Interior panel part and manufacturing method

Abstract

The invention provides an interior panel and a manufacturing method. The manufacturing method comprises the steps that a panel base body part of the interior panel part is heated to a first temperature, the panel base body part is a composite material part, a base body of the composite material part is a first material, a reinforcing material of the composite material part is a second material, and the first temperature is at least the softening temperature of the first material; the heated panel base body part and the panel surface part are stacked and arranged on a mold on one side of compression molding; wherein the panel surface part comprises a surface side part and a back side part, the surface side part provides the surface of the interior panel piece, the back side part is arranged on the back side of the surface side part, and the back side part is provided with a first material piece and is provided with the first material; and the back side part is connected with the panel base body part through the first material piece.

Description

Technical Field

[0001] The present invention relates to an interior trim panel component and a manufacturing method. Background Art

[0002] An interior panel generally includes a panel base portion and a panel surface portion that provides the interior panel surface (ie, the visible surface). In the current interior panel manufacturing process, a process of compression molding the panel base portion and the panel surface portion may be adopted.

[0003] However, this manufacturing process needs to be further simplified to reduce manufacturing costs. Summary of the invention

[0004] An object of the present invention is to provide a method for manufacturing an interior trim panel member.

[0005] An object of the present invention is to provide an interior trim panel member.

[0006] In a first aspect, the present application provides a method for manufacturing an interior trim panel, comprising:

[0007] Heating a panel substrate of an interior panel component to a first temperature, wherein the panel substrate is a composite material component, the matrix of the composite material component is a first material, and the reinforcing material is a second material, and the first temperature is at least a softening temperature of the first material;

[0008] The heated panel base part and the panel surface part are stacked and arranged in a mold on one side of the compression molding; wherein the panel surface part includes a surface side part and a back side part, the surface side part provides the surface of the interior panel part, the back side part is arranged on the back side of the surface side part, the back side part has a first material part, and has the first material; the back side part and the panel base part are connected through the first material part;

[0009] The mold on one side is molded together with the mold on the other side and maintained for a first time;

[0010] The one side mold and the other side mold are separated and opened to obtain the interior trim panel component.

[0011] In the technical solution introduced above, the panel base portion is heated to above the softening temperature before molding, and the panel base portion and the panel surface portion have the same first material. The heated panel base portion heats the panel surface portion during molding, and since the first material of the two parts is softened, the panel base portion and the panel surface portion can be stably fused and connected. During molding, the two need only be stacked and arranged in a mold, and the process is simple.

[0012] In one or more embodiments of the manufacturing method, the first material includes polypropylene (PP), and the second material includes natural fibers and / or synthetic fibers.

[0013] In one or more embodiments of the manufacturing method, the first temperature is 40° C.-60° C. greater than the softening temperature of the first material.

[0014] In one or more embodiments of the manufacturing method, the one side mold is a movable mold, and the other side mold is a fixed mold. The heated panel base portion and the panel surface portion are stacked and arranged on the movable mold for compression molding, and then the movable mold and the fixed mold are molded together and maintained for a first time.

[0015] In one or more embodiments of the manufacturing method, the mold on one side has a first positioning structure, and the panel surface portion and the panel base portion have a first positioning hole and a second positioning hole, respectively. When the heated panel base portion and the panel surface portion are stacked and arranged on one side of the mold for compression molding, the first positioning hole and the second positioning hole are aligned in the stacking direction and cooperate with the first positioning structure for positioning; the mold on the other side has a second positioning structure, and when the mold on one side is molded with the mold on the other side, the first positioning structure cooperates with the second positioning structure for positioning.

[0016] In one or more embodiments of the manufacturing method, the one side mold and the other side mold are arranged in a horizontal injection molding device.

[0017] In one or more embodiments of the manufacturing method, the back side portion includes a foam layer and a base layer, the foam layer is connected to the surface side portion, the base layer is connected to the panel base portion, and the base layer has a non-woven fabric structure as the first material piece, and the fiber material of the non-woven fabric structure is the first material.

[0018] In one or more embodiments of the manufacturing method, the back side portion includes a foam layer, one side of the foam layer is connected to the surface side portion, and the other side is connected to the back side portion, and the material of the foam layer includes the first material, so that the foam layer serves as the first material piece.

