A foamed dashboard covered with 3D mesh and leather and its manufacturing process

Abstract

This invention discloses a foamed dashboard covered with 3D mesh and leather, and its manufacturing process, relating to the automotive interior field. By using 3D mesh positioning grooves and leather positioning grooves on the foamed dashboard, 3D mesh and leather are covered. The 3D mesh layer provides a superior tactile feel, while the leather layer provides a luxurious appearance, forming a "four-layer" or "five-layer" composite structure, improving automotive quality and meeting the demands of luxury models. The invention employs an insert system manufacturing process, significantly reducing mold investment and new product development cycles. Changing or optimizing the size and positioning of the leather and 3D mesh only requires altering the size and position of the inserts and the position of the milled leather grooves. The switching process is flexible, stable, and fast, without requiring the reopening of molds.

Description

Technical Field

[0001] This invention relates to the field of automotive interiors, and more specifically to a foamed dashboard covered with 3D mesh and leather, and its manufacturing process. Background Technology

[0002] The passenger compartment of a car is where passengers interact frequently. Passengers interact with interior components through sight, hearing, touch, and smell. Car dashboards are generally divided into hard dashboards and soft dashboards, with an increasing demand for soft-touch dashboards. Currently, the mainstream manufacturing processes for automotive interiors include: slush molding (or PU spraying) foaming, negative molding, and hand-wrapping, with hand-wrapping being the dominant trend. Foamed dashboards are one type of soft-touch dashboard manufacturing process, as shown in the attached image. Figure 1 As shown, this process involves filling the space between the plastic frame and the outer skin of the dashboard with polyurethane foam to create a sandwich structure. Luxury models, in order to differentiate themselves from mid-to-low-end models, still use slush-molded (or PU-coated) foam structures in their base models. Due to the surface material structure and surface treatment technology of the interior parts, the user's perception is affected, influencing their judgment of the car's quality.

[0003] Document (CN 112606689 A) discloses a dashboard slush-molded foam sealing structure, including a dashboard body frame, a slush-molded skin, and a foam layer. The key feature is that the foaming area containing the foam layer is foamed using a closed mold and equipped with a foaming material injection port; a first soft sealing structure is provided at the front end of the dashboard body frame and the slush-molded skin; and a first hard sealing structure is provided at the rear end of the dashboard body frame and the slush-molded skin. However, this dashboard slush-molded foam sealing structure still cannot meet the requirements of luxury vehicle models.

[0004] Document (CN201710243867) discloses a set of dedicated high-end molds, including slush molding or (PU spraying) molds and foaming molds, which directly form 3D mesh and leather positioning grooves through molding. This method requires a huge investment, and because high-end models account for a very small percentage (generally less than 5%), it is not economically viable. Moreover, if the size and positioning of the 3D mesh and leather need to be changed or optimized, the mold must be remade. Summary of the Invention

[0005] This invention addresses the problems existing in the prior art by devising a foamed dashboard covered with 3D mesh and leather, and its manufacturing process. The foamed dashboard is further covered with 3D mesh and leather. The 3D mesh layer provides a superior tactile feel, and the leather layer provides a luxurious appearance. An inlay system is added to reduce project investment and enable the use of molds for both high-end and low-end configurations.

[0006] One of the technical solutions adopted to realize the present invention is: a foamed dashboard covered with 3D mesh and leather, which includes: an injection-molded skeleton 1, foam 2, and slush-molded skin 3, characterized in that: it also includes: leather 4 and 3D mesh 5, a 3D mesh positioning groove 6 and a leather positioning groove 7 are sequentially provided on the slush-molded skin 3, the 3D mesh 5 is provided in the 3D mesh positioning groove 6, the 3D mesh 5 is bonded to the foam 2, the upper surface of the 3D mesh 5 coincides with the upper surface of the slush-molded skin 3, the leather 4 is provided on the upper surface of the slush-molded skin 3, the joint of the leather 4 is incorporated into the leather positioning groove 7, and the leather 4 is bonded to the foam 2.

[0007] Furthermore, the leather 4 is genuine leather or artificial leather.

[0008] Furthermore, the genuine leather mentioned is cowhide.

