Bumpers for vehicles, film arrangement for manufacturing the same and method for manufacturing the same
The vacuum forming process using a membrane device to manufacture solid wood sheets solves the hardness problem of solid wood skin products, achieving a visual and tactile solid wood effect and softness, simplifying the manufacturing process, improving efficiency and reducing costs.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- HYUNDAI MOBIS CO LTD
- Filing Date
- 2022-06-15
- Publication Date
- 2026-07-21
AI Technical Summary
Existing technologies produce solid wood veneer products that squeak when pushed by customers, which dissatisfies customers who require soft interior materials. Furthermore, the injection molding process is complex and results in low manufacturing efficiency.
Solid wood sheets are manufactured using a membrane device through a vacuum forming process. The device includes a vacuum unit, a silicone membrane, and a control unit. It can achieve solid wood forming and core attachment without pre-forming processes, and combines heating and vibration modules to precisely correct the sheet position.
It offers the same visual effect as solid wood and provides a soft, cushioned feel when touched, simplifying the manufacturing process, increasing efficiency, and reducing costs.
Smart Images
Figure CN115703263B_ABST
Abstract
Description
Technical Field
[0001] This disclosure relates to solid wood veneer for automated packaging and methods and apparatus for manufacturing it. Background Technology
[0002] In related fields, wood veneer used in vehicles is made by pre-forming wood sheets onto decorative veneer wood and then performing insert injection molding (back injection molding).
[0003] Subsequently, the ends of the injection-molded solid wood sheets are trimmed, and then the solid wood sheets are sequentially rolled and coated to create solid wood skin.
[0004] Solid wood skin products manufactured using back-insertion injection molding processes can provide a visually and tactilely pleasing surface. However, because of the high hardness of the solid wood attached to the injection-molded component, the solid wood provides a cheeping sensation when pushed by the customer.
[0005] Of course, some customers may think that the high hardness of solid wood is natural. However, customers who need soft interior materials are not satisfied with solid wood. Summary of the Invention
[0006] This summary is provided to introduce, in a simplified form, some concepts that will be further described in the detailed embodiments below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to help determine the scope of the claimed subject matter.
[0007] This disclosure addresses problems in the relevant field, and one object of this disclosure is to provide a membrane device for manufacturing crash pads for vehicles comprising solid wood sheets, which can visually provide a solid wood feel and provide flexibility.
[0008] Another object of this disclosure is to provide a membrane apparatus for manufacturing a vehicle crash pad comprising solid wood sheets, which can simultaneously perform solid wood forming and core attachment using a membrane method without performing a pre-forming process on the wood.
[0009] The purpose of this disclosure is not limited to the foregoing, and other purposes not mentioned above may be clearly understood from the following description.
[0010] In one general aspect, a membrane device for manufacturing a vehicle crash pad comprising solid wood sheets includes: a vacuum device body having a plurality of vacuum holes and configured such that solid wood sheets temporarily attached to a core are mounted in the vacuum device body; a cover having a silicone film and configured to define a vacuum space together with the vacuum device body; a vacuum module configured to draw air from the vacuum device body through the vacuum holes; and a control unit configured to compress the solid wood sheets temporarily attached to and mounted on the vacuum device body and the core for a preset time by drawing air from the vacuum space through the vacuum holes while the vacuum device body is covered by the cover, the control unit being configured to remove the vacuum from the vacuum space by controlling the vacuum module to separate the compressed solid wood sheets from the vacuum device body.
[0011] The membrane device may include a heater configured to heat the interior of the vacuum space, and the control unit may be configured to heat the wood sheet within a preset time before the vacuum module compresses the core and the wood sheet.
[0012] The main body of the vacuum device may have multiple woodseating pins that can move upward or downward to accommodate solid wood sheets.
[0013] The main body of the vacuum device can have a fixing fixture, the core is mounted on the fixing fixture, the core can be placed on the fixing fixture, and the solid wood sheet can be placed on the wooden base pin.
[0014] The membrane device may include a vibration module configured to correct the position of the solid wood sheet by applying vibration to a core disposed beneath the solid wood sheet.
