperate with the fifth side 722. The second contour welding head 244 is used to weld the diaphragm 8 on the first side 712 and the fifth side 722. The second oscillator group 243 is the same as the first oscillator group 232 in principle, and will not be described again here. In S51 and S54, the second drive member 242 drives the second oscillator group 243 and the second contour welding head 244 to move downward. Then, the first linear module 241 drives the second drive member 242, the second oscillator group 243 and the second contour welding head 244 to move towards the side of the diaphragm 8 to be welded, until the second contour welding head 244 is in contact with the diaphragm 8. After that, the second oscillator group 243 drives the second contour welding head 244 to vibrate at high frequency in the horizontal direction to weld the diaphragm 8. After the welding is completed, the second welding unit 240 resets according to the reverse steps described above. Specifically, in S51, the second contour welding head 244 is attached to the diaphragm 8 on the first side 712, and in S54, the second contour welding head 244 is attached to the diaphragm 8 on the fifth side 722.

[0048] In this embodiment, two sets of first linear modules 241 are arranged parallel to each other to ensure the stable operation of the second drive unit 242, the second transducer group 243, and the second contour welding head 244. The second drive unit 242 includes a drive frame 2421 fixedly connected to the output ends of the two first linear modules 241, and a plurality of second cylinders 2422 fixedly mounted on the drive frame 2421. Each second cylinder 2422 has an ultrasonic transducer fixedly mounted at its output end. The plurality of ultrasonic transducers connected to the second cylinders 2422 form the second transducer group 243. The output end of the ultrasonic transducer connected to the second cylinder 2422 is fixedly connected to the second contour welding head 244 via the connecting seat 245 to avoid interference between the second transducer group 243 and the fixture 120 during movement. The first linear module 241 drives the second cylinder 2422, the second transducer group 243 and the second contour welding head 244 to move horizontally via the drive frame 2421. The output ends of the multiple second cylinders 2422 extend or shorten synchronously, thereby driving the second transducer group 243, the connecting seat 245 and the second contour welding head 244 to descend or rise vertically.

[0049] Example 9: As an optimization of Example 8, such as Figure 2 , Figure 14 and Figure 17 As shown, the third welding unit 250 includes a second linear module 251 fixedly connected to the rotary disk 220, a third drive unit 252 fixedly connected to the output end of the second linear module 251, a third oscillator group 253 fixedly connected to the output end of the third drive unit 252, a mounting base 254 fixedly connected to the output end of the third oscillator group 253, and a third contour welding head 255, a fourth contour welding head 256, and a fifth contour welding head 257 fixedly connected to the mounting base 254. The fourth contour welding head 256 and the fifth contour welding head 257 are located at the same height and are both located below the third contour welding head 255. The third contour welding head 255 mates with the seventh side 724, the fourth contour welding head 256 mates with the second side 713, and the fifth contour welding head 257 mates with the eighth side 725.

[0050] It should be noted that the third contour welding head 255 can also be fitted with the third side 714. The third contour welding head 255 is used to weld the diaphragm 8 on the third side 714 and the seventh side 724. The fourth contour welding head 256 can also be fitted with the sixth side 723. The fourth contour welding head 256 is used to weld the diaphragm 8 on the second side 713 and the sixth side 723. The fifth contour welding head 257 can also be fitted with the fourth side 715. The fifth contour welding head 257 is used to weld the diaphragm 8 on the fourth side 715 and the eighth side 725. The third oscillator group 253 is the same as the first oscillator group 232 in principle, and will not be described again here. In S51, the second linear module 251 drives the third drive unit 252, thereby driving the third oscillator group 253, the mounting base 254, the third contour welding head 255, the fourth contour welding head 256 and the fifth contour welding head 257 to move down synchronously. Then, the third drive unit 252 drives the third oscillator group 253, the mounting base 254, the third contour welding head 255, the fourth contour welding head 256 and the fifth contour welding head 257 to move towards the direction close to the seventh side 724, until the third contour welding head 255 is in contact with the diaphragm 8 on the seventh side 724. After that, the third oscillator group 253 drives the third contour welding head 255 to vibrate and weld the diaphragm 8 in the horizontal direction through the mounting base 254. After the welding is completed, the third welding unit 250 resets according to the reverse steps described above. In S53, the second linear module 251 drives the fourth contour welding head 256 and the fifth contour welding head 257 to move down synchronously. Then, the third drive unit 252 drives the fourth contour welding head 256 and the fifth contour welding head 257 to move synchronously, so that the fourth contour welding head 256 is attached to the diaphragm 8 on the second side 713, and at the same time, the fifth contour welding head 257 is attached to the diaphragm 8 on the eighth side 725. After that, the third oscillator group 253 drives the fourth contour welding head 256 and the fifth contour welding head 257 to vibrate and weld the diaphragm 8 in the horizontal direction through the mounting base 254. After the welding is completed, the third welding unit 250 is reset according to the reverse steps of the above. In S54, the operation process of the third welding unit 250 is the same as that in S51. The third conformal welding head 255 fits onto the diaphragm 8 on the third side 714 and completes the welding. In S55, the operation process of the third welding unit 250 is the same as that in S53. The fourth contour welding head 256 attaches to the diaphragm 8 on the sixth side 723 and completes the welding. The fifth contour welding head 257 attaches to the diaphragm 8 on the fourth side 715 and completes the welding.

