Decorative part, manufacturing method thereof and vehicle

Abstract

The invention discloses a decorating part and a manufacturing method thereof and a vehicle, the decorating part comprises a shading layer and a texture layer which are stacked, the texture layer comprises a light-transmitting base body and short carbon fibers, the short carbon fibers are randomly distributed in the light-transmitting base body, the decorating part further comprises a supporting framework, and the supporting framework is connected to the face, opposite to the texture layer, of the shading layer. The randomly distributed short carbon fibers are adopted as the texture layer, so that the decorating part can present forging textures of the short carbon fibers, the texture layer has the characteristics of short forming period, good toughness and small carbon fiber material consumption, and the manufacturing cost of the decorating part can be reduced; meanwhile, by means of the multi-layer structure, the middle texture layer can present high fiber stereoscopic impression and high permeability, and the attractiveness of the decorating part is improved; the multi-layer structure can be recycled in a classified mode, the recycling value of the decorating part is improved, and finally the purposes of energy conservation and emission reduction can be achieved.

Description

Technical Field

[0001] The present application relates to the technical field of vehicle parts, and in particular to a decorative part and a manufacturing method thereof, and a vehicle. Background Art

[0002] With the evolution of industry trends such as "plastics replacing steel" and "energy conservation and emission reduction" in automobile lightweighting, carbon fiber reinforced resin-based composite materials have attracted widespread attention due to their lightweight, high strength, corrosion resistance and other performance advantages. Compared with traditional thermosetting composite materials, thermoplastic composite materials are gradually playing an increasingly important role in the field of automobile manufacturing due to their advantages such as short molding cycle, good toughness, recyclability and low carbon emissions. Due to the unique texture and gloss of carbon fiber, interior and exterior parts made of resin-based composite materials reinforced with carbon fiber fabrics or unidirectional tapes (sheets) can give cars a unique sense of high-end, luxury and quality.

[0003] The existing technology mostly adopts a single thermosetting prepreg compression molding method reinforced with textile carbon fiber, which has a long molding cycle, high material cost, high product brittleness, and the resulting carbon fiber decorative parts have poor aesthetics; moreover, it is difficult to achieve material recycling for decorative parts formed by compression molding of a single thermosetting prepreg, or the recycling cost is high. Summary of the invention

[0004] The purpose of the present application is to provide a decorative part, a manufacturing method thereof, and a vehicle, so as to solve the problems of high manufacturing and recycling costs of decorative parts and poor aesthetics.

[0005] To achieve the purpose of this application, this application provides the following technical solutions:

[0006] In a first aspect, the present application provides a decorative piece, comprising a stacked shading layer and a texture layer, wherein the texture layer comprises a light-transmitting matrix and a carbon fiber material, wherein the carbon fiber material is randomly distributed in the light-transmitting matrix, and the decorative piece further comprises a supporting frame, wherein the supporting frame is connected to a side of the light-shielding layer facing away from the texture layer.

[0007] In one embodiment, the carbon fiber material is chopped carbon fiber.

[0008] In one embodiment, the texture layer further comprises a plurality of stacked fiber sheets, and a plurality of the chopped fibers constitute the fiber sheets.

[0009] In one embodiment, the fiber sheet has a thickness of 0.08 mm to 0.15 mm.

[0010] In one embodiment, the material of the light-transmitting substrate includes one or more of polymethyl methacrylate, polystyrene, and polycarbonate.

[0011] In one embodiment, the decorative element further includes a light-transmitting layer, and the light-transmitting layer is disposed on a side of the texture layer facing away from the light-shielding layer.

[0012] In one embodiment, the thickness of the light-transmitting layer is 0.15 mm to 0.8 mm; the thickness of the texture layer is 0.1 mm to 0.5 mm; and the thickness of the light-shielding layer is 0.1 mm to 0.5 mm.

[0013] In one embodiment, the light-transmitting layer includes a stacked high-transmittance paint layer and a transparent resin layer, the transparent resin layer is connected to the texture layer, the high-transmittance paint layer is located on the side of the transparent resin layer facing away from the texture layer, and the material transmittance of the transparent resin layer is greater than or equal to 88%.

[0014] In one embodiment, the thickness of the high-transmittance paint layer is 0.05 mm to 0.3 mm; and / or the thickness of the transparent resin layer is 0.1 mm to 0.5 mm.

[0015] In one embodiment, the material of the transparent resin layer includes one or more of polymethyl methacrylate, polystyrene, and polycarbonate; and / or the material of the high-transmittance paint layer is oily polyurethane.

[0016] In one embodiment, the light-shielding layer comprises a light-shielding substrate, the material of which is a polymer modified by toner; and / or, a woven fiber cloth is provided in the light-shielding substrate.

[0017] In one embodiment, the modulus of the support skeleton is greater than or equal to 4800 MPa.

[0018] In one embodiment, the decorative element is a plate-shaped structure, and the decorative element has a first matching portion, and the first matching portion is a protruding plate protruding from a first edge of the decorative element.

[0019] In one embodiment, the edge of the protruding plate is provided with an outwardly protruding edge frame, and a plurality of positioning holes are opened on the edge frame, and the diameter of the positioning holes is 5 mm to 8 mm.

[0020] In one embodiment, the decorative element has a second matching portion, the second matching portion is a first groove in which a second edge of the decorative element is recessed, and the second edge and the first edge are located on two opposite sides of the decorative element.

[0021] In one embodiment, the depression depth of the first groove is 30 mm to 50 mm, and the width of the first groove is 80 nm to 120 nm.

[0022] In one embodiment, the decorative element has a third matching portion, and the third matching portion is a second groove in which a third edge of the decorative element is recessed, and the third edge is respectively connected to the first edge and the second edge.

