Automobile sunroof hemming roof wet one-step forming process method

Abstract

The application relates to a wet one-time forming process method of an automobile sunroof edge covering roof, wherein when being molded, materials include a surface fabric, glass fiber, a PU foam plate, glass fiber and a back layer material from top to bottom in sequence, mutual adhesive is arranged on the glass fiber and the PU foam plate, epoxy resin glue is arranged at an edge covering position of the roof sunroof to replace hot melt glue, the epoxy resin glue is used for separating the edge covering area and a wet framework, the epoxy resin glue facilitates cutting of excess framework during cutting, and finally the surface fabric of the edge covering area is coated with glue and reversely covered. The application has the effects of reducing a process, improving production efficiency and only needing one set of molds for one-time molding.

Description

Technical Field

[0001] This application relates to the field of a wet-process manufacturing process for automotive interior headliners, and more particularly to a wet one-time molding process for automotive sunroof edging headliners. Background Technology

[0002] Currently, the production methods for automotive interior headliners include wet and dry processes. The dry process is a one-step process where PU sandwich panels are heated to about 180°C. The hot melt adhesive powder on the surface of the panels melts and bonds to the fabric on the surface layer. The headliner is then molded in an unheated mold. The wet process uses liquid molding adhesive to bond the upper non-woven fabric, fiberglass, PU foam board, fiberglass, and the backing non-woven fabric together. The wet skeleton is then formed in a mold heated to about 100°C. Finally, polyurethane composite adhesive is used to bond the surface fabric to the surface non-woven fabric of the wet skeleton.

[0003] Wet-laid headliners are characterized by their high rigidity and ability to achieve complex shapes, making them widely used in high-end cars. Another reason for using wet-laid headliners in high-end cars is that the process involves two steps. In the first step, after creating the wet-laid frame, partial cutting is performed on the sunroof and front and rear edges. In the second step, when laminating the surface fabric, the surface fabric can be made larger than the wet-laid frame at the sunroof and front and rear edges. This allows for reverse-wrapping of the surface fabric at the headliner cuts, significantly improving the visual effect of the headliner and making it less prone to separation from the wet-laid frame. Summary of the Invention

[0004] To reduce processes and improve production efficiency, this application provides a wet one-time molding process for automotive sunroof edging and roof coverings, requiring only one set of molds for each molding operation.

[0005] The technical solution provided in this application for a wet one-step molding process for automotive sunroof edging and roof panels is as follows: A wet one-time molding process for a car sunroof edging roof includes the following materials from top to bottom during molding: a surface fabric, fiberglass, PU foam board, fiberglass again, and a backing material. Hot melt adhesive is used between the fiberglass and the PU foam board to bond them together. Epoxy resin adhesive is used at the edging area of ​​the sunroof to replace the hot melt adhesive, separating the edging area from the wet frame and facilitating the removal of excess frame material during cutting. Finally, the surface fabric of the edging area is coated with adhesive and wrapped back.

[0006] By employing the above technical solution, during molding, materials are placed sequentially from top to bottom, including the surface fabric, fiberglass, PU foam board, fiberglass again, and backing material. These materials are layered to form the framework structure of the skylight canopy. Fiberglass and PU foam board are bonded together. This ensures adhesion between materials, enhancing the structure's stability and durability. At the edge of the skylight, epoxy resin adhesive replaces hot melt adhesive. This adhesive film, with its high melting point and fast curing properties, isolates the edge area from the wet-laid framework. It also makes it easier to cut away excess framework during trimming, ensuring a neat and precise edge. Finally, the surface fabric at the edge is coated with adhesive and then reversed. This step aims to fix the surface fabric, ensuring strong adhesion to other materials, thus completing the skylight's construction.

