Vehicle trim panel member, vehicle and manufacturing method

Abstract

The application relates to the technical field of vehicles and discloses a vehicle trim panel component, a vehicle and a manufacturing method. The vehicle trim panel component comprises an outer layer and a base plate. The outer layer comprises a first flat layer and at least one first raised layer, the first raised layer is higher than the first flat layer, and the first flat layer and the first raised layer are continuously spliced together. The base plate is arranged opposite to the outer layer and comprises a second flat layer and at least one second raised layer, the second raised layer is higher than the second flat layer, the second flat layer and the second raised layer are continuously spliced together, the second raised layer corresponds to the first raised layer, the first raised layer is raised in a direction away from the base plate, one side of the first raised layer towards the base plate is provided with a recess, the recess is higher than the first flat layer, the second raised layer is raised in a direction close to the outer layer, and at least part of the second raised layer is matched to extend into the recess. The technical scheme of the application can reduce air trapping, improve product quality and improve the strength between structures.

Description

Technical Field

[0001] This application relates to the field of vehicle technology, and more particularly to a vehicle trim panel component, a vehicle, and a manufacturing method thereof. Background Technology

[0002] In vehicle interiors, to enhance both tactile feel and aesthetics, many areas utilize a combination of hard and soft materials. For example, shelves are often constructed using a two-layer structure formed through two-color injection molding. The bottom layer forms the framework, which can be made of a high-hardness material, while the upper layer is a soft rubber layer made of an elastomer.

[0003] Current related technologies may result in problems such as trapped air in the injection-molded products, leading to low product quality. Summary of the Invention

[0004] This application provides a vehicle trim panel component, a vehicle, and a manufacturing method that can reduce air entrapment, improve product quality, and enhance the strength between structures.

[0005] In a first aspect, embodiments of this application provide a vehicle trim panel component, including an outer layer and a substrate. The outer layer is made of a first material and includes a first flat layer and at least one first raised layer. The first raised layer is higher than the first flat layer, and the first flat layer and the first raised layer are continuously spliced ​​together to form the outer layer. The substrate is disposed opposite to the outer layer and is made of a second material, including a second flat layer and at least one second raised layer. The second raised layer is higher than the second flat layer, and the second flat layer and the second raised layer are continuously spliced ​​together to form the substrate. The second raised layer corresponds to the first raised layer. The first raised layer protrudes in a direction away from the substrate, and the side of the first raised layer facing the substrate has a recess that is higher than the first flat layer. The second raised layer protrudes in a direction close to the outer layer, and at least a portion of the second raised layer extends into the recess. The first material is different from the second material.

[0006] In some possible implementations, there are multiple first protrusions and multiple second protrusions, and multiple first protrusion layers and multiple second protrusion layers, which are set in a one-to-one correspondence.

[0007] In some possible implementations, the difference between the thickness of the first raised layer and the thickness of the first flat layer is less than 20%.

[0008] In some possible implementations, the width of the bottom end of the second raised layer is smaller than the thickness of the second flat layer.

[0009] In some possible implementations, the substrate further includes a mounting structure located at the edge, the mounting structure being integrally spliced ​​with the second planarization layer and having a portion higher than the second planarization layer, the portion of the mounting structure higher than the second planarization layer surrounding at least a portion of the outer edge of the outer layer, the mounting structure having an injection hole provided along the extension direction of the second planarization layer, one end of the injection hole extending into the outer layer and the other end penetrating through the mounting structure.

[0010] In some possible implementations, there are multiple injection holes, which are evenly spaced along the extension direction of the mounting structure.

[0011] In some possible implementations, the vehicle trim panel component also includes an adapter hole located in the middle, which penetrates the outer layer and the substrate in a direction perpendicular to the substrate. The outer layer is divided into a first casting layer and a second casting layer by the adapter hole. The injection area of ​​the first casting layer along its extension direction is larger than the injection area of ​​the second casting layer along its extension direction, and the thickness of the first casting layer is greater than the thickness of the second casting layer.

[0012] Secondly, this application also provides a vehicle, comprising:

[0013] Frame;

[0014] The first aspect is the vehicle trim panel component, which is mounted on the vehicle frame.

[0015] Thirdly, this application also provides a manufacturing method for manufacturing the vehicle trim panel component of the first aspect, comprising:

[0016] First, one of the outer layer and the substrate is injection molded, and then the other is injection molded on the one to form a vehicle trim panel component;

[0017] The outer layer is made of a first material and includes a first flat layer and a first raised layer that are continuously spliced ​​together; the substrate is made of a second material and includes a second flat layer and a second raised layer that are continuously spliced ​​together, with the first raised layer corresponding to the second raised layer; the first material and the second material are different.