[0015] In another general aspect, a method for manufacturing a vehicle crash pad comprising solid wood sheets using a membrane device includes: moving a plurality of wooden pins upward within a vacuum device body with the cover open; positioning a core on a fixing clamp disposed inside the wooden pins; mounting the solid wood sheets on the upper part of the wooden pins; and closing and covering the vacuum device body with the cover; pressing a silicone film disposed on the cover against the solid wood sheets by a control unit while simultaneously achieving a vacuum state in the vacuum device body through a vacuum hole disposed in the lower part of the vacuum device body via an operation of a vacuum module; and removing the vacuum from the interior of the vacuum device body, opening the cover, and separating the fully manufactured solid wood product from the vacuum device body.
[0016] The step of pressing the silicone resin film against the solid wood sheet may include heating the interior of the vacuum device body for a preset time.
[0017] The step of pressing the silicone resin film onto the solid wood sheet may include: maintaining a vacuum state for a preset time and completing the compression process.
[0018] The steps of closing the vacuum device body may include applying vibration to the vacuum device body and the core located under the solid wood sheet by using a vibration module to correct the position of the solid wood sheet.
[0019] According to a first embodiment of this disclosure, the solid wood sheet constituting the table of the vehicle can visually provide the same feel as solid wood and provide a predetermined degree of cushioning when the occupant touches the solid wood sheet.
[0020] According to a second embodiment of this disclosure, a semi-automatic / fully automatic process is developed by improving the film and compression process, thereby solving the problem of injection molding process for manufacturing solid wood inlays in related fields, improving quality, and reducing costs by shortening product manufacturing time.
[0021] According to the second embodiment of this disclosure, such as Figure 9 As shown, when the solid wood sheet is pressed against the edge of the core, the 3D data values (R) of the core edge can be processed very accurately.
[0022] Other features and aspects will be apparent from the following detailed description, drawings and claims. Attached Figure Description
[0023] Figure 1 This is a reference diagram illustrating a solid wood veneer that can be used for automated packaging according to this disclosure.
[0024] Figure 2A , Figure 2B , Figure 2C , Figure 2D and Figure 2E This is a reference diagram illustrating the process of manufacturing a vehicle crash pad comprising solid wood sheets according to a first embodiment of the present disclosure.
[0025] Figure 3 This is a diagram illustrating a film apparatus for manufacturing a vehicle crash pad comprising solid wood sheets, according to a second embodiment of the present disclosure.
[0026] Figure 4 This is a block diagram illustrating the configuration of a film apparatus for manufacturing a vehicle crash pad comprising solid wood sheets, according to a second embodiment of the present disclosure.
[0027] Figure 5 , Figure 6 , Figure 7 and Figure 8 This is a reference diagram illustrating the process of operating a film device for manufacturing a vehicle crash pad comprising solid wood sheets, according to a second embodiment of the present disclosure.
[0028] Figure 9It is used to illustrate compression, such as Figure 3 The reference diagram shows the results of the produced core and solid wood sheets.
[0029] Figure 10 This is a flowchart illustrating a method for manufacturing a vehicle crash pad comprising solid wood sheets using a membrane apparatus according to a second embodiment of the present disclosure. Detailed Implementation
[0030] See below and appendix Figure 1 The advantages and features of this disclosure, as well as the methods for achieving these advantages and features, will become clear from the detailed description of the embodiments herein. However, this disclosure is not limited to the embodiments disclosed herein, but will be implemented in various forms. Embodiments of this disclosure are provided so that this disclosure is fully disclosed and the scope of this disclosure can be fully understood by those skilled in the art. This disclosure will be defined only by the scope of the appended claims. Furthermore, the terminology used in this specification is used to explain the embodiments and not to limit the disclosure. Unless otherwise specifically stated in this specification, the singular form also includes the plural form. The terms “comprising” and / or “including” as used in the specification are intended to specify the presence of the mentioned constituent elements, steps, operations, and / or elements, but do not exclude the presence or addition of one or more other constituent elements, steps, operations, and / or elements.
[0031] Figure 1 This is a reference diagram illustrating a solid wood veneer that can be used for automated packaging according to this disclosure.
