Exterior component preparation method, exterior component, automobile and skin injection mold

Abstract

The invention discloses an exterior trimming component preparation method, an exterior trimming component, an automobile and a skin injection mold, and belongs to the technical field of injection molding technology.The exterior trimming component preparation method comprises the steps that a thermosetting resin material is subjected to injection molding on the surface of a foamed resin inner core, so that the exterior trimming component with a flat injection molding resin skin is formed; and the curing temperature of the thermosetting resin material is lower than the softening temperature of the foamed resin inner core. The exterior member includes a foamed resin core and an injection molded resin skin. An automobile includes an exterior member. An injection molding cavity is formed in the skin injection mold, the shape of the injection molding cavity is matched with that of the foamed resin inner core, and a liquid injection opening is formed in the skin injection mold and used for injecting a thermosetting resin material. Through injection molding of the thermosetting resin material on the surface of the foamed resin inner core, the exterior trimming component with the flat injection molding resin skin can be prepared, so that the problems that the surface appearance of the foamed resin component is uneven and the foamed resin component is not easy to spray are solved, and the foamed resin component is expected to be broadened to the application of exterior trimming components.

Description

Technical Field

[0001] The invention relates to the technical field of injection molding technology, and in particular to an exterior component preparation method, an exterior component, an automobile and a skin injection mold. Background Art

[0002] EPP material (foamed polypropylene material) has good strength and rigidity and can be widely used in various structural parts such as car berths and storage boxes. However, since the surface appearance of components made of EPP material is uneven and difficult to spray, it is difficult to meet the requirements of exterior parts for flatness and spraying, so it is not used in automotive exterior parts. The main reason for its uneven appearance is that the EPP molding process is mostly a water vapor heating foaming method, which requires many micropores to be opened on the mold surface to pass water vapor, resulting in bumps and other unevenness on the EPP surface after molding. Although the mold surface is currently made into texture to weaken the appearance of pores, it will form texture on the EPP surface after molding, which still cannot meet the requirements of automotive exterior parts for flatness and spraying. Summary of the invention

[0003] The purpose of the present invention is to solve the above-mentioned technical problems and to provide a method for preparing an exterior component, an exterior component, an automobile and a skin injection mold. By injecting a thermosetting resin material on the surface of a foamed resin core, an exterior component with a smooth injection-molded resin skin can be prepared, thereby solving the problem that the surface of the foamed resin component is uneven and difficult to spray, so that the foamed resin component is expected to be expanded to the application of exterior parts. At the same time, the curing temperature of the thermosetting resin material used in the injection-molded resin skin is lower than the softening temperature of the foamed resin core, which can ensure that the material properties of the foamed resin core at this temperature are stable during hot injection molding, and no softening phenomenon will occur. It has broad application prospects and commercial value.

[0004] To achieve the above object, the present invention provides the following solution: The present invention discloses a method for preparing an exterior component, comprising the following steps: A thermosetting resin material having a curing temperature lower than a softening temperature of the foamed resin core is injection-molded on the surface of the foamed resin core to form an exterior member having a flat injection-molded resin skin.

[0005] Preferably, the method further comprises the following steps: removing burrs at corners of the injection-molded resin surface, and cleaning and repairing the injection-molded resin surface.

[0006] Preferably, the method further comprises the following steps: preparing a foamed resin inner core, and injecting the foamed resin material into an inner core injection mold to obtain the foamed resin inner core.

[0007] Preferably, during the preparation of the injection-molded resin skin, the skin injection mold is first preheated, the foamed resin core is placed in the skin injection mold and the mold is closed, liquid thermosetting resin material is injected from the injection port of the skin injection mold, and pressure is maintained after the liquid is filled. After the pressure is maintained for a preset time, demolding is performed to obtain the exterior component.