[0018] In some possible implementations, a substrate is first injection molded using a second material, wherein the substrate includes a second flat layer and a second raised layer that are continuously spliced ​​together;

[0019] The outer layer is then formed by injection molding the first material onto the substrate to connect the outer layer and the substrate. The outer layer includes a first flat layer and a first raised layer that are continuously spliced ​​together, and the first raised layer corresponds to the second raised layer.

[0020] The vehicle trim panel component, vehicle, and manufacturing method of this application involve first injection molding one of an outer layer and a substrate, and then injection molding the other onto the formed one to form a vehicle trim panel component. The formed vehicle trim panel component includes an outer layer and a substrate, wherein the outer layer is made of a first material, the substrate is made of a second material, and the first material and the second material are different. The substrate and the outer layer are disposed opposite to each other. The outer layer includes a first flat layer and a first raised layer that are continuously spliced ​​together. The first raised layer protrudes in a direction away from the substrate and is higher than the first flat layer. Thus, the thickness of the first raised layer may be from its top surface to the bottom surface of the first flat layer, which will cause the thickness of the entire outer layer to suddenly increase at the first raised layer. The thickness difference between the first flat layer and the first raised layer is large, which is not conducive to injection molding and affects product quality. However, in the specific structure, the first raised layer has a recess on the side facing the substrate, and this recess is higher than the first flat layer. That is, the entire first raised layer is higher than the first flat layer, and it is also recessed on the non-raised side, forming a recess. Thus, the actual thickness of the first raised layer is not from its top surface to the bottom surface of the first flat layer, but from its top surface to the surface of the recess. In this way, by setting the recess, the thickness of the first raised layer is reduced, decreasing the thickness difference between the first flat layer and the first raised layer, thereby facilitating injection molding and improving product quality. The specific principle is as follows: during the manufacturing of the outer layer and the substrate, hot melt is injected into the corresponding mold using injection molding equipment. The melt then flows into the pre-set product space in the mold, solidifies after filling, is demolded and trimmed, and finally perfected into the product. Given a fixed product area, a smaller product thickness results in less space within the mold, leading to greater resistance to melt flow and a lower flow rate. Conversely, a larger product thickness results in more space within the mold, less resistance to melt flow and a higher flow rate. Consequently, for the outer layer of this application, if the thickness difference between the first flat layer and the first raised layer is significant, the melt will preferentially flow into the thicker area at a faster rate. This may cause the thicker area to be filled prematurely, resulting in overflow and backflow to the thinner area. This overflow will then merge with the slower-flowing melt in the thinner area, causing air entrapment, incomplete filling, and weld lines, thus affecting product quality. This application reduces the thickness difference between the first flat layer and the first protruding layer by setting the recess, so that the flow rate difference of the melt at various positions during injection molding is reduced, making it less likely to backflow and converge. It can correctly squeeze the gas in the mold to the edge of the mold for discharge, and will not cause problems such as trapped air, incomplete filling, and weld lines, thereby improving product quality.Furthermore, the substrate includes a second flat layer and at least one second raised layer continuously spliced ​​together. The second raised layer is higher than the second flat layer and corresponds to the first raised layer. To make the structure more stable, the second raised layer protrudes towards the outer layer, and at least a portion of the second raised layer extends into the recess. In this way, the second raised layer can provide support for the first raised layer. At the same time, the cooperation between the second raised layer and the recess can improve the connection strength between the outer layer and the substrate. Specifically, on the one hand, the fact that at least a portion of the second raised layer extends into the recess is equivalent to the second raised layer and the recess interlocking with each other. Thus, the connection between the outer layer and the substrate includes not only the adhesive effect of the first and second flat layers, but also the effect of the second raised layer and the recess of the first raised layer preventing relative displacement between the outer layer and the substrate along the extension direction of the first flat layer. On the other hand, due to the cooperation between the second raised layer and the recess, the contact area of ​​the adhesive is increased compared to simple flat surface contact, thus increasing the connection strength. Therefore, in summary, the vehicle trim panel component and manufacturing method of this application can reduce air entrapment, improve product quality, and increase the strength between structures. Attached Figure Description

[0021] Figure 1 This is a structural schematic diagram of the vehicle trim panel component of this application;

[0022] Figure 2 This is a partial top view of the vehicle trim panel component of this application;

[0023] Figure 3 for Figure 3 A schematic diagram of a partial cross-sectional structure at point AA;

[0024] Figure 4 for Figure 3 A schematic diagram of the substrate structure in the diagram;

[0025] Figure 5 This application provides a structural schematic diagram of a vehicle trim panel component with injection holes.