[0019] In a second aspect, the present application provides an interior panel component obtained by the manufacturing method as described in the first aspect, the interior panel component comprising: a panel surface portion, comprising a surface side portion and a back side portion; the surface side portion provides the surface of the interior panel component, and the back side portion is arranged on the back side of the surface side portion; a panel base portion, which is a composite material component, the matrix of the composite material component is a first material, and the reinforcing material is a second material; wherein the back side portion has a first material component, having the first material; the back side portion is connected to the panel base portion through the first material component.

[0020] In the technical solution of the interior trim panel introduced above, the manufacturing cost of the interior trim panel is relatively low because it is obtained by adopting the manufacturing method introduced in the first aspect.

[0021] In one or more embodiments of the interior trim panel, the back side portion and the panel base portion are fused and connected without glue through the first material piece. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The above and other features, properties and advantages of the present invention will become more apparent through the following description in conjunction with the accompanying drawings and embodiments. In the accompanying drawings, the same reference numerals always represent the same features. It should be noted that these drawings are only examples and are not drawn according to the conditions of equal scale, and should not be used as a limitation on the actual scope of protection required by the present invention, wherein:

[0023] Figure 1 A schematic flow chart of a method for manufacturing an interior trim panel according to an embodiment;

[0024] Figure 2A 1 is a structural schematic diagram of step S100 included in a method for manufacturing an interior trim panel according to an embodiment;

[0025] Figure 2B A structural schematic diagram of step S200 included in a method for manufacturing an interior trim panel according to an embodiment;

[0026] Figure 2C A structural schematic diagram of step S300 included in a method for manufacturing an interior trim panel according to an embodiment;

[0027] Figure 2D Schematic diagram of the structure of step S400 included in a method for manufacturing an interior trim panel according to an embodiment.

[0028] Figure 3A , Figure 3B They are schematic structural diagrams of the panel surface portion of interior trim panel parts in different embodiments.

[0029] Reference numerals:

[0030] 10-Interior panel parts

[0031] 1-Panel surface

[0032] 11-Surface side part

[0033] 101-Surface

[0034] 12-Back side part

[0035] 13-First positioning hole

[0036] 121-First material piece

[0037] 122-Foam layer

[0038] 123-basal layer

[0039] 2-Panel base

[0040] 21-Second positioning hole

[0041] 201-One side mold

[0042] 2011-First positioning structure

[0043] 202-Mold on the other side

[0044] 2022-Second positioning structure

[0045] 300-Infrared Heating Oven

[0046] 400-Horizontal injection molding equipment. DETAILED DESCRIPTION

[0047] The following embodiments of the technical solution of the present application are described in detail in conjunction with the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present application, and are therefore only used as examples, and cannot be used to limit the scope of protection of the present application.

[0048] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by technicians in the technical field to which this application belongs; the terms used herein are only for the purpose of describing specific embodiments and are not intended to limit this application; the terms "including" and "having" in the specification and claims of this application and the above-mentioned figure descriptions and any variations thereof are intended to cover non-exclusive inclusions.

[0049] In the description of the embodiments of the present application, the technical terms "first", "second", etc. are only used to distinguish different objects, and cannot be understood as indicating or implying relative importance or implicitly indicating the number, specific order or primary and secondary relationship of the indicated technical features. In the description of the embodiments of the present application, the meaning of "multiple" is more than two, unless otherwise clearly and specifically defined.

[0050] Reference to "embodiments" herein means that a particular feature, structure, or characteristic described in conjunction with the embodiments may be included in at least one embodiment of the present application. The appearance of the phrase in various locations in the specification does not necessarily refer to the same embodiment, nor is it an independent or alternative embodiment that is mutually exclusive with other embodiments. It is explicitly and implicitly understood by those skilled in the art that the embodiments described herein may be combined with other embodiments.

[0051] In the description of the embodiments of the present application, the technical terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, which are only for the convenience of describing the embodiments of the present application and simplifying the description, and do not indicate or imply that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the embodiments of the present application.

[0052] In the description of the embodiments of the present application, unless otherwise clearly specified and limited, technical terms such as "install", "connect", "connect", "fixed" and the like should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can also be a mechanical connection. For ordinary technicians in this field, the specific meanings of the above terms in the embodiments of the present application can be understood according to the specific circumstances.

[0053] It can be understood that the flowchart is used below to illustrate the operations performed according to the manufacturing method of the interior panel. It should be understood that, according to the actual situation, the previous or following operations are not necessarily performed precisely in order. Other operations can also be added to these processes, or one or more operations can be removed from these processes.

