INS shape follow-up plastic uptake forming method

Abstract

The invention discloses an INS shape follow-up plastic uptake forming method which comprises the following steps that S1, in the plastic uptake forming or high-pressure forming process, a plane printing film is clamped and fixed in advance according to the curved surface shape closest to the product shape through a specific shape follow-up clamping plate; s2, heating is conducted on a baking plate with the temperature ranging from 200 DEG C to 250 DEG C, the membrane is evenly heated to the temperature ranging from 120 DEG C to 180 DEG C, the shape of the baking plate is the same as that of the curved surface of the shape follow-up clamping plate, and the baking plate and the clamping plate are evenly and equidistantly arranged; s3, the INS membrane heated in a shape follow-up mode is placed on a plastic suction mold, the frame pressing face of the plastic suction mold is also a shape follow-up curved face, and the shape follow-up membrane is evenly attached to the shape follow-up frame pressing face; s4, closing the upper mold and the lower mold of the plastic suction mold, sealing the membrane, performing negative pressure pumping, and stretching the membrane into a molded INS membrane required by a product; s5, punching the formed diaphragm to obtain an INS insert which is the same as the product in appearance and shape; and S6, the insert is installed in a cavity of a fixed mold plate of an injection mold, after the fixed mold plate and a movable mold plate are assembled, molten materials are injected into the cavity, and after cooling, the final INS product, namely the automotive trim INS product, is obtained.

Description

Technical Field

[0001] The present invention relates to the technical field of vehicle body interior and exterior decoration manufacturing, and in particular to an INS conformable plastic suction molding method. Background Art

[0002] With the development of the automobile industry, the design and manufacture of automobile interior products have received more and more attention. Automobile interior is an important part of the car. It not only affects the beauty of the car, but also directly affects the comfort and safety of the driver and passengers. Among them, the interior design and manufacture of the car dashboard, center console cover, door panel, ceiling, trunk door and other parts have an important impact on the appearance and performance of the whole vehicle. As consumers' demand for the beauty and personalization of automobile interiors increases, the design and manufacture of automobile interiors are also constantly innovating and improving.

[0003] In traditional automobile interior design, plastic, metal and other materials are usually used for manufacturing. Although these materials have certain strength and wear resistance, their decorative effects are limited, the decorative effects are not rich enough, and the decorativeness is insufficient.

[0004] Solutions of existing technologies: INS is also called insert injection molding process. This process uses the method of thermal plastic forming or high pressure forming to heat and stretch the printed film, and then cut out the insert according to the product shape, and then accurately place the insert in the injection mold cavity, and injection mold it to obtain a product with surface decoration. It realizes the formation of patterns with different colors and textures on plastic parts, thereby improving the aesthetics and comfort of automobile interiors.

[0005] Existing technical problems: During the production process of INS automotive interiors, there are mainly the following problems for INS parts with complex shapes, large stretching, and regular curved surfaces, especially those with high requirements in areas that are frequently viewed, frequently touched, or easily contaminated:

[0006] First, the texture pattern is deformed and distorted. Second, the texture pattern has poor wear resistance and scratch resistance, and is easily worn out. Third, the texture pattern may even have appearance defects such as cracks, peeling, and discoloration. Summary of the invention

[0007] In order to make up for the above shortcomings, the present invention provides an INS conformable vacuum forming method, which can significantly reduce the stretchability of the INS diaphragm and improve the uniformity of stretching when processing parts with complex shapes, large stretching, and regular curved surfaces, thereby improving the appearance and performance of the product and other technical problems.