[0026] Figure 6 This is a schematic diagram of the outer layer of the vehicle trim panel component of this application;

[0027] Figure 7 This is a flowchart illustrating the manufacturing method of this application.

[0028] Figure label:

[0029] 1-Outer layer; 11-First flat layer; 12-First raised layer; 121-Recess; 13-First casting layer; 14-Second casting layer; 2-Substrate; 21-Second flat layer; 22-Second raised layer; 23-Mounting structure; 24-Injection hole; 3-Adapter hole. Detailed Implementation

[0030] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the specific technical solutions of this application will be further described in detail below with reference to the accompanying drawings of the embodiments of this application. The following embodiments are used to illustrate this application, but are not intended to limit the scope of this application.

[0031] In the embodiments of this application, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of the embodiments of this application, unless otherwise stated, "multiple" means two or more.

[0032] Furthermore, in the embodiments of this application, directional terms such as "upper," "lower," "left," and "right" are defined relative to the positions in which the components are schematically placed in the accompanying drawings. It should be understood that these directional terms are relative concepts, used for relative description and clarification, and can change accordingly depending on the position of the components in the accompanying drawings.

[0033] In the embodiments of this application, unless otherwise explicitly specified and limited, the term "connection" should be interpreted broadly. For example, "connection" can mean a fixed connection, a detachable connection, or an integral part; it can mean a direct connection or an indirect connection through an intermediate medium.

[0034] In embodiments of this application, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element.

[0035] In the embodiments of this application, the terms "exemplary" or "for example" are used to indicate that something is an example, illustration, or description. Any embodiment or design that is described as "exemplary" or "for example" in the embodiments of this application should not be construed as being more preferred or advantageous than other embodiments or design. Specifically, the use of the terms "exemplary" or "for example" is intended to present the relevant concepts in a specific manner.

[0036] This application provides a vehicle, including a frame, with vehicle decorative panel components provided at desired locations on the frame. Exemplarily, the vehicle can refer to a sedan, SUV, sport utility vehicle (SUV), multi-purpose vehicle (MPV), truck, bus, public bus, etc. In this application embodiment, the vehicle can refer to a gasoline-powered vehicle, a new energy vehicle, a hybrid electric vehicle, or a vehicle powered by a traction power supply system, such as a trolleybus.

[0037] This application provides a vehicle trim panel component that can be installed at any location on any vehicle where a trim panel component is required. This arbitrary location can be above the dashboard, on the glove compartment in front of the passenger seat, on the door trim, armrest, rear armrest, headliner, etc.

[0038] Specifically, please refer to Figure 1 , Figure 2 and Figure 3 This application provides a vehicle trim panel component, including an outer layer 1 and a substrate 2. The outer layer 1 is made of a first material and includes a first flat layer 11 and at least one first raised layer 12. The first raised layer 12 is higher than the first flat layer 11. The first flat layer 11 and the first raised layer 12 are continuously spliced ​​together to form the outer layer 1. The substrate 2 is disposed opposite to the outer layer 1 and is made of a second material, including a second flat layer 21 and at least one second raised layer 22. The second raised layer 22 is higher than the second flat layer 11. Layer 21, second flat layer 21 and second raised layer 22 are continuously spliced ​​together to form substrate 2. The second raised layer 22 corresponds to the first raised layer 12. The first raised layer 12 protrudes in a direction away from substrate 2 and has a recess 121 on the side of the first raised layer 12 facing substrate 2. The recess 121 is higher than the first flat layer 11. The second raised layer 22 protrudes in a direction close to outer layer 1 and at least a portion of the second raised layer 22 extends into the recess 121. The first material is different from the second material.

[0039] The vehicle trim panel component of this application includes an outer layer 1 and a substrate 2, wherein the outer layer 1 is made of a first material and the substrate 2 is made of a second material, and the first material and the second material are different, and the substrate 2 and the outer layer 1 are disposed opposite to each other.

[0040] The outer layer 1 includes a first flat layer 11 and a first raised layer 12 that are continuously spliced ​​together. The first raised layer 12 protrudes in a direction away from the substrate 2. The first raised layer 12 is higher than the first flat layer 11. Thus, the thickness of the first raised layer 12 may be from its top surface to the bottom surface of the first flat layer 11. This will cause the thickness of the entire outer layer 1 to suddenly increase at the first raised layer 12. The thickness difference between the first flat layer 11 and the first raised layer 12 is large, which will be detrimental to injection molding and affect product quality. However, in the specific structure, the first protruding layer 12 has a recess 121 on the side facing the substrate 2, and the recess 121 is higher than the first planar layer 11. That is, the entire first protruding layer 12 is higher than the first planar layer 11, and it is also recessed on the non-protruding side to form the recess 121. In this way, the actual thickness of the first protruding layer 12 is not from its top surface to the bottom surface of the first planar layer 11, but from its top surface to the surface of the recess 121. Thus, by setting the recess 121, the thickness of the first protruding layer 12 is reduced, the thickness difference between the first planar layer 11 and the first protruding layer 12 is reduced, thereby facilitating injection molding and improving product quality.