[0051] In this embodiment, the fourth contour welding head 256 and the fifth contour welding head 257 are integrally formed, and two sets of the second linear module 251 are arranged in parallel to each other to ensure the stable operation of the third drive component 252, the third oscillator group 253, the mounting base 254, the third contour welding head 255, the fourth contour welding head 256 and the fifth contour welding head 257. The third driving component 252 includes a second driving plate 2521 fixedly connected to the output ends of the two second linear modules 251, a plurality of third cylinders 2522 fixedly mounted on the second driving plate 2521, a third driving plate 2523 fixedly connected to the output ends of the plurality of third cylinders 2522, and a third vibrator group 253 fixedly mounted on the third driving plate 2523. The second linear module 251 drives the third cylinders 2522, the third driving plate 2523, the third vibrator group 253, the mounting base 254, the third contour welding head 255, the fourth contour welding head 256, and the fifth contour welding head 257 to move vertically through the second driving plate 2521. The output ends of the plurality of third cylinders 2522 extend or shorten synchronously, thereby driving the third driving plate 2523, the third vibrator group 253, the mounting base 254, the third contour welding head 255, the fourth contour welding head 256, and the fifth contour welding head 257 to move horizontally.

[0052] Example 10: As an optimization of Example 9, such as Figure 1 and Figure 9 As shown, a cooling channel 123 is provided inside the fixture 120. The inlet of the cooling channel 123 is connected to the inlet pipe 630, and the outlet of the cooling channel 123 is connected to the outlet pipe 640.

[0053] It should be noted that in S6, while depressurizing, condensate is supplied to the cooling channel 123 through the water inlet pipe 630 to cool the instrument decorative panel 7 after the film is applied, so that the diaphragm 8 is firmly bonded to the instrument decorative panel 7.

[0054] The embodiments of the invention have been described above with reference to the accompanying drawings. However, the embodiments are not limited to the specific implementation methods described above. The specific implementation methods described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms under the guidance of the embodiments without departing from the spirit of the embodiments and the scope of protection of the claims, and all of these forms are within the protection scope of the embodiments.

Claims

1. A vacuum forming device for environmentally friendly instrument decorative panels, characterized in that, include: The upper housing (1) and the lower housing (2) are arranged vertically above the lower housing (2). The upper housing (1) and the lower housing (2) are closed to form a processing cavity (3). The bottom of the lower housing (2) is provided with a lifting unit (100) for supporting the instrument decorative panel (7). The upper housing (1) is provided with an ultrasonic welding assembly (200). The ultrasonic welding assembly (200) is provided with a conformal welding head that matches the surface of the instrument decorative panel (7). The upper housing (1) is provided with a heating unit (300). The lower housing (2) is connected to an upper membrane assembly (400) on the outside. The upper membrane assembly (400) is used to transport and cut the membrane (8). The membrane (8) is sandwiched between the upper housing (1) and the lower housing (2). When the upper housing (1) and the lower housing (2) are closed, the membrane (8) divides the processing chamber (3) into an upper chamber (31) and a lower chamber (32). The upper chamber (31) is connected to a first air pressure regulating unit (510), and the lower chamber (32) is connected to a second air pressure regulating unit (520).

2. The vacuum forming device for environmentally friendly instrument decorative panels according to claim 1, characterized in that, The lifting unit (100) includes a hydraulic cylinder (110) fixedly connected to the lower housing (2) and a fixture (120) drivenly connected to the output end of the hydraulic cylinder (110). The fixture (120) is provided with a contoured protrusion (121) that cooperates with the instrument panel (7). A negative pressure channel (122) is provided inside the fixture (120). The top opening of the negative pressure channel (122) is located on the upper surface of the contoured protrusion (121), and the bottom opening of the negative pressure channel (122) is connected to a negative pressure pump (620) through a hose (610).