[0008] Preferably, the foamed resin inner core is an EPP inner core, and the injection molded resin skin is a PDCPD skin; during preheating, the skin injection mold is preheated to 50°C~80°C, and the injection port of the skin injection mold is used to inject a mixture of liquid A and liquid B, wherein the liquid A includes DCPD and an activator, and the liquid B includes DCPD and a catalyst. After the liquid is filled, the pressure is maintained for 3min~5min, and demolding is performed to obtain the exterior component.

[0009] Also disclosed is an exterior component, comprising a foamed resin inner core and an injection-molded resin skin injected on the surface of the foamed resin inner core, wherein the injection-molded resin skin is injection-molded using a thermosetting resin material having a curing temperature lower than a softening temperature of the foamed resin inner core.

[0010] Preferably, the foamed resin inner core is an EPP inner core, and the injection molded resin skin is a PDCPD skin.

[0011] Preferably, the exterior component is a vehicle deflector, and the thickness of the EPP inner core is 20 mm to 40 mm, and the density is 40 kg / m 3 ~90 kg / m 3 The PDCPD epidermis has a thickness of 1 mm to 2 mm.

[0012] Also disclosed is an automobile comprising the above exterior decoration component.

[0013] Also disclosed is a skin injection mold, which is applied to the above-mentioned exterior component preparation method, wherein an injection cavity is provided in the skin injection mold, the shape of the injection cavity matches the shape of the foamed resin inner core, an injection gap is provided between the cavity wall of the injection cavity and the surface area to be injected of the foamed resin inner core, and an injection port is provided on the skin injection mold, wherein the injection port is connected to the injection gap, and the injection port is used to inject a thermosetting resin material whose curing temperature is lower than the softening temperature of the foamed resin inner core, and the thermosetting resin material can form a smooth injection resin skin on the surface of the foamed resin inner core through the injection gap.

[0014] Preferably, the skin injection mold includes an upper mold and a lower mold that can be molded together, and the injection port includes an injection port A and an injection port B. The upper mold and the lower mold are respectively provided with the injection port A and the injection port B, and the injection port A and the injection port B are both used to inject thermosetting resin materials.

[0015] Compared with the prior art, the present invention has achieved the following technical effects: The present invention can prepare an exterior component with a smooth injection-molded resin skin by injection-molding a thermosetting resin material on the surface of a foamed resin core, thereby solving the problem that the surface of the foamed resin component is uneven and difficult to spray, so that the foamed resin component is expected to be expanded to the application of exterior parts. At the same time, the curing temperature of the thermosetting resin material used in the injection-molded resin skin is lower than the softening temperature of the foamed resin core, which can ensure that the material performance of the foamed resin core at this temperature is stable during hot injection molding without softening. In addition, compared with spray-type solutions such as spraying polyurea, the injection molding method has a shorter production cycle and has broad application prospects and commercial value. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the analysis of these drawings without paying creative work.

[0017] Figure 1 Schematic diagram of the mold closing process of the skin injection mold in an embodiment of the present invention; Figure 2 is a schematic structural diagram of an embodiment of the present invention in which the exterior decoration component is a vehicle deflector; Figure 3 It is a schematic diagram of the partially cutaway structure of a vehicle air deflector in an embodiment of the present invention.

[0018] Explanation of the reference numerals: 1. vehicle air deflector; 2. foamed resin inner core; 3. injection-molded resin skin; 4. upper mold; 5. lower mold; 6. injection port A; 7. injection port B. DETAILED DESCRIPTION

[0019] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments analyzed and obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0020] The purpose of the present invention is to provide a method for preparing an exterior component, an exterior component, an automobile and a skin injection mold to solve the problems existing in the prior art, and solve the problems that the surface appearance of the foamed resin component is uneven and difficult to spray, so that the foamed resin component is expected to be expanded to the application of exterior parts, and has broad application prospects and commercial value.

[0021] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the present invention is further described in detail below with reference to the accompanying drawings and specific embodiments.