[0007] Optionally, a wet one-time molding process for automotive sunroof edging includes the following steps: S1. Place the PU foam board into the glue roller and apply hot melt adhesive to both sides of the PU foam board. Use a film removal machine to remove the hot melt adhesive from the edge area. The amount of adhesive applied is 30-50g / m2 and the temperature of the glue roller is 15-45℃. S2, use a sprinkler to evenly spray purified water on both sides of the PU foam board; S3, lay the surface fabric, fiberglass, PU foam board, fiberglass, and backing material in the order from top to bottom. Among them, at the junction of the edge area of ​​the material ceiling skylight, the surface fabric, epoxy resin, fiberglass, PU foam board, fiberglass, epoxy resin, and backing material are laid from top to bottom. S4. The combined material obtained in step S3 is fed into a hot press mold machine. The mold is pressed down to form the initial shape of the roof. The mold temperature is 130-150℃, the forming pressure is 8-9MPa, and the holding pressure time after the mold is fully closed is controlled at 30-45s.

[0008] S5, the initial shape of the ceiling with the fabric bonded is cooled and shaped at room temperature for 55-60 seconds; S6. After cooling and shaping, the initial roof form is water-jet cut to remove excess frame and obtain the roof. The water pressure for water-jet cutting is 40,000~50,000 psi, and the air pressure for water-jet cutting is 4.0~6.0 kg / cm2. S7, use glue to wrap the outer fabric of the edge area backwards.

[0009] By employing the above technical solution, PU foam boards are placed in a roller glue machine, and hot melt adhesive is applied to both sides. A film-removing machine is used to remove the hot melt adhesive from the edge-wrapping areas. This step ensures the adhesion of the foam board to other materials. Pure water is then evenly sprayed onto both sides of the PU foam board using a sprinkler. This may be to improve the adhesion of the foam board or to better handle subsequent steps. The surface fabric, fiberglass, PU foam board, fiberglass, and backing material are laid in sequence, with additional epoxy resin adhesive and surface fabric applied at the edge-wrapping joints. The assembled materials are then fed into a hot press mold machine for molding to obtain the preliminary ceiling shape. This step ensures tight adhesion between materials and forms the shape of the skylight. The preliminary ceiling is cooled and set at room temperature to fix its shape. This step ensures the stability and structure of the ceiling. The cooled and set ceiling is cut using a water jet to remove excess frame. This step may be to trim the edges of the ceiling for a cleaner look. Finally, the surface fabric in the edge-wrapping areas is reversed to fix its position and ensure adhesion to other materials. This step is the final finishing process to ensure the integrity and aesthetics of the ceiling.

[0010] Optionally, the curing temperature range of the hot melt adhesive is 120-150℃, and the melting point of the epoxy resin adhesive is 150℃.

[0011] By employing the above technical solution, the hot melt adhesive has a melting point of 120-150℃. Within this temperature range, the hot melt adhesive is in a liquid or semi-solid state, enabling it to form a strong bond between PU foam boards and other materials. In step S1, applying hot melt adhesive to the PU foam board ensures sufficient adhesive strength between the layers. During hot pressing (step S4), the temperature of the hot press mold typically reaches the curing temperature range of the hot melt adhesive, promoting adhesive flow and material bonding. Epoxy resin has a melting point of 150℃, which is relatively high, meaning it requires a higher temperature to reach a liquid state. In step S3, placing the epoxy resin between the surface fabric and fiberglass forms a protective layer that is resistant to damage at high temperatures. During hot pressing, the temperature of the hot press mold can reach a sufficiently high level to ensure the epoxy resin reaches its melting point and performs its function.

[0012] Optionally, during cooling and setting, the epoxy resin adhesive solidifies and bonds faster than the hot melt adhesive, thus separating the edge-wrapping area from the wet skeleton.

[0013] By adopting the above technical solution, rapid solidification means that epoxy resin adhesive can form a strong bond more quickly, ensuring a more reliable isolation effect between the edge-wrapped area and the wet skeleton.

[0014] Optionally, the surface fabric of the edge-binding area that is not coated with the hot melt adhesive is separated from the wet skeleton.

[0015] By employing the above technical solution, the absence of hot melt adhesive means that the surface fabric in the edging area is not bonded to the wet-laid skeleton. During manufacturing, the adhesive binds different materials together to form a stable structure. Therefore, the lack of adhesive leads to separation between the surface fabric and the wet-laid skeleton. Separating the surface fabric in the edging area from the wet-laid skeleton makes subsequent processing and handling easier. In step S6, the separated structure facilitates the removal of excess skeleton using a waterjet cutter.

[0016] Optionally, the backing material is one of non-woven fabric, kraft paper, plastic film, and coated non-woven fabric or kraft paper.