[0009] Furthermore, the artificial leather is made by coating a fabric base with synthetic resin and various plastic additives.

[0010] Furthermore, the 3D mesh5 is a three-dimensional mesh fabric.

[0011] Furthermore, the 3D mesh 5 is bonded to the foam 2 using solvent-based adhesive, water-based adhesive, or hot melt adhesive.

[0012] The second technical solution adopted to realize the present invention is: a manufacturing process for a foamed dashboard covered with 3D mesh and leather, characterized in that it includes the following steps:

[0013] 1) An electromagnet 8 is provided on the upper surface of the lower mold 9 of the foamed instrument panel, and the upper surface of the electromagnet 8 coincides with the upper surface of the lower mold 9 of the foamed instrument panel. The lower mold 9 of the foamed instrument panel and the upper mold 10 of the foamed instrument panel are assembled. A slush-molded skin 3 is provided on the upper surface of the lower mold 9 of the foamed instrument panel. An injection-molded skeleton 1 is provided on the lower surface of the upper mold 10 of the foamed instrument panel. An insert 13 is provided on the upper surface of the slush-molded skin 3. The insert 13 is attracted to the electromagnet 8. Then, foam 2 is injected between the slush-molded skin 3 and the injection-molded skeleton 1 to form a foamed instrument panel blank covering 3D mesh and leather.

[0014] 2) Remove the foamed dashboard blank covered with 3D mesh and leather from the lower mold 9 and the upper mold 10 of the foamed dashboard. Clamp the foamed dashboard blank covered with 3D mesh and leather onto the milling mold 11. The milling robot sequentially picks up the cutting milling cutter, the weakening milling cutter, the leather positioning groove milling cutter and the insert ultrasonic cutter from the tool library and performs edge trimming, positioning point modification and weakening respectively. Use a suction cup or strong magnet to remove the insert 13 from the foamed dashboard blank covered with 3D mesh and leather. Mill the 3D mesh positioning groove 6 and the leather positioning groove 7.

[0015] 3) Remove the processed foamed dashboard blank covered with 3D mesh and leather from the milling mold 11, and glue the 3D mesh 5 and leather 4 to the 3D mesh positioning groove 6 and leather positioning groove 7 respectively to complete the manufacturing of the foamed dashboard covered with 3D mesh and leather.

[0016] Furthermore, in step 1), the insert 13 is covered with a non-stick coating, the non-stick coating material being Teflon, silicone resin, or fluorosilicone resin.

[0017] Furthermore, in step 2), the insert 13 is cleaned, brushed with release agent, and air-dried.

[0018] The beneficial effects of the present invention, which describes a foamed dashboard covered with 3D mesh and leather and its manufacturing process, are as follows:

[0019] A foamed dashboard covered with 3D mesh and leather, and its manufacturing process, are disclosed. The process involves covering the 3D mesh and leather with positioning grooves for the 3D mesh and leather on the foamed dashboard. The 3D mesh layer provides a superior tactile feel, while the leather layer provides a luxurious appearance, forming a "four-layer" or "five-layer" composite structure. This enhances the quality of the vehicle and meets the demands of luxury models. The process employs an insert system manufacturing technology, significantly reducing mold investment and new product development cycles. Changing or optimizing the size and positioning of the leather and 3D mesh only requires altering the size and position of the inserts and the position of the milled leather grooves. The switching process is flexible, stable, and fast, without the need to reopen the mold. Attached Figure Description

[0020] Figure 1 This is a cross-sectional structural diagram of the low-spec foam instrument panel;

[0021] Figure 2 This is a cross-sectional structural diagram of a foamed dashboard covered with 3D mesh and leather;

[0022] Figure 3 This is a schematic diagram of the press-fitting of a foamed dashboard blank covered with 3D mesh and leather in the embodiment;

[0023] Figure 4 This is a schematic diagram of the post-processing of the foamed dashboard press blank covered with 3D mesh and leather in the embodiment;

[0024] Figure 5 yes Figure 4 A schematic diagram of a foamed dashboard press-fit preform covered with 3D mesh and leather;

[0025] Figure 6 This is a manufacturing process flow diagram for a foamed dashboard covered with 3D mesh and leather;