[0041] The specific principle is as follows: during the manufacturing of outer layer 1 and substrate 2, hot melt is injected into the corresponding mold using injection molding equipment. The melt then flows into the space of the product pre-set in the mold, solidifies after filling, demolds and trims, and finally becomes the product. Given a fixed product area, a smaller product thickness results in less space within the mold, leading to greater resistance to melt flow and a lower flow rate. Conversely, a larger product thickness results in more space within the mold, less resistance to melt flow and a higher flow rate. Consequently, for the outer layer 1 of this application, if the thickness difference between the first flat layer 11 and the first raised layer 12 is significant, the melt will preferentially flow into the thicker area at a faster rate. This may cause the thicker area to be filled prematurely, resulting in overflow and backflow to the thinner area. This overflow will then merge with the slower-flowing melt in the thinner area, causing air entrapment and preventing the melt from being fully filled, thus creating weld lines and affecting product quality. By setting the recess 121, this application reduces the thickness difference between the first flat layer 11 and the first protruding layer 12, so that the flow rate difference of the melt at various positions during injection molding of the outer layer 1 is reduced, making it less likely to backflow or converge. This allows the gas in the mold to be correctly squeezed to the edge of the mold for discharge, preventing problems such as trapped air, incomplete filling, and weld lines, thereby improving product quality.

[0042] In addition, the substrate 2 includes a second flat layer 21 continuously spliced ​​together and at least one second protruding layer 22. The second protruding layer 22 is higher than the second flat layer 21 and corresponds to the first protruding layer 12. In order to make the structure more stable, the second protruding layer 22 protrudes towards the direction close to the outer layer 1, and at least a portion of the second protruding layer 22 extends into the recess 121. In this way, the second protruding layer 22 can provide support for the first protruding layer 12. At the same time, the connection strength between the outer layer 1 and the substrate 2 can be improved through the cooperation of the second protruding layer 22 and the recess 121. Specifically, on the one hand, at least a portion of the second protruding layer 22 extends into the recess 121, which is equivalent to the second protruding layer 22 and the recess 121 being embedded in each other and interlocked together. Thus, the connection between the outer layer 1 and the substrate 2 includes not only the adhesive effect of the first flattening layer 11 and the second flattening layer 21, but also the effect of the recess 121 of the second protruding layer 22 and the first protruding layer 12 preventing relative displacement between the outer layer 1 and the substrate 2 along the extension direction of the first flattening layer 11. On the other hand, due to the cooperation between the second protruding layer 22 and the recess 121, the contact area for bonding is increased compared to simple flat surface contact, thus increasing the connection strength. Therefore, in summary, the vehicle trim panel component of this application can reduce air trapping, improve product quality, and enhance the strength between structures.

[0043] It should be noted that in the vehicle trim panel component of this application embodiment, the outer layer 1 and the substrate 2 are made of a first material and a second material, respectively. The first material and the second material are different. For example, the outer layer 1 can be a soft rubber layer, and the substrate 2 can be a hard rubber layer. In this way, the substrate 2 can act as a skeleton to support the outer layer 1 and is used to connect and fix it to other components inside the vehicle. The outer layer 1 is soft and has high friction, making it convenient to place items or improve the tactile feel. As another example, the outer layer 1 is a transparent material layer, and the substrate 2 is a non-transparent material layer. In this way, lights can be installed inside the vehicle trim panel component, and the desired lighting effects, such as interior ambient lighting or button indicator lights, can be displayed through the transparent material layer of the outer layer 1. Vehicle trim panel components made of different materials can be made using two-color injection molding. The wall thickness of the soft and hard rubber in the two-color injection molding is smaller than that of general injection molded parts (2mm-3.5mm). For example, the thickness of the outer layer 1 and the substrate 2 is less than 2.5mm or less than 2.0mm.

[0044] Furthermore, in the vehicle trim panel component of this application embodiment, the outer layer 1 and the substrate 2 are formed by step-by-step injection molding of different materials. That is, the outer layer 1 and the substrate 2 can both be used as the base enclosure structure for injection molding of the other. Therefore, the shape of the recess 121 of the first protruding layer 11 of the outer layer 1 and the shape of the second protruding layer 12 of the substrate 2 are matched and bonded together during injection molding. The bonding effect can be achieved by thermal fusion bonding between the melts.