[0017] By adopting the above technical solutions, non-woven fabric, a non-woven material, possesses characteristics such as breathability, waterproofing, and abrasion resistance. As a backing material in sunroof roofs, non-woven fabric provides excellent waterproofing performance while effectively protecting internal materials from external environmental influences. Kraft paper, a tough paper made from pulp, has certain waterproof and tear-resistant properties. Using kraft paper as a backing material in sunroof roofs provides a certain level of protection and increases the overall stability of the roof. Plastic film has excellent waterproof performance and durability, effectively preventing moisture from penetrating into the roof's interior. Using plastic film as a backing material in automotive sunroof roofs ensures the roof remains dry for extended periods while preventing the entry of dust and other contaminants. Laminated membranes are waterproof materials commonly used in outdoor products and building materials. Using laminated non-woven fabric or kraft paper as one of the backing materials provides additional waterproof protection, enhancing the roof's durability and stability.

[0018] Optionally, during the edge-binding process, the wet skeleton near the edge-binding area is heated, and the fabric is pressed and cooled after being wrapped.

[0019] By employing the above technical solutions, heating the wet-laid skeleton increases its surface temperature, improving its plasticity and flexibility. This allows the wet-laid skeleton to more easily adapt to the shape of the fabric, thus better facilitating the hemming process. Heating the wet-laid skeleton also helps it bond better with hot melt adhesives or other adhesives. Heating enhances the adhesive's fluidity, allowing it to penetrate the surface of the wet-laid skeleton more effectively, forming a more uniform and robust bond. After the fabric is wrapped, pressing and cooling it helps to fix the fabric's position and accelerates the adhesive's curing speed. This ensures a stronger bond for the hemming, preventing uneven hemming or detachment due to loosening or displacement. By heating the wet-laid skeleton and pressing and cooling the fabric, the quality and consistency of the hemming are improved. This reduces quality problems caused by poor adhesion or loose hemming, ensuring the ceiling's appearance and performance meet requirements.

[0020] Optionally, during the hot pressing process, venting is performed intermittently, and pressure is released 4–6 seconds after molding.

[0021] By employing the above technical solutions, during hot pressing, the material expands due to heat, and air or bubbles within it may be compressed inside the material or between the material and the mold contact surface. Intermittent venting helps remove these air bubbles and bubbles, preventing the formation of pores or surface defects during molding. If air bubbles or bubbles are present inside the material during molding, they may cause internal defects or surface flaws, affecting the product's quality and appearance. Intermittent venting reduces the occurrence of these defects and improves the molding quality. During hot pressing, the material may be affected by internal stress; if not released in time, this may lead to deformation or cracks in the molded product. Intermittent venting and pressure relief effectively reduce the accumulation of these internal stresses, ensuring the product's stability and strength. The intermittent venting and pressure relief process helps ensure close contact between the mold and the material, and ensures that the material achieves the expected shape and size during molding. This is crucial for ensuring product precision and consistency.