[0023] In one embodiment, the second groove is arc-shaped, and the depression radius of the second groove is 40nm-60nm.

[0024] In one embodiment, the decorative piece of the plate-like structure is curved, and includes a fourth edge opposite to the third edge. The fourth edge is in a direction toward the third edge, and the decorative piece has a bending inclination angle of 20° to 40°.

[0025] In one embodiment, a plurality of positioning posts are further provided on a side of the support frame facing away from the light-shielding layer.

[0026] In a second aspect, the present application also provides a method for manufacturing a decorative part, characterized in that it includes: pressing a shading material and a carbon fiber composite material into a decorative film by a multi-layer molding process, the shading material forms a shading layer, and the carbon fiber composite material forms a texture layer; cutting and shaping the decorative film according to a preset size and shape to obtain the decorative part, the texture layer includes a light-transmitting matrix and chopped carbon fibers, and the chopped carbon fibers are randomly distributed in the light-transmitting matrix.

[0027] In a third aspect, the present application provides a vehicle, comprising the decorative component described in the first aspect, wherein the decorative component is installed in a cabin of the vehicle.

[0028] The decorative piece provided by the present invention adopts randomly distributed short-cut carbon fibers as the texture layer, so that the decorative piece can present the forging texture of the short-cut carbon fibers rather than the woven carbon fiber texture, and the texture layer has the characteristics of short molding cycle, good toughness, and small amount of carbon fiber material, which can reduce the manufacturing cost of the decorative piece; at the same time, the decorative piece is designed to be a multi-layer structure, so that the texture layer in the decorative piece has a good appearance under the protection of the shading layer, and through the shading layer and the matching, the middle texture layer can present a strong fiber three-dimensional sense and high permeability, and the aesthetics of the decorative piece is improved; further, the multi-layer structure is adopted, so that the decorative piece can be disassembled into multi-layer materials during the recycling process, and the multi-layer materials are classified and recycled separately, rather than a single thermosetting material structure that is not recyclable, thereby improving the recyclable value of the decorative piece, and ultimately achieving the purpose of energy conservation and emission reduction. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] In order to more clearly illustrate the implementation methods of the present application or the technical solutions in the prior art, the drawings required for use in the implementation methods or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some implementation methods of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0030] Figure 1 is a schematic diagram of a cross-sectional structure of a decorative element according to an embodiment;

[0031] Figure 2 is a schematic diagram of a top view of a texture according to an embodiment;

[0032] Figure 3 is a front structural diagram of a decorative member according to an embodiment;

[0033] Figure 4 is an exploded view of a decorative element according to one embodiment;

[0034] Figure 5 is a structural diagram of a first mating portion of an embodiment;

[0035] Figure 6 is a curved elevation view of a decorative element of one embodiment;

[0036] Figure 7 is a back structural diagram of a decorative member according to an embodiment;

[0037] Figure 8 is a structural diagram of a positioning column of an implementation method;

[0038] Fig. 9 is a flow chart of a method for manufacturing a decorative part according to an embodiment;

[0039] Fig.10 It is a flow chart of the manufacturing method of the decorative part of Example 1. DETAILED DESCRIPTION

[0040] The following will be combined with the drawings in the embodiments of the present application to clearly and completely describe the technical solutions in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this application.

[0041] It should be noted that when a component is said to be "fixed to" another component, it can be directly on the other component or there can be a central component. When a component is said to be "connected to" another component, it can be directly connected to the other component or there can be a central component at the same time.

[0042] Unless otherwise defined, all technical and scientific terms used in this application have the same meaning as those commonly understood by those skilled in the art to which this application belongs. The terms used in this application and in the specification are only for the purpose of describing specific embodiments and are not intended to limit this application. The term "and / or" used in this application includes any and all combinations of one or more of the related listed items.

[0043] In conjunction with the accompanying drawings, some embodiments of the present application are described in detail below. In the absence of conflict, the following embodiments and features in the embodiments can be combined with each other.

[0044] For ease of understanding, the relevant technical terms involved in this application are explained and described below.

[0045] Forged carbon fiber: The texture state after short carbon fiber sheets are randomly stacked and hot-pressed with resin.

[0046] Powder impregnation: The process of low-temperature crushing of plastic and uniformly mixing with carbon fiber and melt bonding.

[0047] Prepreg: A sheet or strip made by mixing resin and fiber through the impregnation process and then cooling and shaping.

[0048] Insert molding: A molding method in which the insert is pre-fixed in the injection mold and the resin is injected to connect with the insert.

[0049] Thermosetting composite materials: composite materials that are formed by chemical cross-linking and curing reaction and cannot be processed again.

[0050] Thermoplastic composite materials: composite materials that are melted by heating, solidified by cooling, and can be processed again.

[0051] The present application provides a decorative part and a vehicle equipped with the decorative part. The vehicle may be a fuel vehicle or a new energy vehicle, and the decorative part is installed in the cabin of the vehicle to increase the appearance and protect the parts.

[0052] In one embodiment, the decorative component can be installed on the vehicle door, the center console, the center armrest, the steering wheel, etc.

[0053] In one embodiment, the decorative element may be a three-dimensional structure, and the shape is not limited, and the shape of the decorative element may be determined according to the required installation.