[0045] In the vehicle trim panel component of this application embodiment, the number of the first protruding layer 12 and the second protruding layer 22 is not limited. As long as there is a relative arrangement of a first protruding layer 12 and a second protruding layer 22, the generation of trapped air can be reduced at the first protruding layer 12 where the second protruding layer 22 is provided, thereby improving the quality of the product.

[0046] For example, in some embodiments, the first protrusion layer 12 and the second protrusion layer 22 are both one and are disposed in corresponding positions.

[0047] In other embodiments, please refer to Figure 3 There are multiple first protruding layers 12 and second protruding layers 22, and they are arranged in a one-to-one correspondence. This ensures that the occurrence of air entrapment is reduced at each position of the first protruding layer 12, and increases the stability of the connection between the outer layer 1 and the substrate 2. Specifically, for the outer layer 1, each position where a first protruding layer 12 needs to be set for easy placement of items may experience air entrapment due to uneven injection flow rate caused by the large thickness of the first protruding layer 12. However, in the solution of this application, the first protruding layer 12 has a recess 121, which reduces the thickness of the first protruding layer 12, making the thickness of the first protruding layer 12 less different from the thickness of the first flat layer 11, which can effectively reduce the occurrence of quality problems such as air entrapment. Meanwhile, the one-to-one arrangement of multiple first protrusion layers 12 and multiple second protrusion layers 22 allows the outer layer 1 and the substrate 2 to be fixedly connected by multiple sets of first protrusion layers 12 and second protrusion layers 22, increasing the limiting function area along the extension direction of the first flat layer 11, further increasing the contact area of ​​the bonding between the outer layer 1 and the substrate 2, and further improving the connection stability between the structures.

[0048] The uniformity of the thickness of the first flat layer 11 and the first raised layer 12 of the outer layer 1 determines the flow rate of the plastic melt through that area. In order to ensure that the flow rate changes as little as possible and reduce product quality problems such as trapped air caused by backflow, in the embodiments of this application, the thickness difference between the first flat layer 11 and the first raised layer 12 is as small as possible.

[0049] For example, in some embodiments, the difference between the thickness of the first raised layer 12 and the thickness of the first flat layer 11 is less than 20%. Based on the condition that the thickness difference is less than 20%, a better reduction in trapped air effect can be guaranteed. The specific setting of the thickness difference can be measured through multiple actual physical production experiments. The product size is limited by the mold design, and products produced under different sizes are measured and recorded, and quality comparisons are made. Of course, analysis and verification can also be performed using software to avoid resource waste and improve design efficiency. For example, flow analysis can be performed using MOLDFLOW software (plastic injection molding simulation software) to analyze shrinkage marks, trapped air, and weld lines in the shelf soft plastic. By continuously verifying appearance quality issues, the thickness design at each location is continuously adjusted until the requirements are met. The condition that the thickness difference is less than 20% in the embodiments of this application can guarantee a better reduction in trapped air effect, which is derived through multiple experiments and software simulations.

[0050] When the thickness difference of the first protruding layer 11 is large, local unevenness may occur, potentially causing air entrapment and affecting product quality. To avoid this problem, the overall thickness of the first protruding layer 11 can be made as uniform as possible. For example, in some embodiments, the difference between the thickest and thinnest points of the first protruding layer 12 is less than 20%. Similarly, through multiple experiments and software simulations, it has been shown that a thickness difference of less than 20% can ensure a better reduction in air entrapment. Flow analysis using MOLDFLOW software can be used to further adjust the thickness design at each location, which can be referred to... Figure 3 Adjust the thicknesses of H1, H2, and H3 to be uniform until the requirements are met.

[0051] To avoid shrinkage at the second protrusion layer 22 during injection molding of the substrate 2, please refer to... Figure 4 In some embodiments, the width of the bottom end of the second protruding layer 22 is smaller than the thickness of the second flattening layer 21. It should be noted that... Figure 4 The circle drawn below the second protrusion layer 22 is a reference drawing and not a solid structure. The diameter of this circle is the thickness of the substrate 2. It can be clearly seen that the width of the second protrusion layer 22 (refer to...) Figure 4 The diameter of the circle (W) is much smaller than that of the circle. The narrower second protrusion layer 22 can reduce or prevent shrinkage at this location during molding. Simultaneously, the second protrusion layer 22 increases the contact area between the substrate 2 and the mold during molding, further reducing or preventing shrinkage at this location. Furthermore, even if slight shrinkage occurs at this location, the shrinkage area can be completely filled and covered by the first protrusion layer 12 covering the outer layer 1 on the second protrusion layer 22, without affecting the product's appearance.