[0026] In the diagram: 1. Injection-molded skeleton, 2. Foam, 3. Slush-molded outer skin, 4. Leather, 5. 3D mesh, 6. 3D mesh positioning groove, 7. Leather positioning groove, 8. Electromagnet, 9. Foamed instrument panel lower mold, 10. Foamed instrument panel upper mold, 11. Milling mold, 12. Leather positioning groove milling cutter, 13. Inlay. Detailed Implementation

[0027] The following is in conjunction with the appendix Figures 2-6 The present invention will be further described in detail below with reference to specific embodiments. In order to make the purpose, technical solution and advantages of the embodiments clearer, the technical solutions in the embodiments will be clearly and completely described with reference to the accompanying drawings. The specific embodiments described herein are only used to explain the present invention and are not intended to limit the scope of the present invention.

[0028] As attached Figure 2 As shown, a foamed dashboard covered with 3D mesh and leather includes: an injection-molded skeleton 1, foam 2, slush-molded skin 3, leather 4, and 3D mesh 5. The leather 4 is genuine leather or artificial leather. The artificial leather is made by coating synthetic resin and various plastic additives with a fabric base. The 3D mesh 5 is a three-dimensional mesh fabric. 3D mesh positioning grooves 6 and leather positioning grooves 7 are sequentially arranged on the slush-molded skin 3. The 3D mesh 5 is placed in the 3D mesh positioning grooves 6. The 3D mesh 5 is bonded to the foam 2. The upper surface of the 3D mesh 5 coincides with the upper surface of the slush-molded skin 3. The leather 4 is placed on the upper surface of the slush-molded skin 3. The joints of the leather 4 converge into the leather positioning grooves 7. The leather 4 is bonded to the foam 2.

[0029] like Figure 6As shown, the manufacturing process of a foamed dashboard covered with 3D mesh and leather is as follows: 1) An electromagnet 8 is set on the upper surface of the lower mold 9 of the foamed dashboard, the upper surface of the electromagnet 8 coincides with the upper surface of the lower mold 9 of the foamed dashboard, the lower mold 9 of the foamed dashboard and the upper mold 10 of the foamed dashboard are assembled, a slush-molded skin 3 is set on the upper surface of the lower mold 9 of the foamed dashboard, an injection-molded skeleton 1 is set on the lower surface of the upper mold 10 of the foamed dashboard, an insert 13 is set on the upper surface of the slush-molded skin 3, and a non-stick coating is applied to the outside. The coating, the non-stick coating material is Teflon, silicone resin or fluorosilicone resin, and the insert material is martensitic stainless steel, mainly of types 403, 410, 414, 416, 416(Se), 420, 430, 431, 440A, 440B and 440C. Then, a robotic arm is used to install the insert 13 into the designated position of the slush-molded skin 3, and it is fixed by the electromagnet 8 of the lower mold 9 of the foamed instrument panel. Then, foam 2 is injected between the slush-molded skin 3 and the injection-molded skeleton 1 to form a foamed instrument panel blank covering 3D mesh and leather, as shown in the attached figure. Figure 3 As shown;

[0030] 2) The foamed dashboard blank covered with 3D mesh and leather is removed from the lower mold 9 and the upper mold 10 of the foamed dashboard. The foamed dashboard blank covered with 3D mesh and leather is clamped on the milling mold 11. The milling robot sequentially picks up the cutting cutter, the weakening cutter, the leather positioning groove cutter 12, and the insert ultrasonic cutter from the tool library, and performs edge trimming, positioning point modification, and weakening respectively, as shown in the attached figure. Figure 4 As shown; peel off the outer skin of the insert, and use a suction cup or strong magnet to remove the insert 13 from the foamed dashboard blank covering the 3D mesh and leather. Mill the 3D mesh positioning groove 6 and the leather positioning groove 7. Then, clean the insert 13, apply a release agent, and air dry it. Cleaning the insert uses an automatically rotating brush, while applying the release agent is done manually with a brush. The release agent is applied by a robot that picks up the insert and immerses it in the release agent container. Air drying is done using an electric hairdryer at a temperature of 100-200℃, a distance of 50-200mm from the insert, and a blowing time of 10-30 seconds. Finally, place the insert 13 in the designated position for use by the next part, as shown in the attached diagram. Figure 5 As shown;

[0031] 3) Remove the processed foamed dashboard blank, which is covered with 3D mesh and leather, from the milling mold 11. Attach the 3D mesh 5 and leather 4 to the 3D mesh positioning groove 6 and leather positioning groove 7 respectively using adhesive, including solvent-based adhesive, water-based adhesive, and hot melt adhesive. This completes the manufacturing of the foamed dashboard covered with 3D mesh and leather, as shown in the attached figure. Figure 2 As shown.