[0054] refer to Figure 1 as well as FIG. 2A to FIG. 2D As shown, in some embodiments, the method for manufacturing the interior trim panel 10 includes:

[0055] Step S100: heating the panel base portion 2 of the interior trim panel member 10 to a first temperature.

[0056] The interior trim panel 10 may be a door side panel, a roof lining, a dashboard or instrument panel, a center console, or other automotive interior trim component. The lining components may be in various forms and have a substantially flat profile or a three-dimensional profile, as dictated by the relevant specific design, with raised areas and recessed areas, and may also have one or more openings and recesses for decoration and operating controls as required.

[0057] The panel base portion 2 provides support for the interior panel surface portion 1, so the panel base portion 2 generally has a certain structural strength and is a composite material. The matrix of the composite material is a first material, and the reinforcing material is a second material. The type of the first material can be common polypropylene (PP) plastic, and the type of the second material can be natural fiber (Natural Fiber) or synthetic fiber to form a fiber-reinforced plastic composite material, such as natural fiber reinforced PP plastic (NFPP), glass fiber reinforced PP plastic (GFPP), a composite material rCF NFPP composed of 40% natural fiber, 50% polypropylene and 10% recycled carbon fiber, and another example is a composite material combining natural hemp fiber and PP. Etc. In addition, the material of the substrate is not limited to PP plastic, for example, it can also be acrylonitrile-butadiene-styrene copolymer (ABS plastic), PC / ABS alloy (ABS engineering plastic), etc.

[0058] The types of natural fibers may include wood fibers, kenaf, hemp, jute, flax, ramie, rattan, soy, okra (coffee okra), musa, bamboo, coconut, coir, cotton, curaua fiber (pineapple leaf fiber), abaca (Manila hemp), pineapple, pineapple, raffia palm leaves (Raffia farinifera) and / or sisal.

[0059] Synthetic fibers include, for example, carbon fibers, polyester fibers, acrylic fibers, aramid fibers, Twaron fibers, Kevlar fibers, Technoral fibers, Vinalon fibers, Zylon fibers, and / or polypropylene fibers, and the like.

[0060] The panel surface portion 1 provides a surface 101 of the interior panel component 1, i.e., a visible surface, which faces the vehicle when the interior panel 10 is located in the vehicle. The panel surface portion 1 includes a surface side portion 11 and a back side portion 12. The back side is the side that faces away from the vehicle when the interior panel 10 is located in the vehicle. The surface side component 11 provides a surface 101, and the back side portion 12 is arranged on the back side of the surface side portion 11, and the back side portion 12 has a first material piece 121, which has a first material; the back side portion 12 is connected to the panel base portion 2 through the first material piece 121.

[0061] The material of the surface side portion 11 can be adjusted as needed. For example, common materials may be polyethylene plastic (PC), polyvinyl chloride plastic (PVC), thermoplastic elastomer (TPE), thermoplastic polyolefin (TPO), polyethylene terephthalate (PET) plastic, etc., but it is not limited to these. For example, it can also be genuine leather, solid wood, stone and other materials, which can be selected according to actual needs.

[0062] refer to Figure 3A As shown, in some embodiments, the specific structure of the back side portion 12 may include a foam layer 122 and a base layer 123, wherein the foam layer 122 is connected to the surface side portion 11, and the base layer 123 is connected to the panel base portion 2, and the base layer 123 has a non-woven fabric structure as the first material piece 121, and the fiber material of the non-woven fabric structure is the first material. For example, when the first material is PP plastic, the non-woven fabric structure of the base layer 123 is PP non-woven fabric (i.e., polypropylene non-woven fabric). Similarly, if the first material is ABS plastic, the non-woven fabric structure of the base layer 123 is acrylic non-woven fabric.

[0063] refer to Figure 3B As shown, in other embodiments, the specific structure of the back side portion 12 may also include a foam layer 122, one side of the foam layer 122 is connected to the surface side portion 11, and the other side is connected to the back side portion 12, and the material of the foam layer 122 includes a first material, so that the foam layer 122 serves as the first material piece 121. For example, when the first material of the panel base portion 2 is PP plastic, the foam layer 122 is a PP foam layer.

[0064] Figure 3A , Figure 3B In order to illustrate the layered structure, a planar structure diagram is used, but this is only schematic. As mentioned above, in the actual interior panel part 10, the shape of the interior panel part 10 can be a plane, a curved surface, a mixture of a plane and a curved surface, and have a concave, convex, opening and other structures.