[0052] The specific shape and structure of the first raised layer 12 and the second raised layer 22 can take many forms. For example, they can both be arranged in a dot matrix, or both can be strip-shaped raised, or they can be specific drawn patterns, reliefs, etc.

[0053] From the perspective of the longitudinal cross-section of the first protruding layer 12 and the second protruding layer 22, in some embodiments, the longitudinal cross-section of the first protruding layer 12 and the second protruding layer 22 can be a "U" structure.

[0054] Furthermore, in some embodiments, the longitudinal structure of the first protrusion layer 12 and the second protrusion layer 22 is a tapered structure that is larger at the bottom and smaller at the top.

[0055] For aesthetic purposes or ease of installation, special structures may be incorporated into the substrate 2. These structures may be located at the outer edge of the entire vehicle trim panel component. This means that in certain areas of the structure, the outer layer 1 may be missing its soft adhesive. Consequently, during injection molding of the outer layer 1, it may only be possible to injection mold from one side, resulting in a wider injection width and hindering the flow of the soft adhesive. For an example, please refer to [reference needed]. Figure 5 The substrate 2 has a flanged mounting structure 22. The holes in the mounting structure 22 require side core pulling in the mold, and there is no space to arrange a hot runner structure. Therefore, the parting surface of the hard plastic of the substrate 2 and the parting surface of the soft plastic of the outer layer 1 are not in the same position, and the gate cannot be arranged at the front end of the soft plastic of the outer layer 1 of the entire vehicle trim panel component.

[0056] To resolve the above issues, please refer to Figure 5 In some embodiments of this application, the substrate 2 further includes a mounting structure 23 located at the edge. The mounting structure 23 is integrally spliced ​​with the second flat layer 21 and has a portion higher than the second flat layer 21. The portion of the mounting structure 23 higher than the second flat layer 21 surrounds at least a portion of the outer edge of the outer layer 1. The mounting structure 23 is provided with an injection hole 24 disposed along the extending direction of the second flat layer 21. One end of the injection hole 24 extends into the outer layer 1, and the other end penetrates through the mounting structure 23. By providing the injection hole 24 corresponding to the outer layer 1 in the mounting structure 23, the outer layer 1 can be injection molded with molten plastic through the injection hole 24 on the side blocked by the mounting structure 23, which facilitates the injection molding of the outer layer 1. Moreover, after the outer layer 1 is molded, the injection hole 24 is filled with the first material corresponding to the outer layer 1, which can be integrated with the substrate 2, resulting in good surface quality and increasing the connection between the outer layer 1 and the substrate 2, making the connection more robust.

[0057] The number of injection holes 24 can be set according to actual needs. For example, in some embodiments, there is one injection hole 24.

[0058] Please see Figure 5In other embodiments, there are multiple injection holes 24, and the multiple injection holes 24 are evenly spaced along the extension direction of the mounting structure 23.

[0059] Please see Figure 5 For example, seven injection holes 24 are provided on the case structure. The ends of the injection holes 24 are connected to the soft rubber of the outer layer 1. Thus, seven gates are arranged at the beginning of the injection holes 24, which can be used to inject the soft rubber part of the outer layer 1 from the injection holes 24.

[0060] In some embodiments, the injection hole 24 is a straight strip-shaped hole to ensure the fluidity of the melt.

[0061] Please see Figure 1 and Figure 6 In some embodiments, the vehicle trim panel component further includes an adapter hole 3 disposed in the center, the adapter hole 3 penetrating the outer layer 1 and the substrate 2 in a direction perpendicular to the substrate 2. Please refer to [link to relevant documentation]. Figure 6 The outer layer 1 is divided into a first casting layer 13 and a second casting layer 14 with the adapter hole 3 as the boundary. The injection area of ​​the first casting layer 13 along its extension direction is larger than the injection area of ​​the second casting layer 14 along its extension direction, and the thickness of the first casting layer 13 is greater than the thickness of the second casting layer 14.

[0062] It should be noted that, for various design or structural functional requirements, the adapter hole 3 in the middle of the vehicle trim panel component can take many forms. For example, the adapter hole 3 could be a mounting hole for an ambient light. When these adapter holes 3 separate the outer layer 1 into a first gating layer 13 and a second gating layer 14, if the distances of the first gating layer 13 and the second gating layer 14 relative to their corresponding gates are inconsistent, the time required for the melt to flow to the adapter hole 3 will differ. If the melt flows past the adapter hole 3 too early, it will bypass the adapter hole 3 and continue its previous flow, forming a long weld line at the point of merging with the melt at the other end. If the melt flows slowly, it may not even reach the adapter hole 3 before forming a stagnation line due to the flow rate.