[0022] Example 1 This embodiment provides a method for preparing an exterior component. Figures 1 to 3 As shown, the following steps are included: A thermosetting resin material is injection molded on the surface of the foamed resin core 2 to form an exterior component with a smooth injection-molded resin skin 3, wherein the curing temperature of the thermosetting resin material is lower than the softening temperature of the foamed resin core 2. Due to its molding process, the foamed resin core 2 has an uneven surface appearance and is not easy to spray, making it unsuitable for exterior decoration. By injecting the injection-molded resin skin 3 on the surface of the foamed resin core 2 and curing it together with the foamed resin core 2, a relatively smooth surface can be provided, thereby solving the problem that the uneven surface of the foamed resin component causes poor appearance and is not easy to spray, making it unsuitable for use as an exterior component. The curing temperature of the thermosetting resin material used in the injection-molded resin skin 3 is lower than the softening temperature of the foamed resin core 2, which can ensure that the material properties of the foamed resin core 2 are stable at this temperature during hot injection molding, and no softening will occur. In addition, the injection resin skin 3 is injection molded on the surface of the foamed resin core 2 to solve the problem of uneven surface appearance and difficulty in spraying. Compared with spraying polyurea on the surface of the foamed resin core 2, the preparation cycle of this method can be greatly shortened.

[0023] The surface of the foamed resin core 2 mentioned above includes but is not limited to the outer surface of the foamed resin core 2 (the side displayed outside, i.e., the outer facing) or the inner and outer surfaces of the foamed resin core 2 (the inner surface is the side not displayed outside). As a preferred option, the inner and outer surfaces of the foamed resin core 2 can be injection molded with an injection molded resin skin 3, so that the injection molded resin skin 3 can completely wrap the foamed resin core 2 inside to form a sandwich structure. This method can be widely applied to different types of foamed resin cores 2, such as EPP material cores, EPS material cores, and polyurethane material cores. The exterior components mentioned above are various components with decorative functions. Of course, the components can also include other practical functions at the same time, not limited to decorative functions only, such as automotive exterior parts, life exterior parts or industrial exterior parts, etc., automotive exterior parts such as automotive air deflectors, front masks, side skirts or door lower decorative panels. Note: EPS material is polystyrene material.

[0024] In one embodiment, if Figures 1 to 3 As shown, the following steps are also included: removing the corner burrs of the injection resin skin 3, cleaning and repairing the injection resin skin 3. When repairing, the focus is on repairing the missing material area and cleaning and repairing the installation point area.

[0025] In one embodiment, if Figures 1 to 3 As shown, the method further includes the following steps: preparing a foamed resin inner core 2, and injecting the foamed resin material into an inner core injection mold to obtain the foamed resin inner core 2.

[0026] In one embodiment, if Figures 1 to 3 As shown, during the preparation process of the injection-molded resin skin 3, the skin injection mold is first preheated, the foamed resin core 2 is placed in the skin injection mold and the mold is closed, and liquid thermosetting resin material is injected from the injection port of the skin injection mold. After the liquid is filled, the pressure is maintained. After the pressure is maintained for a preset time, demolding is performed to obtain the exterior component.

[0027] In one embodiment, if Figures 1 to 3 As shown, the foamed resin core 2 is an EPP core, and the injection resin skin 3 is a PDCPD skin. When preparing the EPP core, the EPP material is injected into the core injection mold to obtain the EPP core. When preparing the PDCPD skin, first preheat the skin injection mold to 50°C~80°C, then place the EPP core in the skin injection mold and close the mold. The injection port of the skin injection mold is used to inject a mixture of liquid A and liquid B. Liquid A includes DCPD and an activator, and liquid B includes DCPD and a catalyst. After the liquid is filled, the pressure is maintained for 3min~5min, and then demolding is performed to obtain the exterior component. Note: EPP is a foamed polypropylene material, PDCPD material is a polydicyclopentadiene material, and DCPD is dicyclopentadiene.