[0022] In summary, this application includes at least one of the following beneficial technical effects: 1. During molding, materials are placed sequentially from top to bottom, including the surface fabric, fiberglass, PU foam board, fiberglass again, and backing material. These materials are layered to form the framework of the skylight canopy. Fiberglass and PU foam board are bonded together. This ensures adhesion between materials, enhancing the structure's stability and durability. At the edge of the skylight, epoxy resin adhesive replaces hot melt adhesive. This adhesive film, with its high melting point and rapid solidification upon cooling, isolates the edge area from the wet framework. It also makes it easier to cut away excess framework during trimming, ensuring a neat and precise edge. Finally, the surface fabric at the edge is coated with adhesive and then reversed. This step aims to fix the surface fabric, ensuring strong adhesion to other materials, thus completing the skylight construction. 2. The curing temperature range of hot melt adhesive is 120-150℃. Within this temperature range, the hot melt adhesive is in a liquid or semi-solid state, forming a strong bond between PU foam and other materials. In step S1, applying hot melt adhesive to the PU foam ensures sufficient adhesive strength between the layers. During hot pressing (step S4), the temperature of the hot press mold typically reaches the curing temperature range of the hot melt adhesive, promoting adhesive flow and material bonding. Epoxy resin adhesive has a melting point of 150℃. Its high melting point means it requires a higher temperature to reach a liquid state. In step S3, placing the epoxy resin adhesive between the surface fabric and fiberglass forms a protective layer that is resistant to high temperatures. During hot pressing, the temperature of the hot press mold can reach a sufficiently high level to ensure the epoxy resin reaches its melting point and functions properly. 3. Heating the wet-laid skeleton increases its surface temperature, improving its plasticity and flexibility. This allows the wet-laid skeleton to more easily adapt to the shape of the fabric, thus better facilitating the hemming process. Heating the wet-laid skeleton also helps it bond better with hot melt adhesives or other adhesives. Heating increases the fluidity of the adhesive, allowing it to penetrate the surface of the wet-laid skeleton better, forming a more uniform and strong bond. After the fabric is wrapped, pressing and cooling it helps to fix the fabric's position and accelerates the curing speed of the adhesive. This ensures a stronger bond for the hemming, preventing uneven hemming or detachment due to loosening or displacement. By heating the wet-laid skeleton and pressing and cooling the fabric, the quality and consistency of the hemming are improved. This reduces quality problems caused by poor adhesion or loose hemming, ensuring the appearance and performance of the ceiling meet requirements. Attached Figure Description

[0023] Figure 1 This is a structural schematic diagram of the connection between the molded roof edging area and the wet frame in an embodiment of this application.

[0024] Explanation of reference numerals in the attached diagram: 1. Surface fabric; 2. Fiberglass; 3. PU foam board; 4. Backing material; 5. Hot melt adhesive; 6. Epoxy resin adhesive; 7. Edge binding area; 8. Wet skeleton. Detailed Implementation

[0025] The following is in conjunction with the appendix Figure 1 This application will be described in further detail.

[0026] This application discloses a wet one-time molding process for automotive sunroof edging and roof coverings.

[0027] Reference Figure 1 The process for wet-laid one-step molding of a car sunroof edging roof involves placing materials in a top-to-bottom order during molding: surface fabric 1, fiberglass 2, PU foam board 3, fiberglass 2 again, and backing material 4. These layers form the framework of the sunroof roof. To enhance structural stability and durability, fiberglass 2 and PU foam board 3 are bonded together. This ensures a strong bond between the materials, making the sunroof roof more robust and durable. At the edging area of ​​the sunroof roof, epoxy resin adhesive 6 replaces hot melt adhesive 5. This adhesive film has a high melting point and fast curing speed. Through these characteristics, epoxy resin adhesive 6 effectively separates the edging area 7 from the wet-laid framework 8, making it easier to cut away excess framework in subsequent cutting steps, ensuring a clean and precise edging. Finally, the surface fabric of the edging area 7 is coated with adhesive and then reversed. This step aims to fix the surface fabric 1, ensuring a strong bond with other materials, ultimately completing the sunroof manufacturing process. This step not only enhances the stability of the structure, but also ensures the skylight's aesthetic appeal and reliable quality.

[0028] Reference Figure 1In step S1, the PU foam board 3 is placed in a roller glue machine, and hot melt adhesive 5 is applied to both sides. The hot melt adhesive in the edge-wrapping area is then removed using a film-removing machine. This ensures the adhesion of the PU foam board 3 to other materials and guarantees the strength and stability of the bond. In step S2, purified water is evenly sprayed onto both sides of the PU foam board 3 using a sprinkler. This step may be to improve the adhesion of the foam board or to better handle subsequent steps. The addition of water can improve the softness and plasticity of the material. In step S3, the surface fabric 1, fiberglass 2, PU foam board 3, fiberglass 2, and backing material 4 are laid out sequentially from top to bottom. At the joint of the edge-wrapping area 7, epoxy resin adhesive 6 and surface fabric 1 are additionally laid. This step ensures the correct placement and bonding sequence of each layer of material. In step S4, the assembled material is fed into a hot press mold machine for molding, resulting in the initial ceiling shape. The temperature, pressure, and holding time of the mold are strictly controlled to ensure tight adhesion between materials and to form the shape of the skylight. In step S5, the initial roof form with the fabric bonded is cooled and set at room temperature for 55-60 seconds. This step ensures the stability and structure of the roof, maintaining its required shape and size. In step S6, the cooled and set roof is cut using a water jet to remove excess frame. This step is to refine the edges of the roof, making it neater and ensuring that the appearance and shape of the roof meet the requirements. In step S7, the surface fabric 1 of the edging area 7 is reversed. This step is to fix the position of the surface fabric 1, ensuring its firm adhesion to other materials, ultimately completing the skylight production.