[0054] In one implementation, please refer to Figure 1 The decorative part includes a shading layer 4, a texture layer 3 and a light-transmitting layer stacked in sequence, and the texture layer 3 includes a light-transmitting matrix and a carbon fiber material, and the carbon fiber material is distributed in the light-transmitting matrix. Specifically, along the outermost surface of the decorative part (the surface that the passenger can touch) inward, there are a light-transmitting layer, a texture layer 3 and a shading layer 4 in sequence. It can be understood that the light-transmitting layer has a high light transmittance and less light scattering; the texture layer 3 has a preset texture state, and the pattern of the decorative part that the passenger can directly see comes from the texture layer 3; the shading layer 4 has a low light transmittance and is used to block the light that passes through the texture layer 3. In one embodiment, please refer to Figure 2 , the texture layer 3 is composed of forged carbon fiber, that is, the carbon fiber material is forged chopped carbon fiber. The texture layer 3 includes a light-transmitting matrix and chopped carbon fiber, and the chopped carbon fiber is randomly distributed in the texture layer 3. Specifically, the texture layer 3 is composed of a light-transmitting light-transmitting matrix and chopped carbon fiber, and the chopped carbon fiber in the light-transmitting matrix is ​​similar to the relationship between jelly and fruit in fruit jelly. Since the light-transmitting matrix is ​​a light-transmitting material, passengers can directly see the pattern formed by the distribution of chopped carbon fibers.

[0055] In one implementation, please refer to Figure 2 The texture layer 3 includes a plurality of chopped carbon fibers. The random distribution can be understood as the plurality of chopped carbon fibers being randomly arranged in the texture layer 3 ( Figure 2 Forged carbon fiber) has no regular arrangement relationship between short carbon fibers. Forged carbon fiber is different from existing carbon fiber fabrics, which are woven into a specific structure by long carbon fibers. There is a regularity between the long carbon fibers ( Figure 2 plain weave, twill weave, satin weave); whereas forged carbon fibers can be randomly stacked on top of each other resulting in a loose bond.

[0056] In one embodiment, the texture layer 3 can provide the main texture appearance, and the edges of the chopped carbon fibers are clear without scattered and disordered lines. The chopped carbon fibers and the transparent matrix can be compounded by an impregnation process, and the impregnation process can be one of a film lamination method, a powder impregnation method, and a mud impregnation method.

[0057] The decorative piece provided by the present invention adopts randomly distributed short-cut carbon fibers as the texture layer 3, so that the decorative piece can present the forging texture of the short-cut carbon fibers rather than the woven carbon fiber texture, and the texture layer 3 has the characteristics of short molding cycle, good toughness, and small amount of carbon fiber material, which can reduce the manufacturing cost of the decorative piece; at the same time, the decorative piece is designed to be a multi-layer structure, so that the texture layer 3 in the decorative piece has a good appearance under the protection of the light-transmitting layer and the light-shielding layer 4, and through the cooperation of the light-transmitting layer and the light-shielding layer 4, the middle texture layer 3 can present a strong fiber three-dimensional sense and high permeability, and the aesthetics of the decorative piece is improved; further, the multi-layer structure is adopted, so that the decorative piece can be disassembled into multi-layer materials during the recycling process, and the multi-layer materials can be classified and recycled separately, rather than a single thermosetting material structure that is not recyclable, thereby improving the recyclable value of the decorative piece and ultimately achieving the purpose of energy saving and emission reduction.

[0058] In one embodiment, the texture layer 3 further comprises a plurality of stacked fiber sheets, and a plurality of chopped fibers form the fiber sheets. Specifically, the chopped carbon fibers in the texture layer 3 may be in sheet form, and each fiber sheet may contain a plurality of chopped carbon fibers. Alternatively, the fiber sheets may be understood to be fiber bundles.

[0059] In one embodiment, the plurality of fiber sheets are randomly arranged, and the plurality of fiber sheets may be stacked, interlaced, entangled, etc.

[0060] In one embodiment, the thickness of the fiber sheet is 0.08 mm to 0.15 mm. Specifically, the thickness of the fiber sheet can be 0.08 mm, 0.09 mm, 0.10 mm, 0.11 mm, 0.12 mm, 0.13 mm, 0.14 mm, or 0.15 mm. When the thickness of the fiber sheet is less than this range, the manufacturing difficulty of the fiber sheet increases, which is not conducive to controlling the cost; when the thickness of the fiber sheet is greater than this range, the fiber sheet is too thick, resulting in the texture layer 3 being too thick, which is not conducive to controlling the thickness of the decorative part.

[0061] In one embodiment, the material of the light-transmitting substrate includes one or more of polymethyl methacrylate, polystyrene, and polycarbonate.

[0062] In one embodiment, pigments are added to the light-transmitting matrix to achieve a carbon fiber decorative effect with a variety of color appearances.

[0063] In one embodiment, the thickness of the light-transmitting layer is 0.15 mm to 0.8 mm. Specifically, the thickness of the light-transmitting layer is 0.15 mm, 0.2 mm, 0.25 mm, 0.3 mm, 0.35 mm, 0.4 mm, 0.45 mm, 0.5 mm, 0.55 mm, 0.6 mm, 0.65 mm, 0.7 mm, 0.75 mm, 0.8 mm. When the thickness of the light-transmitting layer is less than this range, the wear resistance and corrosion resistance of the light-transmitting layer are poor, and being too thin is not conducive to protecting the texture layer 3; when the thickness of the light-transmitting layer is greater than this range, the light transmittance of the light-transmitting layer is poor, that is, the light transmittance is poor, which makes it difficult for the texture layer 3 to present a three-dimensional effect, and will cause the decorative piece to be too thick.

[0064] In one embodiment, the thickness of the texture layer 3 is 0.1 mm to 0.5 mm. Specifically, the thickness of the texture layer 3 is 0.1 mm, 0.15 mm, 0.2 mm, 0.25 mm, 0.3 mm, 0.35 mm, 0.4 mm, 0.45 mm, and 0.5 mm. When the thickness of the texture layer 3 is less than this range, the stacking effect formed between the chopped carbon fibers is poor, the three-dimensional sense is poor, and the aesthetics of the texture layer 3 is reduced. When the thickness of the texture layer 3 is greater than this range, the decorative effect of the texture layer 3 does not change much, and the cost of the texture layer 3 increases.