[0063] In the embodiments of the vehicle trim panel component of this application, since the injection area of ​​the first gating layer 13 is larger than that of the second gating layer 14, that is, if the thicknesses of the first gating layer 13 and the second gating layer 14 are the same, the melt will take longer to flow through the first gating layer 13 than the second gating layer 14, which may result in weld lines and retention lines. Therefore, the thickness of the first gating layer 13 is set to be greater than that of the second gating layer 14. In this way, the melt flow resistance of the thicker first gating layer 13 is less than that of the thinner first gating layer 13. That is to say, comparatively speaking, the melt flow velocity of the thicker first gating layer 13 is greater than that of the thinner first gating layer 13, thereby allowing the first gating layer 13 and the second gating layer 14 to flow back to the adapter hole 3 at the same time.

[0064] In some embodiments, the reduction in thickness of the second pouring layer 14 can be gradual or directly lower than the thickness of the first pouring layer 13. Gradual reduction includes linear, continuous thickness reduction and stepped thickness reduction. Furthermore, in the stepped thickness reduction scheme, a proportional reduction can be used.

[0065] It should be noted that the thickness settings of the first pouring layer 13 and the second pouring layer 14, or the setting scheme of the thickness of the second pouring layer 14 gradually decreasing, can be achieved through software simulation analysis.

[0066] It should be noted that the principles of adjusting melt flow rate through thickness are all the same, similar to the principle of a showerhead in daily life; small holes increase the flow resistance of the fluid. When the melt is injected into the mold, the spaces within the mold are interconnected. Areas with smaller spaces experience greater flow resistance and a higher flow rate, while areas with larger spaces experience less flow resistance and a faster flow rate. The melt will preferentially flow to areas with larger spaces. For the vehicle trim panel component of this application embodiment, the greater the product thickness, the larger the space in the mold at that location, resulting in lower flow resistance and a faster flow rate, making it easy to overflow and cause backflow. Conversely, the smaller the product thickness, the smaller the space in the mold at that location, resulting in higher flow resistance and a slower flow rate, potentially causing faster-flowing melt to flow into that area first, leading to confluence and air trapping. Therefore, in the vehicle trim panel component of this application embodiment, the thickness is optimized to be uniform in areas prone to backflow, confluence, and air trapping.

[0067] This application also provides a vehicle, including a frame and the vehicle trim panel component described in the above embodiments, wherein the vehicle trim panel component is disposed on the frame.

[0068] The vehicle in this embodiment of the application, since it includes the vehicle decorative panel component in the above embodiment, has the same beneficial effects, namely, it can reduce air entrapment, improve product quality, and increase the strength between structures.

[0069] This application also provides a manufacturing method for manufacturing the vehicle trim panel component of the above embodiments, comprising the following steps:

[0070] First, one of the outer layer 1 and the substrate 2 is injection molded, and then the other is injection molded on the one to form a vehicle trim panel component;

[0071] The outer layer 1 is made of a first material and includes a first flat layer 11 and a first raised layer 12 that are continuously spliced ​​together; the substrate 2 is made of a second material and includes a second flat layer 21 and a second raised layer 22 that are continuously spliced ​​together, and the first raised layer 12 corresponds to the second raised layer 22; the first material and the second material are different.

[0072] The manufacturing method of this application embodiment first injection molds one of the outer layer 1 and the substrate 2, and then injection molds the other on the one formed to form a vehicle trim panel component. Since the manufactured vehicle trim panel component is the vehicle trim panel component of the above embodiment, it can reduce air entrapment, improve product quality, and improve the strength between structures.

[0073] In the manufacturing method of this application embodiment, the injection sequence of the outer layer 1 and the substrate 2 can be determined according to actual needs. For example, in order to achieve a good bonding effect between the outer layer 1 and the substrate 2, the one with a higher injection temperature can be injected first, followed by the one with a lower injection temperature. In this way, the temperature of the one with a higher temperature decreases more slowly after injection, and when it is injected with the other one with a lower temperature, it can be ensured that the fluidity and adhesion of the melt with the lower temperature will not be affected.

[0074] Specifically, in some embodiments, the first material is a transparent material and the second material is a non-transparent material. The transparent material can be injection molded first to form the outer layer 1, and then the non-transparent material can be injection molded on top of the outer layer 1 to form the substrate 2. Finally, the material is demolded to form the vehicle trim panel component of this application embodiment. In other embodiments, the first material is a soft rubber material and the second material is a hard rubber material. The hard rubber material can be injection molded first to form the substrate 2, and then the soft rubber material can be injection molded on top of the substrate 2 to form the outer layer 1. Finally, the material is demolded to form the vehicle trim panel component of this application embodiment.