[0008] In order to achieve the above object, the present invention adopts the following technical scheme: an INS form-fitting blister forming method, comprising the following steps:

[0009] S1: During the vacuum forming or high pressure forming process, the INS membrane is pre-clamped and fixed with a specific conformable clamping plate to the flat printed membrane in a curved shape that is closest to the product shape;

[0010] S2: heating on a baking plate in the range of 200-250°C, so that the diaphragm is evenly heated to the range of 120-180°C, wherein the shape of the baking plate is the same as the curved surface of the conformal clamping plate, and the baking plate is evenly equidistant from the clamping plate;

[0011] S3: placing the conformally heated INS diaphragm on a blister mold, the blister mold press frame surface is also a conformally curved surface, and the conformally heated diaphragm is evenly fitted with the conformally pressed frame surface;

[0012] S4: The upper and lower molds of the blister mold are closed, the diaphragm is sealed, and negative pressure is drawn to stretch the diaphragm into the shaped INS diaphragm required by the product;

[0013] S5: punching the formed membrane to obtain an INS insert with the same appearance as the product; S6: installing the insert in the cavity of the fixed mold plate of the injection mold, closing the fixed mold plate with the movable mold plate, injecting the molten material into the cavity, and cooling to obtain the final INS product, i.e., the automotive interior INS product.

[0014] Compared with the existing technology, the beneficial effects are as follows: 1. The visual effect of the designed pattern texture is restored to the greatest extent in the real object, the positioning accuracy of the product texture is improved, and the higher demands of the product and customers for the pattern texture are greatly met. 2. Improve product quality: The present invention can better handle parts with complex shapes, large stretching, and regular curved surfaces, especially those parts that are often touched or easily contaminated, by modifying the blister equipment and molds, thereby reducing the stretching and uneven stretching of the INS diaphragm, improving the appearance and performance of the product, and also improving the problems of wear resistance, easy discoloration, and delamination and shedding of the ink layer caused by the substrate layer, ink layer, and touch layer being pulled too thin. 3. The INS automotive interior of the present invention can be applied to more complex modeling curved surface requirements that cannot be met by conventional INS processes, so that the application of INS is not limited by the stretching limit and can be more widely used. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 Schematic diagram of the process of making a form-fitting INS product according to an embodiment of the present invention;

[0016] Figure 2 Schematic diagram of the initial state of the INS diaphragm in an embodiment of the present invention;

[0017] Figure 3 It is a schematic diagram of an INS diaphragm in a closed state of the upper and lower clamping plates in an embodiment of the present invention;

[0018] Figure 4 This is an example of the style of the INS diaphragm after preforming the conformable splint in the embodiment of the present invention;

[0019] Figure 5 It is a schematic diagram of the positional relationship between the INS diaphragm and the heating baking plate during preforming of the conformable clamping plate in an embodiment of the present invention;

[0020] Figure 6 It is a schematic diagram of an INS diaphragm in an embodiment of the present invention after being preformed on a conformable splint, when the upper and lower molds of the blister mold are closed;

[0021] Figure 7 It is a state and overall schematic diagram of an INS diaphragm after being vacuum-formed in a vacuum-forming cavity in an embodiment of the present invention;

[0022] Figure 8 It is a schematic diagram of a fixed platen, an INS diaphragm and a movable platen of an injection mold in an embodiment of the present invention when they are in a separated state;

[0023] Fig. 9 It is the finished product of the form-fitting INS in the embodiment of the invention.

[0024] Description of reference numerals:

[0025] 1. INS diaphragm, 2. Upper clamping plate, 3. Lower clamping plate, 4. Preformed INS diaphragm, 5. Upper baking plate, 6. Lower baking plate, 7. Upper template of blister mold, 8. Lower template of blister mold, 9. Fixed plate of lower template of blister mold, 10. Area to be blister molded, 11. Molded INS diaphragm, 12. Moving template, 13. Punched and formed INS diaphragm, 14. Fixed template, 15. Finished INS product DETAILED DESCRIPTION

[0026] 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 obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0027] like Figure 1 , an INS conformable blister forming method, comprising the following steps:

[0028] S1: During the vacuum forming or high pressure forming process, a 0.5 / 0.8mm thick printed INS film 1 is pre-clamped and fixed by a specific conformable clamping plate according to a curved surface shape closest to the product shape. The conformable clamping plate is divided into an upper clamping plate 2 and a lower clamping plate 3;