[0065] In one embodiment, the thickness of the light shielding layer 4 is 0.1 mm to 0.5 mm. Specifically, the thickness of the light shielding layer 4 is 0.1 mm, 0.15 mm, 0.2 mm, 0.25 mm, 0.3 mm, 0.35 mm, 0.4 mm, 0.45 mm, and 0.5 mm. When the thickness of the light shielding layer 4 is less than this range, the light shielding effect of the light shielding layer 4 is poor, light is easily transmitted, and the aesthetics of the decorative piece is reduced; when the thickness of the light shielding layer 4 is greater than this range, the decorative piece will be too thick and the cost will increase.

[0066] In one embodiment, the light-transmitting layer includes a stacked high-transmittance paint layer 1 and a transparent resin layer 2, the transparent resin layer 2 is connected to the texture layer 3, the high-transmittance paint layer 1 is located on the side of the transparent resin layer 2 facing away from the texture layer 3, and the material transmittance of the transparent resin layer 2 is greater than or equal to 88%. Specifically, the transparent resin layer 2 is manufactured on the texture layer 3, and the transparent resin layer 2 has high permeability (i.e., high transmittance), and light can pass through the transparent resin layer 2 to irradiate the chopped carbon fibers in the texture layer 3 and enter the human eye through reflection.

[0067] In one embodiment, the high-transmittance paint layer 1 is coated on the transparent resin layer 2. The high-transmittance paint layer 1 is also made of a light-transmitting material, and the materials and functions of the high-transmittance paint layer 1 and the transparent resin layer 2 are different. The high-transmittance paint layer 1 is used to protect the inner transparent resin layer 2 to prevent the transparent resin layer 2 from directly contacting the external environment, thereby causing the transparent resin layer 2 to be corroded or scratched; and the high-transmittance paint layer 1 also has certain waterproof and moisture-resistant properties.

[0068] In one embodiment, the thickness of the high-transmittance paint layer 1 is 0.05mm to 0.3mm. Specifically, the thickness of the high-transmittance paint layer 1 is 0.05mm, 0.1mm, 0.15mm, 0.2mm, 0.25mm, and 0.3mm. When the thickness of the high-transmittance paint layer 1 is less than this range, the high-transmittance paint layer 1 is very easy to be scratched, resulting in damage to the transparent resin layer 2, that is, the protection effect of the high-transmittance paint layer 1 is poor; when the thickness of the high-transmittance paint layer 1 is greater than this range, the light transmittance of the high-transmittance paint layer 1 is poor, that is, the light transmittance is poor, which makes it difficult for the texture layer 3 to present a three-dimensional effect, and will cause the decorative piece to be too thick.

[0069] In one embodiment, the thickness of the transparent resin layer 2 is 0.1 mm to 0.5 mm. Specifically, the thickness of the transparent resin layer 2 is 0.1 mm, 0.15 mm, 0.2 mm, 0.25 mm, 0.3 mm, 0.35 mm, 0.4 mm, 0.45 mm, and 0.5 mm. When the thickness of the transparent resin layer 2 is less than this range, the wear resistance and corrosion resistance of the light-transmitting layer are poor, and being too thin is not conducive to protecting the texture layer 3; when the thickness of the transparent resin layer 2 is greater than this range, the light transmittance of the transparent resin layer 2 is poor, that is, the light transmittance is poor, which makes it difficult for the texture layer 3 to present a three-dimensional effect, and causes the decorative piece to be too thick.

[0070] In one embodiment, the material of the transparent resin layer 2 includes one or more of polymethyl methacrylate, polystyrene, and polycarbonate.

[0071] In one embodiment, the transparent resin layer 2 can provide appearance smoothness, permeability and fiber protection function, so the material can be a transparent resin with a light transmittance of not less than 88%.

[0072] In one embodiment, the material of the high-transmittance paint layer 1 is oily polyurethane.

[0073] In one embodiment, the high-transmittance paint layer 1 can provide surface gloss, scratch resistance, chemical resistance and light aging resistance. Therefore, the material of the high-transmittance paint layer 1 can be an oily polyurethane (PU) varnish system.

[0074] In one embodiment, the light-shielding layer 4 includes a light-shielding matrix, the material of which is a polymer modified by a toner; and / or, a woven fiber cloth is provided in the light-shielding matrix. Specifically, the light-shielding matrix can be a light-transmitting material, and by adding plastic toner or woven fiber cloth into the light-shielding matrix, the light transmittance of the light-shielding layer 4 is changed, so that the light-shielding layer 4 presents a low light transmittance characteristic. The plastic toner can be black.

[0075] In one embodiment, the light-shielding functional layer serves to shield the light-transmitting area to prevent the bottom from being exposed, thereby improving the quality of the decorative element, so the color may be pure black.

[0076] In one embodiment, the material of the light-shielding substrate includes one or more of polymethyl methacrylate, polystyrene, and polycarbonate.

[0077] In one embodiment, the light-transmitting layer, the light-transmitting substrate, and the light-shielding substrate are made of the same material. The advantage of using the same material is that the light-shielding layer 4, the light-transmitting layer, and the texture layer 3 are formed by compression molding, and the same material has better connection characteristics and no interface dispersion occurs, thereby improving the aesthetics of the texture layer 3.