[0029] Reference Figure 1 The curing temperature range of hot melt adhesive 5 is 120-150℃, which means that during hot pressing, the temperature of the hot press mold usually reaches the melting point range of hot melt adhesive 5. In step S1, hot melt adhesive 5 is applied to PU foam board 3 to ensure sufficient adhesive strength between the layers. During hot pressing (step S4), the high temperature of the hot press mold promotes the flow of hot melt adhesive 5 and the adhesion of the materials, thus forming a strong bond. The melting point of epoxy resin adhesive 6 is 150℃, which is higher than that of hot melt adhesive 5. In step S3, epoxy resin adhesive 6 is placed between the surface fabric 1 and the fiberglass 2 to form an insulating layer that is not easily damaged at high temperatures. This design aims to protect the edge area 7 and the wet skeleton 8, preventing premature melting or damage of epoxy resin adhesive 6 during hot pressing.

[0030] Reference Figure 1Epoxy resin adhesive 6 has a high melting point and rapid solidification characteristics, allowing it to form a strong bond much faster during the cooling and setting process compared to hot melt adhesive 5. This means a stronger isolation layer formed between the edging area 7 and the wet skeleton 8, helping to prevent adhesion between the two and ensuring easier cutting and finishing of the ceiling in subsequent processing steps. Because epoxy resin adhesive 6 solidifies quickly, it rapidly forms a strong barrier, preventing adhesion between the edging area 7 and the wet skeleton 8. This rapid solidification characteristic ensures a more reliable isolation effect, reducing the possibility of adhesion or mixing and helping to maintain the structural integrity of the ceiling. The rapid-setting epoxy resin adhesive 6 can speed up the entire process and shorten the cooling and setting time. This means shorter production cycles, increased production efficiency, and reduced production costs and resource consumption. The rapid-setting epoxy resin adhesive 6 more effectively ensures the isolation effect between the edging area 7 and the wet skeleton 8, thereby optimizing product quality and consistency. It reduces the possibility of poor adhesion or mixing, ultimately improving the appearance and performance of the ceiling.

[0031] Reference Figure 1 Removing the hot melt adhesive 5 means that the surface fabric 1 of the edging area 7 is no longer bonded to the wet skeleton 8, thus achieving separation. This allows for easier handling and processing of the material in subsequent steps, especially when using water jet cutting to remove excess skeleton in step S6. The separated structure makes operation more convenient. Because the surface fabric 1 is separated from the wet skeleton 8, the operator can more easily identify and process the target area during subsequent processing steps, such as cutting excess skeleton, without being interfered with by the adhesion between the surface fabric 1 and the skeleton. The separation of the surface fabric 1 and the wet skeleton 8 allows for more precise processing. The operator can more accurately locate and cut excess skeleton, ensuring that the final product's dimensions and appearance meet requirements. The separated structure also helps avoid material waste. If the surface fabric 1 is bonded to the wet skeleton 8 during subsequent processing, it may lead to material damage or waste. The separated structure allows for better control of the processing and reduces waste.

[0032] Reference Figure 1The backing material 4 can be one of the following: non-woven fabric, kraft paper, plastic film, or laminated non-woven fabric or kraft paper. Non-woven fabric is a non-woven material with breathable, waterproof, and wear-resistant properties. As the backing material 4 in a car sunroof roof, non-woven fabric provides good waterproof performance while effectively protecting the internal materials from external environmental influences. Its breathability helps maintain air circulation inside the vehicle, increasing passenger comfort. Kraft paper is a tough paper made from pulp, possessing certain waterproof and tear-resistant properties. Using kraft paper as the backing material 4 in a car sunroof roof provides a certain level of protection while also increasing the overall stability of the roof. Its toughness and durability help the roof maintain its shape and function over a long period. Plastic film has excellent waterproof performance and durability, effectively preventing moisture from penetrating into the roof's interior. Using plastic film as the backing material 4 in a car sunroof roof ensures the roof remains dry for extended periods while preventing the entry of dust and other contaminants. Its lightweight nature also helps reduce the overall weight of the vehicle. A waterproof membrane is a material commonly used in outdoor products and building materials. The non-woven fabric or kraft paper used as a backing material in the membrane provides additional waterproof protection, enhancing the durability and stability of the roof. Its highly effective waterproofing ensures the roof remains dry and reliable in various weather conditions.