[0075] Since the hardness of the second material of substrate 2 is greater than the hardness of the first material of outer layer 1, substrate 2 can be fabricated first, and then outer layer 1 can be directly formed on substrate 2 using substrate 2 as a framework. For details, please refer to [link to relevant documentation]. Figure 7 This includes the following steps:

[0076] S1: First, a substrate 2 is formed by injection molding using a second material. The substrate 2 includes a second flat layer 21 and a second raised layer 22 that are continuously spliced ​​together.

[0077] S2: Then, the outer layer 1 is formed by injection molding on the substrate 2 using the first material to connect the outer layer 1 and the substrate 2. The outer layer 1 includes a first flat layer 11 and a first raised layer 12 that are continuously spliced ​​together, and the first raised layer 11 corresponds to the second raised layer 22.

[0078] This type of injection molding can reduce process steps, improve production efficiency, and enable two-color injection molding of vehicle trim panel components.

[0079] The above are merely preferred embodiments of this application and do not limit the patent scope of this application. Any equivalent structural or procedural transformations made using the content of this application's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of this application.

Claims

1. A vehicle trim panel component, characterized in that, include: The outer layer is made of a first material and includes a first flat layer and at least one first raised layer, wherein the first raised layer is higher than the first flat layer, and the first flat layer and the first raised layer are continuously spliced ​​together to form the outer layer; A substrate, disposed opposite to the outer layer and made of a second material, includes a second flat layer and at least one second raised layer. The second raised layer is higher than the second flat layer. The second flat layer and the second raised layer are continuously spliced ​​together to form the substrate. The second raised layer corresponds to the first raised layer. The first raised layer protrudes in a direction away from the substrate and has a recess on the side facing the substrate, the recess being higher than the first flat layer. The second raised layer protrudes in a direction close to the outer layer, and at least a portion of the second raised layer extends into the recess. The first material is different from the second material. The substrate also includes a mounting structure located at the edge. The mounting structure is spliced ​​integrally with the second flat layer and has a portion higher than the second flat layer. The portion of the mounting structure higher than the second flat layer surrounds at least a portion of the outer edge of the outer layer. The adapter hole penetrates the outer layer and the substrate in a direction perpendicular to the substrate. The outer layer is divided into a first casting layer and a second casting layer with the adapter hole as the boundary. The injection area of ​​the first casting layer along its extension direction is greater than the injection area of ​​the second casting layer along its extension direction. The thickness of the first casting layer is greater than or equal to the thickness of the second casting layer.

2. The vehicle trim panel component according to claim 1, characterized in that, There are multiple first protrusion layers and multiple second protrusion layers, and they are set in a one-to-one correspondence.

3. The vehicle trim panel component according to claim 1, characterized in that, The difference between the thickness of the first raised layer and the thickness of the first flat layer is less than 20%.

4. The vehicle trim panel component according to claim 1, characterized in that, The width of the bottom of the second raised layer is less than the thickness of the second flattening layer.

5. The vehicle trim panel component according to any one of claims 1 to 4, characterized in that, The mounting structure is provided with an injection hole along the extension direction of the second flat layer, one end of the injection hole extends into the outer layer, and the other end penetrates the mounting structure.

6. The vehicle trim panel component according to claim 5, characterized in that, The injection holes are multiple and are evenly spaced along the extension direction of the mounting structure.

7. A vehicle, characterized in that, include: Frame; The vehicle trim panel component according to any one of claims 1 to 6 is disposed on the vehicle frame.

8. A manufacturing method for manufacturing vehicle trim panel components according to any one of claims 1 to 6, characterized in that, include: First, one of the outer layer and the substrate is injection molded, and then the other is injection molded on the one that has been made to form the above-mentioned vehicle trim panel component; The outer layer is made of a first material and includes a first flat layer and a first raised layer that are continuously spliced ​​together; the substrate is made of a second material and includes a second flat layer and a second raised layer that are continuously spliced ​​together, and the first raised layer corresponds to the second raised layer; the first material and the second material are different.

9. The manufacturing method according to claim 8, characterized in that, The substrate is first injection molded using the second material, wherein the substrate includes a second flat layer and a second raised layer that are continuously spliced ​​together; The outer layer is then formed by injection molding the first material onto the substrate to connect the outer layer and the substrate. The outer layer includes a first flat layer and a first raised layer that are continuously spliced ​​together, and the first raised layer corresponds to the second raised layer.

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