[0078] In one embodiment, the decorative part further includes a support frame 5, which is connected to the side of the light shielding layer 4 facing away from the texture layer 3, and the modulus of the support frame 5 is greater than or equal to 4800 MPa. Specifically, the support frame 5 is used to assemble the decorative part with the inner frame of the vehicle, and the support frame 5 can be detachably connected to the inner frame of the vehicle.

[0079] In one implementation, the support frame 5 can provide the main mechanical properties of the decorative component and the assembly structure with surrounding components, so the material modulus of the support frame 5 is required to be no less than 4800 MPa.

[0080] In one embodiment, the material of the support frame 5 can be glass fiber reinforced polypropylene PP, polyamide PA, polyphenylene sulfide PPS, and an alloy of polycarbonate PC and acrylonitrile-butadiene-styrene copolymer ABS (PC / ABS).

[0081] In one embodiment, the material of the supporting skeleton 5 is a PC / ABS alloy with 20 wt% short glass fiber reinforcement or 30 wt% glass fiber reinforced PP composite material added thereto.

[0082] In one embodiment, the thickness of the support frame 5 is 2.0 mm to 3.0 mm. Specifically, the thickness of the support frame 5 is 2 mm, 2.1 mm, 2.2 mm, 2.3 mm, 2.4 mm, 2.5 mm, 2.6 mm, 2.7 mm, 2.8 mm, 2.9 mm, or 3.0 mm.

[0083] In one embodiment, an assembly buckle is formed on a surface of the support frame 5 facing away from the light shielding layer 4 .

[0084] In one embodiment, the support frame 5 is injection molded.

[0085] In one implementation, please refer to Figure 3 and Figure 4 The decorative piece is a plate-shaped structure, and the decorative piece has a first matching portion, and the first matching portion is a protruding plate 11 protruding from the first edge of the decorative piece. Specifically, the decorative piece can be a plate for a door armrest. The first matching portion is used to match with the door armrest box.

[0086] In one implementation, please refer to Figure 3 and Figure 5 The edge of the protruding plate 11 is provided with an outwardly protruding edge frame 14, and a plurality of positioning holes 15 are opened on the edge frame 14, and the diameter of the positioning holes 15 is 5mm to 8mm. Specifically, the diameter of the positioning holes 15 can be 5mm, 6mm, 7mm, and 8mm. The number of the positioning holes 15 can be 4, so as to ensure the assembly and positioning of the screw column of the first matching part and the armrest box.

[0087] In one implementation, please refer to Figure 3 The decorative piece has a second matching portion, which is a first groove 12 in which the second edge of the decorative piece is recessed, and the second edge and the first edge are located on opposite sides of the decorative piece. Specifically, the first groove 12 can be a second matching portion for matching with the inner handle of the door; the first groove 12 is in the shape of a "concave".

[0088] In one embodiment, the first groove 12 has a depth of 30 mm to 50 mm, and a width of 80 nm to 120 nm. Specifically, the depth of the first groove 12 can be 30 mm, 35 mm, 40 mm, 45 mm, or 50 mm. The width of the first groove 12 can be 80 nm, 90 nm, 100 nm, 110 nm, or 120 nm. Of course, the specific setting size of the first groove 12 can be matched according to the assembly position of the door handle.

[0089] In one implementation, please refer to Figure 3 The decorative element has a third matching portion, which is a second groove 13 in which the third edge of the decorative element is recessed, and the third edge is respectively connected to the first edge and the second edge. Specifically, the third matching portion is used to match with the door speaker.

[0090] In one embodiment, the second groove 13 is arc-shaped, and the concave radius of the second groove 13 is 40nm to 60nm. Specifically, the concave radius of the second groove 13 can be 40nm, 45nm, 50nm, 55nm, or 60nm. Of course, the specific setting size can be matched according to the size of the speaker.

[0091] In one implementation, please refer to Figure 6 The decorative piece of the plate-like structure is curved, and includes a fourth edge opposite to the third edge. The fourth edge has a bending elevation angle α of 20° to 40° in the direction of the third edge. Specifically, the bending elevation angle of the decorative piece can be 20°, 25°, 30°, 35°, or 40°. Of course, the specific size is matched according to the size of the armrest box and the speaker.

[0092] In one implementation, please refer to Figures 6 to 8The side of the support frame facing away from the light shielding layer is also provided with a plurality of positioning posts 16. Specifically, the positioning posts 16 can be screw posts, and the number of the positioning posts 16 can be 30 groups.

[0093] Most of the door interior decorative panels in the prior art are made of thermosetting epoxy resin composite materials with cross-linked molecular chains, which are brittle and not impact-resistant, and the assembly process is a mixed assembly process of gluing and bolting, which is complex and difficult to achieve convenient disassembly and replacement. However, the present application uses a polycarbonate thermoplastic material with a linear molecular chain and a carbon fiber material to form a shell, thereby improving the impact resistance; and supports the assembly and positioning structures of the back of the frame, such as screw columns, positioning holes 15, etc., to achieve good assembly and detachable functions of the decorative parts.

[0094] In one embodiment, the present application also provides a method for manufacturing a decorative element, please refer to Fig. 9 , including the following steps:

[0095] S10, pressing the shading material and the carbon fiber composite material into a decorative film by a multi-layer molding process, wherein the shading material forms a shading layer and the carbon fiber composite material forms a texture layer.

[0096] S20, cutting and shaping the decorative film into a preset size and shape to obtain a decorative piece.

[0097] In one implementation, in step S10, the shading material, the carbon fiber composite material and the light-transmitting material can refer to the material types provided in the above implementation, and will not be described in detail here.

[0098] In one embodiment, in step S10, the multilayer molding process is a composite material molding process, in which multiple layers of pre-fabricated resin materials are stacked together and cured into one under the action of heat and pressure to finally form a desired product shape.