[0065] The first temperature is at least the softening temperature of the first material, for example, for PP, the softening temperature is 150°C, but it can be understood that. Figure 1As shown, the heating method can be an infrared heating oven 300 (IR Oven). Preferably, the first temperature is generally 40°C-60°C greater than the softening temperature of the first material. For example, if the panel base part 2 is a PP plastic part, the first temperature is 190°C-210°C, so that it can be fully softened, and the heat of the heated panel base part 2 can soften the first material part 121 of the panel surface part 1, so that the two are fused and connected. It can be understood that sufficient softening requires a certain heating time, and the heating time is adjusted according to the specific softening requirements.

[0066] The structure in which the base layer 123 or the foam layer 122 is connected to the panel base portion 2 can avoid affecting the surface quality of the surface 101 provided by the surface side portion 11, so as to optimize the visual effect of the interior trim panel.

[0067] Step S200: Figure 2B As shown, the heated panel base portion 2 and the panel surface portion 1 are stacked and arranged in a side mold 201 for compression molding.

[0068] Preferably, in some embodiments, Figure 2B As shown, the mold 201 on one side has a first positioning structure 2011, and the panel surface part 1 and the panel base part 2 respectively have a first positioning hole 13 and a second positioning hole 21. When the heated panel base part 2 and the panel surface part 1 are stacked and arranged on the mold 201 on one side of the molding process, the first positioning hole 13 and the second positioning hole 21 are aligned in the stacking direction and cooperate with the first positioning structure 2011 for positioning; the mold 202 on the other side has a positioning structure 2021. When the mold 201 on one side is molded with the mold 202 on the other side, the first positioning structure 2011 and the second positioning structure 2022 cooperate for positioning. Figure 2B As shown, the first positioning structure 2011 can be a columnar positioning member, such as a positioning pin, and the second positioning structure 2022 can be a corresponding groove structure, but it is not limited thereto. In this way, the panel base part 2 and the panel surface part 1 can be kept stable during the molding process, further improving the molding quality.

[0069] Step S300: Figure 2C As shown, the one side mold 201 and the other side mold 202 are molded together and maintained for a first time. Specifically, the one side mold 201 can be a movable mold, and the other side mold 202 can be a fixed mold. The heated panel base part 2 and the panel surface part 1 are stacked and set in the movable mold for compression molding, and then the movable mold moves toward the fixed mold to close the mold, and the mold is maintained for the first time after closing the mold.

[0070] contrast Figure 2A , Figure 2B as well as Figure 2CIt can be seen that the panel surface part 1 and the panel base part 2 can be pressed together by the mold clamping force, and Figure 2A , Figure 2B The panel surface portion 1 and the panel base portion 2 of the plate-like two-dimensional structure shown in FIG. 1 are formed into a three-dimensional structure according to the shape of the mold.

[0071] The mold closing time can be adjusted according to different situations, and the specific details can be obtained through experiments or simulations.

[0072] Preferably, the one side mold 201 and the other side mold 202 can be arranged on a horizontal injection molding device 400, and the corresponding movement and pressure can be provided by the horizontal injection molding device, that is, the existing horizontal injection molding machine for manufacturing the panel base can be used to provide driving force and pressure to achieve compression molding, and there is no need to purchase a hot press machine separately. Compared with the prior art solution that requires a hot press machine to be specially set up on the basis of the injection molding equipment, the equipment cost of the solution introduced in the embodiment is reduced.

[0073] Step S400: Figure 2D As shown, after the first time, the one side mold 201 and the other side mold 202 are separated and opened to obtain the interior trim panel 10.

[0074] The manufacturing method introduced in the above embodiments has beneficial effects including but not limited to: heating the panel base portion to above the softening temperature before molding, and utilizing the same first material for the panel base portion and the panel surface portion, the heated panel base portion heats the panel surface portion during molding, and since the first material of the two parts is softened, the panel base portion and the panel surface portion can be stably fused and connected, and during molding, only the two need to be stacked and arranged in a mold, and the process is simple.

[0075] As described above, the interior panel 10 obtained by the manufacturing method described in the above embodiment of the present application includes a panel surface portion 1 and a panel base portion 2. The panel surface portion 1 includes a surface side portion 11 and a back side portion 12; the surface side portion 11 provides a surface 101 of the interior panel 10, and the back side portion 12 is arranged on the back side of the surface side portion 11. The panel base portion 2 includes a composite material member, the matrix of the composite material member is a first material, and the reinforcing material is a second material; wherein the back side portion 12 has a first material member 121, which has a first material; the back side portion 12 and the panel base portion 2 are connected through the first material member 121. Preferably, since the back side portion 12 and the panel base portion 2 are fused and connected through the first material member 121, the connection between the back side portion 12 and the panel base portion 2 can be a glue-free connection, which further simplifies the process and manufacturing cost.