[0028] The foamed resin core 2 adopts an EPP core. The EPP material has good strength and rigidity, and can meet the requirements of products with high rigidity. Compared with fiberglass exterior parts, in addition to better rigidity, it is also lighter, meeting the lightweight requirements. The injection-molded resin skin 3 is a PDCPD skin. The PDCPD material is a low-temperature curing resin with a curing temperature below 100°C. The maximum temperature that the EPP material can withstand is usually 130°C. The material performance of the EPP material is stable at this temperature and will not soften. The two materials have good matching. And if the inner and outer surfaces (overall surface) of the EPP core are injection-molded with PDCPD skins, the PDCPD will shrink to a certain extent after molding and curing. The PDCPD skin tightly wraps the EPP core, which can combine the PDCPD skin and the EPP core together, solving the appearance problem and the problem of difficulty in spraying.

[0029] In one embodiment, if Figures 1 to 3As shown, the injection molding resin skin 3 is a PDCPD skin. The PDCPD skin is used to wrap the EPP inner core. After the PDCPD is formed and cured, it will shrink to a certain extent and combine with the EPP inner core, solving the appearance problem and the problem of difficult spraying. At the same time, the PDCPD material is a low-temperature curing resin with a curing temperature below 100°C. The EPP material performance is stable at this temperature and will not soften. The two materials have good matching. Of course, in addition to the PDCPD skin, the injection molding resin skin 3 can also use other thermosetting resin materials with a curing temperature below 130°C. However, in order to avoid the influence of the adjacent temperature, the curing temperature of the thermosetting resin material used in the injection molding resin skin 3 is usually lower than 125°C, such as epoxy resin material.

[0030] In one embodiment, if Figures 1 to 3 As shown, the mounting nuts are embedded in advance during the preparation of the foamed resin inner core 2, and the mounting nuts are temporarily blocked before the resin skin 3 is injection molded.

[0031] Example 2 This embodiment provides an exterior decoration component, which can be made by the exterior decoration component preparation method in Embodiment 1, or can be made by other preparation methods, such as Figures 1 to 3 As shown, it includes a foamed resin core 2 and an injection-molded resin skin 3. The injection-molded resin skin 3 is injection-molded on the surface of the foamed resin core 2. The injection-molded resin skin 3 is made of a thermosetting resin material whose curing temperature is lower than the softening temperature of the foamed resin core 2.

[0032] The surface of the foamed resin core 2 mentioned here includes the outer surface of the foamed resin core 2 (the side displayed outside, i.e., the outer surface) or the inner and outer surfaces of the foamed resin core 2 (the inner surface is the side not displayed outside). If the inner and outer surfaces of the foamed resin core 2 are both injection molded with the injection molded resin skin 3, the exterior component formed at this time is a sandwich structure. By injecting the injection molded resin skin 3 on the surface of the foamed resin core 2, after being molded and cured together with the foamed resin core 2, a relatively flat surface can be provided, thereby solving the problem of the appearance and difficulty in spraying caused by the uneven surface of the foamed resin component, which is not suitable for use as an exterior component.

[0033] In one embodiment, if Figures 1 to 3As shown, the foamed resin core 2 is an EPP core, and the injection-molded resin skin 3 is a PDCPD skin. The exterior components prepared with the EPP core can meet the requirements of products with high rigidity and lightweight. The PDCPD skin is used. On the one hand, the PDCPD material is a low-temperature curing resin with a curing temperature below 100°C. The EPP material performance is stable at this temperature and will not soften. The two materials have good matching. On the other hand, when making exterior components, if the PDCPD skin is injection-molded on the entire surface of the EPP core, the PDCPD skin will wrap the EPP core after PDCPD molding, and a certain degree of shrinkage will occur during the PDCPD molding and curing process, making the PDCPD skin and the EPP core more tightly combined.