[0032] like Figure 1 As shown, the solid wood skin that can be used for automated packaging according to the first embodiment of this disclosure includes a wood layer 101, a mesh layer 102, and a flexible layer 103.
[0033] Wood layer 101 is a layer that provides the same visual feel as wood material. Wood layer 101 can have a thickness of 0.1t to 0.2t and can have a wood texture made by a coloring machine.
[0034] In addition, the mesh layer 102 is a layer stacked on the underside of the wood layer 101 and constructed as a reinforcing sheet.
[0035] Additionally, the flexible layer 103 is stacked on the lower part of the mesh layer 102 and is configured to provide flexibility. The flexible layer 103 can be made of either polypropylene (PP) foam or thermoplastic polyolefin (TPO) foam. Furthermore, the flexible layer 103 can have a thickness of 1 t to 2 t.
[0036] Additionally, according to a first embodiment of this disclosure, the solid wood veneer may further include a protective film 104, which is stacked on top of the wood layer 101 and configured to protect the wood layer. The protective film 104 may have a thickness of 0.1t.
[0037] Figures 2A to 2E This is a reference diagram used to illustrate the process of manufacturing solid wood sheets according to the first embodiment of this disclosure.
[0038] like Figure 2A As shown, in the solid wood sheet according to the first embodiment of this disclosure, the mesh layer 102 is stacked on the lower end of the wood layer 101. Thereafter, as... Figure 2B As shown, the flexible layer 103 is stacked on the lower end of the mesh layer 102. Furthermore, as... Figure 2C As shown, the protective film 104 can be stacked on the top of the wood layer 101 and protect the wood layer 101.
[0039] like Figure 2D As shown, the solid wood sheet 100, which includes a wood layer 101, a mesh layer 102 and a flexible layer 103, also includes a filament cross pad 140 and a core 150 disposed on its underside.
[0040] Silk cross pad 140 is placed in a localized area of the table to provide cushioning for the localized area of the table in the vehicle.
[0041] Furthermore, the cross pad 140, disposed in one area of the table, can be stacked on the underside of the flexible layer 103. In this case, the cross pad 140 can have a thickness of 2 to 5 tons. In this case, the area to which the cross pad 140 is applied is the entire area accessible by hand, i.e., the area within 3 mm or less from the end of the injection-molded portion of the solid wood sheet. The cross pad 140 can be a pad made of materials such as PP or TPO. However, the material of the cross pad 140 is not limited to these.
[0042] Furthermore, the core 150 can be mounted on a table in a vehicle and has a thickness of 0.3 tons.
[0043] Furthermore, after applying a primer to the core 150, a bonding process is performed by applying an adhesive to the core 150, and then the wire cross pad 140 is attached to the core 150. In this case, the wire cross pad 140 can be attached by using a membrane or by pressing. Here, the membrane process is a method that utilizes a membrane pressing machine to perform vacuum compression molding with heat and pressure, and the sheet is attached as air is released.
[0044] Next, a bonding process is performed by applying a bonding agent to the upper part of the wire cross pad 140, and then the wood layer 101, the mesh layer 102, the flexible layer 103, the wire cross pad 140 and the protective film are compressed by a compression clamp.
[0045] As described above, the solid wood sheet 100 constituting the vehicle's table can provide the same visual feel as solid wood and provides a predetermined degree of cushioning when the occupant touches the solid wood sheet 100.
[0046] According to a first embodiment of this disclosure, PP foam / TPO foam can be applied to the back surface of wood to increase the elongation percentage of the solid wood sheet and improve the surface quality of the solid wood sheet, and silk cross pads used in the related fields for natural or artificial leather can be applied to the core, thereby providing a product of solid wood packaging with a softness that cannot be achieved when solid wood sheets in the related fields are manufactured by injection molding.
[0047] Figure 3 This is a diagram illustrating a film apparatus for manufacturing a vehicle crash pad comprising solid wood sheets, according to a second embodiment of the present disclosure. Figure 4 This is a block diagram illustrating the configuration of a film apparatus for manufacturing a vehicle crash pad comprising solid wood sheets, according to a second embodiment of the present disclosure.