[0033] Reference Figure 1 During the hemming process, heating the wet-laid skeleton 8 near the hemming area 7 helps increase its surface temperature, enhancing its plasticity and softness. This allows the wet-laid skeleton 8 to more easily adapt to the shape of the fabric and better cooperate with the hemming process. Heating also promotes the flow of the adhesive, allowing it to better penetrate the surface of the wet-laid skeleton 8, forming a more uniform and strong bond. This ensures a stronger and more durable bond between the fabric and the wet-laid skeleton 8. Once the fabric is wrapped, pressing and cooling it helps to fix the position of the fabric and accelerates the curing speed of the adhesive. This ensures a stronger bonding effect for the hemming, preventing uneven hemming or detachment due to loosening or displacement. The cooling process also helps the adhesive cure faster, accelerating the completion of the hemming and improving production efficiency. By heating the wet-laid skeleton 8 and pressing and cooling the fabric, the quality and consistency of the hemming can be improved. This reduces quality problems caused by poor adhesion or loose hemming, ensuring that the appearance and performance of the canopy meet requirements. At the same time, this method also reduces repairs and rework caused by uneven hemming, lowering production costs.

[0034] Reference Figure 1During hot pressing, the material expands due to heat, potentially generating air or bubbles. If these air and bubbles are not effectively removed, they can form pores or surface defects during molding, affecting product quality and appearance. Intermittent venting allows for timely removal of these air and bubbles, ensuring the compactness and uniformity of the material during molding. During hot pressing, the material may be subject to internal stress. If not released in time, this can lead to deformation or cracks in the molded product. Intermittent venting and pressure relief effectively reduce the accumulation of these internal stresses, ensuring product stability and strength, and minimizing product quality problems caused by internal stress. The intermittent venting and pressure relief process ensures close contact between the mold and the material, preventing air from becoming trapped between them. This helps ensure that the material fully fills all parts of the mold during molding, ensuring that the shape and dimensions of the molded product meet design requirements. By removing air and bubbles, releasing internal stress, and ensuring close contact, the intermittent venting and pressure relief process helps improve product precision and consistency. This is crucial for ensuring that the product's appearance and performance meet expected standards, helping to reduce the defect rate and improve production efficiency.

[0035] The implementation principle of the wet one-time molding process for automotive sunroof edging and roof in this application embodiment is as follows: Prepare the necessary raw materials, including PU foam board 3, surface fabric 1, fiberglass 2, backing material 4 (non-woven fabric, kraft paper, plastic film, etc.), hot melt adhesive 5, and epoxy resin adhesive 6. Ensure that the production equipment, such as the glue roller, water sprayer, hot press mold machine, and waterjet cutter, is in good working order. Place the PU foam board 3 in the glue roller and apply hot melt adhesive 5 to both sides. Use a film removal machine to remove the hot melt adhesive 5 from the edge-wrapping area 7. Ensure the adhesive application rate is within the range of 30-50 g / m², and control the glue roller temperature between 15-45℃. Use a water sprayer to evenly spray purified water on both sides of the PU foam board 3. This helps improve the adhesion of the foam board and the effectiveness of subsequent processing steps. Lay the surface fabric 1, fiberglass 2, PU foam board 3, fiberglass 2, and backing material 4 sequentially from top to bottom. At the junction of the edging area 7 of the ceiling skylight, from top to bottom, lay the following layers: surface fabric 1, epoxy resin adhesive 6, fiberglass 2, PU foam board 3, fiberglass 2, epoxy resin adhesive 6, and backing material 4. The assembled materials are then fed into a hot press mold for hot pressing, with the mold temperature controlled at 130-150℃ and the molding pressure at 8-9MPa. After complete mold closing, the pressure holding time is controlled at 30-45 seconds. During the hot pressing process, intermittent venting is performed to remove air or air bubbles from the material. Pressure is released within 4-6 seconds after molding to release internal stress and ensure the stability and strength of the product. The fabric-bonded ceiling prototype is then cooled and set at room temperature for 55-60 seconds. This helps to fix the shape and structure of the ceiling. The cooled and set ceiling prototype is then fed into a waterjet cutting machine to cut off excess framework. The water pressure for waterjet cutting is 40,000~50,000 psi, and the air pressure is 4.0~6.0 kg / cm2. The surface fabric 1 of the edging area 7 is reverse-wrapped to fix its position and ensure adhesion to other materials.