[0032] The above description is only a preferred embodiment of the present invention. It should be noted that, for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A foamed instrument panel clad with 3D mesh and leather, comprising: The injection molded skeleton (1), foam (2), slush skin (3) are characterized in that: it also includes: leather (4) and 3D mesh (5), 3D mesh positioning groove (6) and leather positioning groove (7) are arranged in sequence on the slush skin (3), 3D mesh (5) is arranged in the 3D mesh positioning groove (6), the 3D mesh (5) is glued with the foam (2), the upper surface of the 3D mesh (5) is coincident with the upper surface of the slush skin (3), the leather (4) is arranged on the upper surface of the slush skin (3), the joint of the leather (4) is merged into the leather positioning groove (7), the leather (4) is glued with the foam (2).

2. A foamed instrument panel of claim 1, wherein, The leather (4) is real leather or artificial leather.

3. A foamed instrument panel of claim 2, wherein, The real leather is yellow cowhide.

4. A foamed instrument panel of claim 2, wherein, The artificial leather is made of fabric, synthetic resin and various plastic additives.

5. The foamed instrument panel of claim 1, wherein, The 3D mesh (5) is a three-dimensional mesh fabric.

6. A foamed instrument panel of claim 1, wherein, The 3D mesh (5) is glued with the foam (2), and the glue is solvent glue, water-based glue or hot melt glue.

7. A process for manufacturing a foamed instrument panel coated with 3D mesh and leather, characterized in that, It includes the following steps: 1) An electromagnet (8) is arranged on the upper surface of the foaming instrument panel lower mold (9), the upper surface of the electromagnet (8) is coincident with the upper surface of the foaming instrument panel lower mold (9), the foaming instrument panel lower mold (9) and the foaming instrument panel upper mold (10) are assembled, the slush skin (3) is arranged on the upper surface of the foaming instrument panel lower mold (9), the injection molded skeleton (1) is arranged on the lower surface of the foaming instrument panel upper mold (10), the inlay block (13) is arranged on the upper surface of the slush skin (3), the inlay block (13) is attracted to the electromagnet (8), then the foam (2) is injected between the slush skin (3) and the injection molded skeleton (1) to form a foaming instrument panel blank covered with 3D mesh and leather; 2) The foaming instrument panel blank covered with 3D mesh and leather is taken out from the foaming instrument panel lower mold (9) and the foaming instrument panel upper mold (10), the foaming instrument panel blank covered with 3D mesh and leather is clamped on the milling mold (11), the milling robot sequentially grabs the cutting milling cutter, the weakening milling cutter, the leather positioning groove milling cutter and the inlay block ultrasonic cutter from the tool library to respectively perform edge cutting, positioning point changing and weakening, the inlay block (13) is taken out from the foaming instrument panel blank covered with 3D mesh and leather by suction cup or strong magnet, and the 3D mesh positioning groove (6) and the leather positioning groove (7) are milled; 3) The foaming instrument panel blank covered with 3D mesh and leather after processing is unloaded from the milling mold (11), the 3D mesh (5) and the leather (4) are respectively pasted to the 3D mesh positioning groove (6) and the leather positioning groove (7) using glue, and the foaming instrument panel covered with 3D mesh and leather is completed.

8. A process for manufacturing a foamed instrument panel coated with 3D mesh and leather according to claim 7, characterized in that, In step 1), the inlay block (13) is coated with a non-stick coating on the outside, and the non-stick coating material is Teflon, silicone resin or fluorosilicon resin.

9. A process for manufacturing a foamed instrument panel coated with 3D mesh and leather according to claim 7, characterized in that, In step 2), the inlay block (13) is cleaned, demolding agent is brushed, and air dried.

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