[0076] Although the present invention is disclosed as above with preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art may make possible changes and modifications without departing from the spirit and scope of the present invention. Therefore, any modification, equivalent change and modification made to the above embodiments according to the technical essence of the present invention without departing from the content of the technical solution of the present invention shall fall within the protection scope defined by the claims of the present invention.

Claims

1. A method for manufacturing an interior trim panel (10), characterized in that: include: Heating a panel base portion (2) of an interior panel component to a first temperature, wherein the panel base portion (2) is a composite material component, the matrix of the composite material component is a first material, and the reinforcing material is a second material, and the first temperature is at least the softening temperature of the first material; The heated panel base part (2) and the panel surface part (1) are stacked and arranged in a side mold (201) of a compression molding process; wherein the panel surface part (1) comprises a surface side part (11) and a back side part (12); the surface side part (11) provides a surface (101) of the interior panel part (10); the back side part (12) is arranged on the back side of the surface side part (11); the back side part (12) has a first material part (121) and has the first material; the back side part (12) and the panel base part (2) are connected via the first material part (121); The one side mold (201) and the other side mold (202) are molded together and maintained for a first time; The one side mold (201) and the other side mold (202) are separated and opened to obtain the interior trim panel component (10).

2. The manufacturing method according to claim 1, characterized in that The first material includes polypropylene (PP), and the second material includes natural fiber and / or synthetic fiber.

3. The manufacturing method according to claim 1, characterized in that: The first temperature is 40° C. to 60° C. greater than the softening temperature of the first material.

4. The manufacturing method according to claim 1, characterized in that: The one side mold (201) is a movable mold, and the other side mold (202) is a fixed mold. The heated panel base part (2) and the panel surface part (1) are stacked and arranged on the movable mold for compression molding, and then the movable mold and the fixed mold are molded together and maintained for a first time.

5. The manufacturing method according to claim 1, characterized in that: The mold (201) on one side has a first positioning structure (2011), and the panel surface part (1) and the panel base part (2) respectively have a first positioning hole (13) and a second positioning hole (21). When the heated panel base part (2) and the panel surface part (1) are stacked and arranged on the mold (201) on one side for compression molding, the first positioning hole (13) and the second positioning hole (21) are aligned in the stacking direction and cooperate with the first positioning structure (2011) for positioning; the mold (202) on the other side has a second positioning structure (2021). When the mold (201) on one side is molded with the mold (202) on the other side, the first positioning structure (2011) and the second positioning structure (2022) are cooperated for positioning.

6. The manufacturing method according to claim 1, characterized in that: The one side mold (201) and the other side mold (202) are arranged on a horizontal injection molding device (400).

7. The manufacturing method according to claim 1, characterized in that: The back side portion (12) includes a foam layer (122) and a base layer (123), wherein the foam layer (122) is connected to the surface side portion (11), and the base layer (123) is connected to the panel base portion (2), and the base layer (123) has a non-woven fabric structure to serve as the first material piece (121), and the fiber material of the non-woven fabric structure is the first material.

8. The manufacturing method according to claim 1, characterized in that: The back side portion (12) includes a foam layer (122), one side of the foam layer (122) is connected to the surface side portion (11), and the other side is connected to the back side portion (12), and the material of the foam layer (122) includes the first material, so that the foam layer (122) serves as the first material piece (121).

9. An interior trim panel (10), characterized in that: Obtained by the manufacturing method according to any one of claims 1 to 8, the interior trim panel (10) comprises: A panel surface portion (1) comprises a surface side portion (11) and a back side portion (12); the surface side portion (11) provides a surface (101) of the interior panel member (10), and the back side portion (12) is arranged on the back side of the surface side portion (11); The panel base part (2) is a composite material part, the base of the composite material part is a first material, and the reinforcing material is a second material; wherein the back side portion (12) has a first material piece (121) having the first material; The back side portion (12) is connected to the panel base portion (2) via the first material piece (121).

10. The interior trim panel member (10) according to claim 9, characterized in that: The back side portion (12) and the panel base portion (2) are fused and connected without glue via the first material piece (121).

Images