[0048] like Figure 3 and Figure 4 As shown, the membrane device for manufacturing a vehicle crash pad including solid wood sheets according to the second embodiment of this disclosure includes a vacuum device body 310, a cover 320, a vacuum module 330, and a control unit 340.
[0049] The vacuum device body 310 has a vacuum hole 313, and a solid wood sheet 100 temporarily attached to the core 150 is mounted on the vacuum device body 310. In addition, the vacuum device body 310 is closed by a cover 320 and then maintained in a vacuum state through the vacuum hole 313.
[0050] The cover 320 has a silicone film 321 and together with the vacuum device body 310 defines a vacuum space. The cover 320 may have a structure that provides space within the vacuum device body 310 for accommodating the solid wood sheet 100, the wooden base pin, the core, and the fixing clamp 312 when the vacuum device body 310 is closed.
[0051] The vacuum module 330 achieves a vacuum state by drawing air from the vacuum device body 310 through a vacuum hole 313 located in the lower part of the vacuum device body 310.
[0052] With the vacuum device body 310 covered by the cover 320, the control unit 340 compresses the core 150 and the solid wood sheet 100 temporarily attached to and mounted on the vacuum device body 310 within a preset time by drawing air from the vacuum space through the vacuum hole 313 of the vacuum device body 310. Subsequently, the control unit 340 removes the vacuum from the vacuum space by controlling the vacuum module, allowing the compressed solid wood sheet 100 to be separated.
[0053] Furthermore, the membrane device according to the second embodiment of this disclosure also includes a heater 350, which is configured to heat the interior of the vacuum space.
[0054] In addition, the control unit 330 also includes a vibration module (not shown) and controls a vacuum module 340 to vibrate the solid wood sheet 100 for a preset time before the core 150 and the solid wood sheet 100 are compressed, so that the solid wood sheet 100 can be placed at a precise position on the core 150.
[0055] In addition, multiple wooden pins 311 are provided on the vacuum device body 310 so that they can be moved up or down and are used to hold the solid wood sheet 100.
[0056] Furthermore, the vacuum device body 310 has a fixing clamp 312, on which the core 150 is mounted. The core 150 is placed on the fixing clamp 312, and the solid wood sheet 100 is placed on the wooden base pin 311.
[0057] In a second embodiment of this disclosure, the membrane device further includes a vibration module 360 configured to correct the position of the solid wood sheet 100 by applying vibration to the vacuum device body 310 and the core 150 below the solid wood sheet 100.
[0058] In addition, in the second embodiment of this disclosure, the heater is disposed above the silicone resin film 321. The temperature of the heater can be 90°C.
[0059] In the following text, reference will be made to the appendix. Figures 5 to 10 A method for manufacturing a vehicle crash pad comprising solid wood sheets using a membrane apparatus according to a second embodiment of the present disclosure is described.
[0060] First, such as Figure 5 As shown, with the cover 320 open from the vacuum device body 310, a plurality of wooden seat pins 311 move upward within the vacuum device body 310 (S110). In this case, a fixing clamp 312 can be provided inside the plurality of wooden seat pins 311 that move upward within the vacuum device body 310.
[0061] After that, as Figure 6As shown, the core 150 is disposed inside the wooden base pin 311 and positioned on the fixing clamp 312, and the solid wood sheet 100 is mounted on the upper part of the wooden base pin 311. Thereafter, as... Figure 7 As shown, the vacuum device body 310 is covered and closed by the cover 320 (S120). Furthermore, in the step S120 of closing the vacuum device body 310, the vibration module can apply vibration to the core under the vacuum device body and the solid wood sheet, thereby correcting the position of the solid wood sheet.
[0062] After that, as Figure 8 As shown, by operating the vacuum module 340, the control unit 330 achieves a vacuum state in the vacuum device body 310 through the vacuum hole 313 provided in the lower part of the vacuum device body 310, thereby pressing the silicone resin film provided on the cover 320 against the solid wood sheet 100 (S130). Therefore, as the wooden base pin 311 moves downward, the solid wood sheet 100 is placed on the surface of the core 150.