3. The vacuum forming device for environmentally friendly instrument decorative panels according to claim 1, characterized in that, The heating unit (300) includes a plurality of mounting brackets (310) installed in the upper housing (1). The plurality of mounting brackets (310) are spaced apart along the circumferential inner sidewall of the upper housing (1), and each mounting bracket (310) is equipped with an infrared heating plate (320).

4. The vacuum forming device for environmentally friendly instrument decorative panels according to claim 1, characterized in that, The first pressure regulating unit (510) includes a first vacuum pump (512) connected to the upper chamber (31) via a first connecting pipe (511), and the second pressure regulating unit (520) includes a second vacuum pump (522) connected to the lower chamber (32) via a second connecting pipe (521).

5. The vacuum forming device for environmentally friendly instrument decorative panels according to claim 4, characterized in that, The first air pressure regulating unit (510) also includes a pressure pump (514) connected to the upper cavity (31) via a third connecting pipe (513).

6. The vacuum forming device for environmentally friendly instrument decorative panels according to claim 2, characterized in that, The ultrasonic welding assembly (200) includes a servo motor (210) fixedly installed on the upper housing (1). The servo motor (210) extends into the output end of the upper housing (1) and drives a rotating disk (220). A first welding unit (230), a second welding unit (240) and a third welding unit (250) are installed on the rotating disk (220). Two contoured protrusions (121) are provided, and the two contoured protrusions (121) are arranged in a circular array around the axis of the rotating disk (220). An instrument decorative panel A (71) and an instrument decorative panel B (72) are respectively placed on the two contoured protrusions (121). The instrument decorative panel A (71) has a first top surface (711) and a first side (712), a second side (713), a third side (714) and a fourth side (715) connected end to end. The instrument decorative panel B (72) has a corresponding second top surface (721), a fifth side (722), a sixth side (723), a seventh side (724) and an eighth side (725). The first side (712) and the fifth side (722) are the sides of the instrument decorative panel A (71) and the instrument decorative panel B (72) that are close to each other. The first welding unit (230) welds the diaphragm (8) on the first top surface (711) and the second top surface (721), the second welding unit (240) welds the diaphragm (8) on the first side (712) and the fifth side (722), and the third welding unit (250) welds the diaphragm (8) on the remaining sides.

7. The vacuum forming device for environmentally friendly instrument decorative panels according to claim 6, characterized in that, The first welding unit (230) includes a first driving member (231) fixedly connected to the rotating disk (220), a first oscillator group (232) fixedly connected to the output end of the bottom of the first driving member (231), and a first contour welding head (233) fixedly connected to the output end of the bottom of the first oscillator group (232). The first contour welding head (233) cooperates with the first top surface (711).

8. The vacuum forming device for environmentally friendly instrument decorative panels according to claim 6, characterized in that, The second welding unit (240) includes a first linear module (241) fixedly connected to the rotary disk (220), a second drive unit (242) fixedly connected to the output end of the first linear module (241), a second oscillator group (243) fixedly connected to the output end of the second drive unit (242), and a second contour welding head (244) fixedly connected to the output end of the second oscillator group (243). The second contour welding head (244) cooperates with the first side (712).

9. The vacuum forming device for environmentally friendly instrument decorative panels according to claim 6, characterized in that, The third welding unit (250) includes a second linear module (251) fixedly connected to the rotary disk (220), a third drive unit (252) fixedly connected to the output end of the second linear module (251), a third oscillator group (253) fixedly connected to the output end of the third drive unit (252), a mounting base (254) fixedly connected to the output end of the third oscillator group (253), and a third profile welding head (255), a fourth profile welding head (256), and a fifth profile welding head (257) fixedly connected to the mounting base (254). The fourth contour welding head (256) and the fifth contour welding head (257) are located at the same height and are both located below the third contour welding head (255). The third contour welding head (255) cooperates with the seventh side (724), the fourth contour welding head (256) cooperates with the second side (713), and the fifth contour welding head (257) cooperates with the eighth side (725).

10. The vacuum forming device for environmentally friendly instrument decorative panels according to claim 2, characterized in that, The fixture (120) is provided with a cooling channel (123), the inlet of the cooling channel (123) is connected to the inlet pipe (630), and the outlet of the cooling channel (123) is connected to the outlet pipe (640).

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