[0034] In one embodiment, if Figures 1 to 3 As shown, the exterior component is a vehicle deflector 1, the thickness of the EPP inner core is 20mm~40mm, and the density is 40kg / m 3 ~90 kg / m 3 , the PDCPD skin thickness is 1mm-2mm. Of course, this is just one implementation, and the external component can also be other vehicle exterior parts or non-vehicle exterior parts, such as front cover, side skirts or door lower decorative panels.

[0035] Example 3 This embodiment provides an automobile, comprising the exterior decoration component in Embodiment 2. The exterior decoration component may be a vehicle air deflector, a front cover, a side skirt, a door lower decorative panel or other vehicle exterior decoration components.

[0036] Example 4 This embodiment provides a skin injection mold, which can be applied to the exterior component preparation method in Example 1, and of course can also be used in other component preparation methods requiring skin injection molding, such as Figures 1 to 3 As shown, an injection cavity is provided in the skin injection mold, and the shape of the injection cavity matches the shape of the foamed resin core 2. An injection gap is provided between the cavity wall of the injection cavity and the surface area to be injected of the foamed resin core 2. An injection port is provided on the skin injection mold, and the injection port is connected to the injection gap. The injection port is used to inject liquid thermosetting resin material whose curing temperature is lower than the softening temperature of the foamed resin core 2. The cavity wall of the injection cavity is smooth. After the thermosetting resin material is injected through the injection port, a smooth injection resin skin 3 can be formed on the surface of the foamed resin core 2 under the action of the injection gap.

[0037] In one embodiment, if Figures 1 to 3As shown, the skin injection mold includes an upper mold 4 and a lower mold 5, and the upper mold 4 and the lower mold 5 can be molded together to form the skin injection mold. The injection port includes an injection port A 6 and an injection port B 7. The upper mold 4 and the lower mold 5 are respectively provided with an injection port A 6 and an injection port B 7. For example, the upper mold 4 is provided with an injection port A 6, and the lower mold 5 is provided with an injection port B 7, or the upper mold 4 is provided with an injection port B 7, and the lower mold 5 is provided with an injection port A 6. The injection port A 6 and the injection port B 7 are both used to inject thermosetting resin materials. For example, when the injection resin skin 3 is a PDCPD skin, the injection port A 6 and the injection port B 7 are both injected with a mixture of liquid A and liquid B. Liquid A includes DCPD and an activator; liquid B includes DCPD and a catalyst.

[0038] In one embodiment, if Figures 1 to 3 As shown, the exterior component is a vehicle air deflector 1, and the shape of the foamed resin inner core 2 is the shape of the vehicle air deflector 1, so the injection mold cavity is a shape that matches the shape of the vehicle air deflector 1. Specifically, the foamed resin inner core 2 includes an arc-shaped plate-shaped portion and vertical plate support portions arranged on both sides of the arc-shaped plate-shaped portion, forming an end portion (such as Figure 1 The upper mold 4 includes an upper mold groove, the shape of which matches the shape of the outer surface of the foamed resin core 2, and the upper mold groove also forms an end (such as Figure 1 The upper mold 5 is shaped like a guide hood with an opening at the left end of the upper mold groove and the bottom. The end opening of the upper mold groove is provided with an upper mold end edge, and the bottom opening of the upper mold groove is provided with an upper mold bottom edge. The upper mold groove is larger than the size of the foamed resin inner core 2, that is, the groove surface of the upper mold groove and the outer surface of the foamed resin inner core 2 should have a liquid injection gap. The lower mold 5 includes a lower mold protrusion, and the lower mold protrusion is a lower mold protrusion whose shape matches the inner surface of the foamed resin inner core 2. The lower mold protrusion is larger than the size of the foamed resin inner core 2, that is, the convex surface of the lower mold protrusion and the inner surface of the foamed resin inner core 2 should have a liquid injection gap. The bottom and end of the lower mold protrusion are respectively provided with a lower mold end edge and a lower mold bottom edge. The lower mold bottom edge is used to support the upper mold bottom edge and two vertical plate support parts of the foamed resin inner core 2 to ensure that there is a liquid injection gap between the convex surface of the lower mold protrusion and the inner surface of the foamed resin inner core 2, and there is a liquid injection gap between the groove surface of the upper mold groove and the outer surface of the foamed resin inner core 2. The edge of the lower mold end is used to fit with the edge of the upper mold end to limit the upper mold 4.