[0063] In step S130, which involves pressing a silicone film onto a solid wood sheet according to this disclosure, the interior of the vacuum device body 310 can be heated for a preset time (50 seconds). The compression process is completed by maintaining the vacuum state for a preset time (55 seconds). Using this process, the solid wood sheet 100 and the core 150 can be compressed very tightly, which allows for minimizing the 3D data value (R) of the edge of the core 150.
[0064] When the compression process is completed as described above, the vacuum is removed from the inside of the vacuum device body 310, the cover 320 is opened, and then the fully produced solid wood product is separated from the vacuum device body 310 (S140).
[0065] According to the embodiments of this disclosure, the problems of the injection molding process for manufacturing solid wood inlays in the prior art can be solved, the quality can be improved, and the cost can be reduced by shortening the product manufacturing time.
[0066] According to embodiments of this disclosure, semi-automatic / fully automatic processes can be developed by improving the film and compression processes, thereby solving the problems of injection molding processes for manufacturing solid wood inlays in related fields, improving quality, and reducing costs by shortening product manufacturing time.
[0067] According to embodiments of this disclosure, such as Figure 9 As shown, when the solid wood sheet is pressed against the edge of the core, the 3D data values (R) of the core edge can be processed very accurately.
[0068] Furthermore, the advantage of the second embodiment of this disclosure is that it does not require an anti-deformation fixture.
[0069] According to a third embodiment of the present disclosure, a membrane device for manufacturing a vehicle crash pad comprising solid wood sheets includes a vacuum device body 310, a cover 320, a vacuum module 330, and a control unit 340.
[0070] The vacuum device body 310 has a vacuum hole 313, and a solid wood sheet 100 temporarily attached to the core 150 is mounted on the vacuum device body 310. In addition, the vacuum device body 310 is closed by a cover 320 and then maintained in a vacuum state through the vacuum hole 313.
[0071] In addition, multiple wooden pins 311 are provided on the vacuum device body 310 for upward or downward movement and for holding the solid wood sheet 100. The vacuum device body 310 has a fixing clamp 312 on which the core 150 is mounted. The core 150 is placed on the fixing clamp 312, and the solid wood sheet 100 is fixed to the wooden pins 311.
[0072] In addition, the vacuum device body 310 includes an introduction space 314 located on the lower side of the fixing clamp 312, and the remaining portion of the solid wood sheet that is not pressed against the core 150 during the main vacuum process can be introduced into the introduction space 314 to enable automatic packaging of the solid wood sheet.
[0073] The fixing clamp 312 according to this embodiment also includes a slider 315, which is positioned on two opposite sides of the fixing clamp 312 and configured to define a clamp for supporting the core 150 during the main vacuum compression process. The slider 315 moves downward during the packaging process using solid wood sheets, and moves upward when the solid wood sheets are introduced into the introduction space 314, thereby performing the process of packaging the solid wood sheets 100 around the interior of the core 150.
[0074] The cover 320 has a silicone film 321 and together with the vacuum device body 310 defines a vacuum space. The cover 320 may have a structure that provides space for accommodating the solid wood sheet 100, the wooden base pin, the core, and the fixing clamp 312 within the vacuum device body 310 when the vacuum device body 310 is closed.
[0075] The vacuum module 330 achieves a vacuum state by drawing air from the vacuum device body 310 through a vacuum hole 313 located in the lower part of the vacuum device body 310.
[0076] With the vacuum device body 310 covered by the cover 320, the control unit 340 compresses the core 150 and the solid wood sheet 100 temporarily attached to the vacuum device body 310 by evacuating air from the vacuum space through the vacuum hole 313 of the vacuum device body 310 within a preset time. Afterward, the control unit 340 removes the vacuum from the vacuum space by controlling the vacuum module, allowing the compressed solid wood sheet 100 to be separated.
[0077] Subsequently, a vehicle crash pad including the solid wood sheet 100 can be manufactured by cutting off the remaining portion except for the solid wood sheet 100 pressed against the core 150.