[0099] In one embodiment, in step S10, the decorative film is in the shape of a flat plate, and includes the light shielding layer, the texture layer and the light transmitting layer in the above embodiment.

[0100] In one embodiment, in step S10, in the multi-layer molding process, the total thickness of the decorative film is controlled to be between 0.4 mm and 1.2 mm by the mold gap.

[0101] In one embodiment, in step S20, the decorative film is placed in a punching tool having a shape consistent with the 2D unfolded shape of the final product, and the die is closed and blanked to obtain a carbon fiber surface layer.

[0102] In one embodiment, in step S20, the final product 2D unfolded shape can be understood as: a two-dimensional sheet mold obtained after the final three-dimensional decorative part is unfolded into a plane. It can be understood that the external surface area of ​​the 2D unfolded shape is the same as the external specific surface area of ​​the final three-dimensional decorative part.

[0103] In one embodiment, in step S20, the die-closing blanking means that when the mold is closed, the overlapping part of the blanking die and the punch is the die-closing blanking. When the punch enters the die, the ejector will eject the ejector mounted on the upper die seat, so that the workpiece falls from the concave and convex dies.

[0104] In one embodiment, in step S20, after the decorative film is cut into a preset size and shape, the method further includes: compounding and shaping the decorative film with a supporting frame to obtain a decorative piece.

[0105] In one embodiment, in step S20, the decorative film is compounded with the supporting frame and shaped, including the following two process routes:

[0106] (1) Compression molding and injection molding: The decorative film is heated to above the melting point by heating, and then the decorative film is placed in the mold cavity and pressed together. The material of the supporting frame is then injected into the mold, and the decorative part is obtained by maintaining pressure, cooling and opening the mold.

[0107] (2) Compression molding + injection molding: Place the decorative film in a hot pressing mold, and after hot pressing and shaping, open the mold to obtain a decorative film with the shape of the product; Place the decorative film in the product injection mold, inject the material of the supporting frame, and open the mold after pressure maintenance and cooling to obtain the decorative part.

[0108] In one embodiment, the integrated molding of compression molding and injection molding includes: heating the decorative film to 10℃ to 20℃ above the melting point of the resin by infrared or oven baking heating, the baking time is not less than 5 minutes to allow the material to be fully heated and melted, and the material is quickly transferred to the mold cavity of the final product by a manipulator and then molded and pressed, the mold temperature is set to 60℃ to 100℃, the material transfer and mold closing process does not exceed 5 seconds to ensure that the material is in a softened state, and the inner wall of the cavity is sprayed with a release agent in advance. Then, the resin melt is injected to form the back skeleton, and the decorative part is obtained after pressure maintenance, cooling and mold opening.

[0109] In one embodiment, the two-stage molding of compression molding + injection molding includes: placing the decorative film sheet on the surface hot pressing mold of the product, spraying the release agent on the upper and lower molds in advance to prevent sticking to the mold, setting the mold temperature to 10℃ to 20℃ higher than the melting point of the resin, closing the mold for hot pressing and shaping, and then opening the mold to obtain the decorative film sheet with the shape of the product. The decorative film sheet is placed in the product injection mold, the mold is heated to 15-20℃ above the softening temperature of the resin, and then the back frame is injection molded by closing the mold, and the decorative part is obtained after pressure maintenance, cooling and opening the mold.

[0110] In one embodiment, in step S20, after the decorative film is composited with the supporting frame and shaped, the process further includes: spraying paint on the light-transmitting layer so that the light-transmitting layer includes a high-transmittance paint layer and a transparent resin layer. The spraying paint forms a high-transmittance paint layer, and the light-transmitting material forms a transparent resin layer.

[0111] In one embodiment, in step S20, spraying paint on the light-transmitting layer includes: grinding and polishing the light-transmitting layer and then spraying transparent varnish, first spraying primer and baking at 75°C for 20 minutes to increase paint adhesion, then spraying topcoat and baking at 80°C for 60 minutes to solidify the paint film, and finally obtaining a decorative part.

[0112] The present invention designs a unique multi-layer thermoplastic material structure and molding process for the special forged texture appearance of chopped carbon fiber, and realizes the stable combination of the forged carbon fiber surface with good appearance and the complex support skeleton on the back by multi-layer hot pressing and insert injection molding, ensuring the strong fiber stereoscopic sense and high permeability of non-woven carbon fiber decorative parts. At the same time, the manufacturing method also has the advantages of short molding cycle, good toughness, small amount of carbon fiber material and recyclability. It is a low-cost, high-efficiency, high-quality and low-carbon and environmentally friendly automotive interior parts molding technology that can be widely promoted and applied.

[0113] The technical solution of the present invention is described in detail below through specific embodiments. It should be noted that the following embodiments and comparative examples select the manufacturing process of the forged carbon fiber textured front door central decorative panel for detailed description. The front door central decorative panel is large in size and has a large number of back assembly buckles (greater than 30).

[0114] Example 1

[0115] The present embodiment provides a front door central decorative panel and a manufacturing method, wherein the front door central decorative panel is made of a multi-layer thermoplastic carbon fiber composite material, the matrix resin used is thermoplastic polymethyl methacrylate PMMA, the glass transition temperature is 105°C, the melting temperature is 190°C, and the carbon fiber tow is Toray 12K T300 unidirectional tow.

[0116] Please refer to Fig.10 , the manufacturing method comprises the following steps:

[0117] 1) The transparent PMMA carbon fiber prepreg film (texture layer) is manufactured by the powder impregnation method: the resin is manufactured by low-temperature crushing, fiber impregnation, roller pressing to determine thickness, cutting and spreading, hot pressing and film forming, etc. The cutting length of a single piece of carbon fiber is 12.5 mm, the width is 8 mm, and the overall thickness of the prepreg film is controlled to be 0.4 mm.