[0029] S2: heating on a baking plate at a temperature of about 200 to 250° C., so that the diaphragm is evenly heated to a temperature of about 120 to 180° C., wherein the shape of the baking plate is the same as the curved surface of the conformal clamping plate, and the baking plate is evenly spaced from the clamping plate, and the baking plate is divided into an upper baking plate 5 and a lower baking plate 6;

[0030] S3: Place the preformed INS membrane 4 that has been heated in a conforming manner on a blister mold, whose blister mold frame surface is also a conforming curved surface, and the conforming membrane and the conforming frame surface are evenly attached. Figure 4 , preformed INS diaphragms of various curves 4.1, 4.2, 4.3, 4.4.

[0031] S4: The upper mold plate 7 and the lower mold plate 8 of the blister mold are molded together, the diaphragm is sealed, and negative pressure is drawn to stretch the diaphragm into a formed INS diaphragm 11 required for the product. The lower mold plate 8 of the blister mold is fixed by the lower mold fixing plate 9 of the blister mold, and the area to be blister molded 10 is between the preformed INS diaphragm and the lower mold plate 8 of the blister mold.

[0032] S5: The formed membrane is punched to obtain an INS inlay having the same appearance as the product, that is, the punched INS membrane 13.

[0033] S6: installing the insert in the cavity of the fixed platen of the injection mold, closing the fixed platen 14 with the movable platen 12, injecting the molten material into the cavity, and after cooling, obtaining the final conformable INS product 15, i.e., the automotive interior INS product.

[0034] The existing traditional vacuum forming technology methods, no matter how complex the product shape is, how many curves there are, or how large the height difference is, all form the flat membrane into the required product shape. For products with particularly large stretching and height difference, it is very easy to cause the substrate layer, ink layer, touch layer, etc. of the INS membrane to be extremely thinned, and even exceed the stretching limit of the printed membrane to cause cracking, which ultimately leads to distortion of the texture pattern of the INS product, poor wear resistance and scratch resistance of the texture pattern, and even cracks, peeling, discoloration and other defects in the texture pattern.

[0035] Compared with the existing traditional technology, the embodiment of the present invention takes into account the curved surface characteristics of each product and customizes a variety of standardized conformal design solutions in a targeted manner, so that each diaphragm can conform to the curved surface trend of its own product to the greatest extent, and the diaphragm is pre-bent in advance to minimize the stretching and distortion of the diaphragm during the vacuum forming / high-pressure forming process.

[0036] Finally, it should be noted that the above is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, it is still possible for those skilled in the art to modify the technical solutions described in the aforementioned embodiments or to make equivalent substitutions for some of the technical features therein. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. An INS form-fitting blister forming method, characterized in that: The following steps are involved: S1: During the vacuum forming or high pressure forming process, the INS membrane is pre-clamped and fixed with a specific conformable clamping plate to the flat printed membrane in a curved shape that is closest to the product shape; S2: heating on a baking plate in the range of 200-250°C, so that the membrane is evenly heated to the range of 120-180°C, wherein the shape of the baking plate is the same as the curved surface of the conformal clamping plate, and the baking plate is evenly equidistant from the clamping plate; S3: placing the INS diaphragm that has been heated conformally on the blister mold, the pressing frame surface of the blister mold is also a conformally curved surface, and the conformally diaphragm and the conformally pressing frame surface are evenly attached; S4: The upper and lower molds of the blister mold are closed, the diaphragm is sealed, and negative pressure is drawn to stretch the diaphragm into the shaped INS diaphragm required by the product; S5: Punch the formed membrane to obtain an INS insert with the same appearance as the product; S6: installing the insert in the cavity of the fixed mold plate of the injection mold, closing the fixed mold plate with the movable mold plate, injecting the molten material into the cavity, and obtaining the final INS product, i.e., the automotive interior INS product, after cooling.

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