[0039] The present invention uses specific examples to illustrate the principles and implementation methods of the present invention. The above examples are only used to help understand the method and core ideas of the present invention. At the same time, for those skilled in the art, according to the ideas of the present invention, there will be changes in the specific implementation methods and application scopes. In summary, the content of this specification should not be understood as limiting the present invention.

Claims

1. A method for preparing an exterior component, characterized in that: The following steps are involved: A thermosetting resin material having a curing temperature lower than a softening temperature of the foamed resin core is injection-molded on the surface of the foamed resin core to form an exterior member having a flat injection-molded resin skin.

2. The method for preparing an exterior component according to claim 1, characterized in that: The following steps are also included: The burrs at the edges and corners of the injection-molded resin surface are removed, and the injection-molded resin surface is cleaned and repaired.

3. The method for preparing an exterior component according to claim 1 or 2, characterized in that: The following steps are also included: A foamed resin inner core is prepared, and a foamed resin material is injected into an inner core injection mold to obtain the foamed resin inner core.

4. The method for preparing an exterior component according to claim 3, characterized in that: During the preparation of the injection-molded resin skin, the skin injection mold is first preheated, the foamed resin core is placed in the skin injection mold and the mold is closed, liquid thermosetting resin material is injected from the injection port of the skin injection mold, and pressure is maintained after the liquid is filled. After the pressure is maintained for a preset time, demolding is performed to obtain the exterior component.

5. The method for preparing an exterior component according to claim 4, characterized in that: The foamed resin inner core is an EPP inner core, and the injection resin skin is a PDCPD skin; during preheating, the skin injection mold is preheated to 50°C~80°C, and the injection port of the skin injection mold is used to inject a mixture of liquid A and liquid B, wherein the liquid A includes DCPD and an activator, and the liquid B includes DCPD and a catalyst. After the liquid is filled, the pressure is maintained for 3min~5min, and demolding is performed to obtain the exterior component.

6. An exterior component, characterized in that: The invention comprises a foamed resin inner core and an injection-molded resin skin which is injection-molded on the surface of the foamed resin inner core. The injection-molded resin skin is formed by injection molding a thermosetting resin material whose curing temperature is lower than the softening temperature of the foamed resin inner core.

7. The exterior component according to claim 6, characterized in that: The foamed resin inner core is an EPP inner core, and the injection molded resin skin is a PDCPD skin.

8. A car, characterized in that: Comprising the exterior component as claimed in claim 6 or 7.

9. A skin injection mold, characterized in that: Applicable to the method for preparing exterior components as described in any one of claims 1 to 5, an injection cavity is provided in the skin injection mold, the shape of the injection cavity matches the shape of the foamed resin inner core, an injection gap is provided between the cavity wall of the injection cavity and the surface area to be injected of the foamed resin inner core, an injection port is provided on the skin injection mold, the injection port is connected to the injection gap, the injection port is used to inject a thermosetting resin material whose curing temperature is lower than the softening temperature of the foamed resin inner core, and the thermosetting resin material can form a smooth injection resin skin on the surface of the foamed resin inner core through the injection gap.

10. The skin injection mold according to claim 9, characterized in that: The skin injection mold includes an upper mold and a lower mold that can be molded together, and the injection port includes an injection port A and an injection port B. The upper mold and the lower mold are respectively provided with the injection port A and the injection port B, and the injection port A and the injection port B are both used to inject thermosetting resin materials.

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