[0078] According to embodiments of this disclosure, the solid wood sheet constituting the table of a vehicle can provide the same visual feel as solid wood and provide a predetermined degree of cushioning when occupants touch the solid wood sheet.
[0079] Furthermore, according to embodiments of this disclosure, the edge portion of a vehicle crash pad comprising solid wood sheets is manufactured using a film method, which allows for more precise attachment of the solid wood sheets to the core.
[0080] Although the configuration of this disclosure has been described in detail above with reference to the accompanying drawings, the description of the configuration is for illustrative purposes only, and those skilled in the art can make various modifications and variations without departing from the technical spirit of this disclosure. Therefore, the scope of protection of this disclosure should not be limited to the above-described embodiments, but should be determined by the appended claims.
[0081] Cross-reference to related applications
[0082] This application claims the benefit of Korean Patent Application No. 10-2021-0102382, filed on August 4, 2021, with the Korean Intellectual Property Office, the entire disclosure of which is incorporated herein by reference for all purposes.
Claims
1. A membrane apparatus for manufacturing a vehicle crash pad comprising solid wood sheets, the membrane apparatus comprising: A vacuum device body having a plurality of vacuum holes and configured such that the solid wood sheet temporarily attached to the core is installed in the vacuum device body; The cover has a silicone film and is configured to define a vacuum space together with the body of the vacuum device; A vacuum module configured to draw air from the main body of the vacuum device through the vacuum port; as well as A control unit is configured to compress the wood sheet and the core temporarily attached to and mounted on the vacuum device body by drawing air from the vacuum space through the vacuum port while the vacuum device body is covered by the cover; the control unit is also configured to control the vacuum module to remove the vacuum from the vacuum space, causing the compressed wood sheet to separate from the vacuum device body. The vacuum device body includes a plurality of wooden pins that can move upward or downward to accommodate the solid wood sheet, and as the wooden pins move downward, the solid wood sheet is placed on the surface of the core.
2. The membrane device according to claim 1, further comprising: A heater configured to heat the interior of the vacuum space. The control unit is configured to heat the solid wood sheet for a preset heating time before compressing the core and the solid wood sheet by operating the vacuum module.
3. The membrane device according to claim 1, wherein, The vacuum device body includes a fixing clamp, the core is mounted on the fixing clamp, the core is placed on the fixing clamp, and the solid wood sheet is placed on the wooden base pin.
4. The membrane device according to claim 1, further comprising: A vibration module configured to correct the position of the solid wood sheet by applying vibration to a core disposed beneath the solid wood sheet.
5. A crash pad for a vehicle, the crash pad comprising solid wood sheets manufactured from a membrane device for a vehicle according to claim 1.
6. A method for manufacturing a vehicle crash pad comprising solid wood sheets using a membrane device, the method comprising the following steps: With the cover open from the vacuum device body, multiple wooden pins move upward within the vacuum device body; Position the core on the fixing clamp located inside the wooden base pin, install the solid wood sheet on the upper part of the wooden base pin, and close and cover the vacuum device body with the cover; The control unit, by operating the vacuum module to achieve a vacuum state in the vacuum device body through the vacuum hole located in the lower part of the vacuum device body, presses the silicone resin film on the cover against the solid wood sheet, wherein, as the wooden base pin moves downward, the solid wood sheet is placed on the surface of the core; as well as Remove the vacuum from the inside of the vacuum device body, open the cover, and separate the fully produced solid wood product from the vacuum device body.
7. The method according to claim 6, wherein, The step of pressing the silicone resin film against the solid wood sheet includes heating the interior of the vacuum device body for a preset time.
8. The method according to claim 6, wherein, The step of pressing the silicone resin film against the solid wood sheet includes: maintaining the vacuum state for a preset time and completing the compression process.
9. The method according to claim 6, wherein, The step of closing the vacuum device body includes: applying vibration to the vacuum device body and the core disposed below the solid wood sheet by using a vibration module to correct the position of the solid wood sheet.
10. A crash pad for a vehicle, the crash pad comprising: Solid wood sheets manufactured by the method for manufacturing anti-collision pads for vehicles according to claim 6.