[0118] 2) Multi-layer molding to form a decorative film: From top to bottom, transparent PMMA film (light-transmitting layer), PMMA carbon fiber prepreg film (texture layer), and pure black PMMA film (light-shielding layer) are stacked and hot-pressed at a temperature of 200°C. After hot pressing, the total thickness of the decorative film is controlled to be 1.0 mm.

[0119] 3) Cutting and shaping the membrane according to the preset size and shape: The obtained decorative membrane is punched and blanked according to the 2D unfolded shape of the product, and then placed on the surface of the product for hot pressing and shaping in a hot pressing mold at a temperature of 200°C, thereby obtaining a forged carbon fiber decorative membrane with injection molding positioning holes.

[0120] 4) Injection molding to form a support frame: Place the decorative film in the injection mold of the final product, and use a two-stage process of first molding and then injection molding to achieve insert injection molding. Set the mold temperature to 120°C, fix the surface layer according to the positioning holes and attach it to the contoured surface. The injection molding material is made of PC / ABS alloy reinforced with 20% glass fiber, and the injection molding machine barrel temperature is 270°C. Then, the mold is closed and the support frame with the assembly structure is injection molded. After holding the pressure for 30 seconds, the mold is cooled and opened, and the front door center decorative panel with a chopped forged carbon fiber texture appearance surface and a back support frame is taken out.

[0121] 5) Spraying to form a paint surface (high-transparency paint layer): The central decorative panel product is ground and polished to eliminate local defects, and then the appearance is protected by a painting process. First, spray the primer and bake it at 75°C for 20 minutes to increase the adhesion of the paint, then spray the topcoat and bake it at 80°C for 60 minutes to solidify the paint film.

[0122] In addition, the front door central decorative panel provided in this embodiment also has the following structural features: there are 4 positioning holes with a diameter of 8 mm on the edge frame of the protruding plate to ensure assembly and positioning with the armrest box screw columns; the depth of the first groove is 40 mm and the width is 100 mm; the radius of the second groove is 50 mm; the bending angle of the decorative panel is 20°; the number of positioning columns is 30 groups.

[0123] Comparative Example 1

[0124] This comparative example provides a front door central decorative panel, which is a front door central decorative panel manufactured by existing technology on the market.

[0125] The following experimental tests were performed on the front door central decorative panels provided in Example 1 and Comparative Example 1 to obtain the experimental results:

[0126] High temperature storage test

[0127] Place the product in a constant temperature box at 100±2℃ for 168 hours, take it out and observe the surface condition of the product.

[0128] Test results: The front door central decorative panel provided in Example 1 did not show distortion, deformation, cracks, peeling, delamination, softening, hardening, blistering, whitening, wrinkling, discoloration, etc. The front door central decorative panel provided in Comparative Example 1 showed distortion, deformation, cracks, peeling, delamination, softening, hardening, blistering, whitening, wrinkling, and discoloration.

[0129] Cyclic damp heat test

[0130] Carry out alternating damp heat test according to the test conditions in Table 1 below, and observe the surface condition of the part after at least 5 cycles.

[0131] Table 1

[0132]

[0133] Test results: The front door central decorative panel provided in Example 1 did not show distortion, deformation, cracks, peeling, delamination, softening, hardening, blistering, whitening, wrinkling, discoloration, etc. The front door central decorative panel provided in Comparative Example 1 showed distortion, deformation, cracks, peeling, delamination, softening, hardening, blistering, whitening, wrinkling, discoloration, etc.

[0134] Low temperature impact test

[0135] Place the workpiece in a thermostatic box and set the temperature of the thermostatic box to -40℃. Take it out after 4 hours. Place and fix it with the impacted surface facing up. Use a 500g, 50mm diameter steel ball to naturally drop from 400mm above to the impacted surface. The impact process must be completed within 15s after the workpiece is taken out of the thermostatic box. Then observe the surface condition of the sample.

[0136] Test results: The front door central decorative panel provided in Example 1 had no fractures, cracks, or breaks. The front door central decorative panel provided in Comparative Example 1 had fractures, cracks, and breaks.

[0137] Xenon lamp weathering test

[0138] The product is installed in the test box, and the xenon lamp is used as the irradiation light source. The irradiance is set to 0.55±0.02W / m2. The test steps are as follows (one cycle): 38±3℃ blackboard temperature, 38±3℃ box air temperature, 95%±5% relative humidity, front + back water spraying at the same time, running time 60 minutes in the dark stage; 70±3℃ blackboard temperature, 47±3℃ box air temperature, 50%±5% relative humidity, running time 40 minutes in the light stage; 70±3℃ blackboard temperature, 47±3℃ box air temperature, 50%±5% relative humidity, front spraying at the same time, running time 20 minutes in the light stage; 70±3℃ blackboard temperature, 47±3℃ box air temperature, 50%±5% relative humidity, running time 60 minutes in the light stage. Observe the surface state of the product after the above test process is repeated for no less than 125 cycles.

[0139] Test results: The front door central decorative panel provided in Example 1 did not show any changes in color, gloss, etc., and did not show any aging phenomena such as cracking, blistering, peeling, etc. The front door central decorative panel provided in Comparative Example 1 showed yellowing, reduced transparency, etc.