[0036] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A wet one-time molding process for automotive sunroof edging and roof covering, characterized in that, During molding, the materials, from top to bottom, include a surface fabric (1), glass fiber (2), PU foam board (3), glass fiber (2), and backing material (4). Hot melt adhesive (5) is provided between the glass fiber (2) and the PU foam board (3) to bond them together. Epoxy resin adhesive (6) is provided at the edge of the skylight to replace the hot melt adhesive (5), which is used to separate the edge area (7) from the wet frame (8) to facilitate the removal of excess frame during cutting. Finally, the surface fabric (1) of the edge area (7) is coated with adhesive and wrapped back. The process method includes the following steps: S1. Place the PU foam board into the glue roller and apply hot melt adhesive to both sides of the PU foam board. Use a film removal machine to remove the hot melt adhesive from the edge area. The amount of adhesive applied is 30-50g / m2, and the temperature of the glue roller is 15-45℃. S2, use a sprinkler to evenly spray purified water on both sides of the PU foam board; S3, lay the surface fabric, fiberglass, PU foam board, fiberglass, and backing material in the order from top to bottom. Among them, at the junction of the edge area of ​​the material ceiling skylight, the surface fabric, epoxy resin, fiberglass, PU foam board, fiberglass, epoxy resin, and backing material are laid from top to bottom. S4. The combined material obtained in step S3 is fed into a hot press mold machine. The mold is pressed down to form the initial shape of the roof. The mold temperature is 130-150℃, the forming pressure is 8-9MPa, and the holding pressure time after the mold is fully closed is controlled at 30-45s. S5, the initial shape of the ceiling with the fabric bonded is cooled and shaped at room temperature for 55-60 seconds; S6. After cooling and shaping, the initial roof form is water-jet cut to remove excess frame and obtain the roof. The water pressure for water-jet cutting is 40,000~50,000 psi, and the air pressure for water-jet cutting is 4.0~6.0 kg / cm2. S7, use glue to wrap the outer fabric of the edge area backwards.

2. The wet one-time molding process for automotive sunroof edging and roof lining according to claim 1, characterized in that: The curing temperature range of the hot melt adhesive (5) is 120-150℃, and the curing temperature of the epoxy resin adhesive (6) is 150℃.

3. The wet one-time molding process for automotive sunroof edging and roof lining according to claim 2, characterized in that: During curing, the epoxy resin adhesive (6) solidifies and bonds faster than the hot melt adhesive (5), separating the edge area (7) from the wet skeleton (8).

4. The wet one-time molding process for automotive sunroof edging and roof lining according to claim 3, characterized in that: The surface fabric (1) of the edge-binding area (7) where the hot melt adhesive (5) is not applied separates from the wet skeleton (8).

5. The wet one-time molding process for automotive sunroof edging and roof lining according to claim 4, characterized in that: The backing material (4) is one of non-woven fabric, kraft paper, plastic film, and coated non-woven fabric or kraft paper.

6. The wet one-time molding process for automotive sunroof edging and roof lining according to claim 5, characterized in that: During the edge-binding process, the wet skeleton (8) near the edge-binding area (7) is heated, and the fabric is pressed and cooled after being wrapped.

7. The wet one-time molding process for automotive sunroof edging and roof lining according to claim 6, characterized in that: During the hot pressing process, air is vented intermittently, and pressure is released 4–6 seconds after molding.

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