[0140] In summary, the front door central decorative panel provided by the present invention is designed with a unique multi-layer thermoplastic material structure and molding process for the special forged texture appearance of chopped carbon fiber, and a stable combination of the forged carbon fiber surface with good appearance and the complex back support frame is achieved by multi-layer hot pressing and insert injection molding, ensuring the strong fiber three-dimensional sense and high permeability of the front door central decorative panel, and having relatively excellent physical properties. The front door central decorative panel provided by the present invention also has the advantages of short molding cycle, good toughness, small amount of carbon fiber material and recyclability, etc. It is a low-cost, high-efficiency, high-quality, low-carbon and environmentally friendly automotive interior parts and molding technology that can be widely promoted and applied.

[0141] In the description of the embodiments of the present application, it should be noted that the orientation or positional relationship of terms such as "center", "up", "down", "left", "right", "vertical", "horizontal", "inside" and "outside" are based on the orientation or positional relationship described in the accompanying drawings, and are only for the convenience of describing 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 cannot be understood as a limitation on the present application.

[0142] What is disclosed above is only a preferred embodiment of the present application, and it certainly cannot be used to limit the scope of rights of the present application. Ordinary technicians in this field can understand that all or part of the processes of implementing the above embodiment and equivalent changes made according to the claims of the present application are still within the scope covered by the present application.

Claims

1. A decorative part, characterized in that: It comprises a stacked shading layer and a texture layer, wherein the texture layer comprises a light-transmitting matrix and a carbon fiber material, wherein the carbon fiber material is distributed in the light-transmitting matrix, and the decorative component further comprises a supporting frame connected to the side of the shading layer facing away from the texture layer.

2. The decorative element according to claim 1, characterized in that: The carbon fiber material is chopped carbon fiber.

3. The decorative element according to claim 2, characterized in that: The texture layer further comprises a plurality of fiber sheets, and a plurality of the chopped fibers constitute the fiber sheets.

4. The decorative element according to claim 3, characterized in that: The thickness of the fiber sheet is 0.08 mm to 0.15 mm.

5. The decorative element according to claim 1, characterized in that: The material of the light-transmitting substrate includes one or more of polymethyl methacrylate, polystyrene and polycarbonate.

6. The decorative element according to claim 1, characterized in that: The decorative element further comprises a light-transmitting layer, and the light-transmitting layer is arranged on a side of the texture layer facing away from the light-shielding layer.

7. The decorative element according to claim 6, characterized in that: The thickness of the light-transmitting layer is 0.15 mm to 0.8 mm; the thickness of the texture layer is 0.1 mm to 0.5 mm; and the thickness of the light-shielding layer is 0.1 mm to 0.5 mm.

8. The decorative element according to claim 6, characterized in that: The light-transmitting layer includes a stacked high-transmittance paint layer and a transparent resin layer, the transparent resin layer is connected to the texture layer, the high-transmittance paint layer is located on the side of the transparent resin layer facing away from the texture layer, and the material transmittance of the transparent resin layer is greater than or equal to 88%.

9. The decorative element according to claim 8, characterized in that: The thickness of the high-transmittance paint layer is 0.05 mm to 0.3 mm; and / or the thickness of the transparent resin layer is 0.1 mm to 0.5 mm.

10. The decorative element according to claim 8, characterized in that: The material of the transparent resin layer includes one or more of polymethyl methacrylate, polystyrene, and polycarbonate; and / or the material of the high-transmittance paint layer is oily polyurethane.

11. The decorative element according to claim 1, characterized in that: The light-shielding layer comprises a light-shielding matrix, the material of which is a polymer modified by toner; and / or, a woven fiber cloth is arranged in the light-shielding matrix.

12. The decorative element according to claim 1, characterized in that: The modulus of the supporting skeleton is greater than or equal to 4800 MPa.

13. The decorative element according to claim 1, characterized in that: The decorative piece is a plate-shaped structure and has a first matching portion, which is a protruding plate protruding from a first edge of the decorative piece.

14. The decorative element according to claim 13, characterized in that: The edge of the protruding plate is provided with an outwardly protruding edge frame, and a plurality of positioning holes are opened on the edge frame. The diameter of the positioning holes is 5mm to 8mm.

15. The decorative element according to claim 13, characterized in that: The decorative element has a second matching portion, which is a first groove in which a second edge of the decorative element is recessed, and the second edge and the first edge are located at two opposite sides of the decorative element.

16. The decorative element according to claim 15, characterized in that: The depression depth of the first groove is 30 mm to 50 mm, and the width of the first groove is 80 nm to 120 nm.

17. The decorative element according to claim 15, characterized in that: The decorative element has a third matching portion, which is a second groove in which a third edge of the decorative element is recessed, and the third edge is respectively connected to the first edge and the second edge.

18. The decorative element according to claim 17, characterized in that: The second groove is in an arc shape, and the concave radius of the second groove is 40nm-60nm.

19. The decorative element according to claim 17, characterized in that: The decorative piece of the plate-like structure is curved, and comprises a fourth edge opposite to the third edge. In the direction of the fourth edge toward the third edge, the decorative piece has a bending elevation angle of 20° to 40°.

20. The decorative element according to claim 1, characterized in that A plurality of positioning columns are also provided on a side of the support frame facing away from the light-shielding layer.

21. A method for manufacturing a decorative part, characterized in that: include: The shading material and the carbon fiber composite material are pressed together into a decorative film by a multi-layer molding process, wherein the shading material forms a shading layer and the carbon fiber composite material forms a texture layer; The decorative film is cut and shaped according to a preset size and shape to obtain the decorative piece. The texture layer includes a light-transmitting matrix and a carbon fiber material. The carbon fiber material is distributed in the light-transmitting matrix.

22. A vehicle, characterized in that: The decorative element comprises a decorative element as claimed in any one of claims 1 to 20, wherein the decorative element is installed in a cabin of the vehicle.

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