A method for ins thermoforming

Abstract

The application discloses an INS conformal blister forming method, comprising the following steps: S1: in the process of blister forming or high-pressure forming, the INS film is clamped and fixed by a specific conformal clamp according to the curved surface shape closest to the product shape; S2: heating is performed on a baking plate in the range of 200-250 DEG C, so that the film is uniformly heated to the range of 120-180 DEG C, wherein the shape of the baking plate is also the same as the curved surface of the conformal clamp, and the baking plate maintains uniform equidistance with the clamp; S3: the conformally heated INS film is placed on a blister mold, the pressing frame surface of the blister mold is also a conformal curved surface, and the conformal film and the conformal pressing frame surface are uniformly attached; S4: the upper and lower molds of the blister mold are closed, the film is sealed, negative pressure is drawn, and the film is stretched into a formed INS film required by the product; S5: the formed film is subjected to punching treatment, and an INS insert piece with the same appearance as the product is obtained; and S6: the insert piece is installed in a cavity of a fixed mold plate of an injection mold, the fixed mold plate and a movable mold plate are closed, a molten material is injected into the cavity, and finally, an INS product, i.e., an automotive interior INS product, is obtained.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of car body interior and exterior manufacturing, in particular to an INS conformal vacuum forming method. BACKGROUND

[0002] With the development of the automobile industry, the design and manufacture of automotive interior products are attracting more and more attention. Automotive interior is an important part of the car, which not only affects the appearance of the car, but also directly affects the comfort and safety of the driver and passengers. Among them, the interior design and manufacture of automobile instrument panel, center console cover, door panel, ceiling, trunk door and other parts have an important influence on the appearance and performance of the whole vehicle. With the increasing demand of consumers for the beauty and individuality of automotive interior, the design and manufacture of automotive interior are constantly innovating and improving.

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

[0004] Prior art solution: INS, also known as embedded sheet injection molding process, this process uses hot vacuum forming or high pressure forming method to heat stretch the printed film, then cut the embedded sheet according to the product shape, then accurately place the embedded sheet in the injection molding cavity, and injection molding to obtain a product with surface decoration. Realize the formation of patterns with different colors and textures on plastic parts, so as to improve the beauty and comfort of automotive interior.

[0005] Problems of prior art: INS automotive interior in the production process, for the complex shape, large stretch, regular curved surface INS parts, especially those often visual area, often touch or easy to be contaminated area of high requirement INS parts, mainly exist following several problems:

[0006] First, the texture pattern is distorted. Second, the texture pattern has poor wear resistance and scratch resistance, and is easy to be worn out. Third, even the texture pattern has cracks, peeling, discoloration and other appearance defects. SUMMARY

[0007] In order to make up for the above shortcomings, the present application provides an INS conformal vacuum forming method, which can significantly reduce the stretchability of INS film and improve the uniformity of stretching when processing parts with complex shape, large stretch and regular curved surface, thereby improving the appearance and performance of the product.

[0008] In order to achieve the above purpose, the present application adopts the following technical scheme: an INS conformal vacuum forming method, comprising the following steps:

[0009] S1: In the process of plastic forming or high pressure forming, the INS film is pre-clamped and fixed by a special contour clamp, and the flat printed film is fixed according to the curved surface shape closest to the product shape;

[0010] S2: Heating is performed on a baking plate in the range of 200-250 DEG C, so that the film is uniformly heated to the range of 120-180 DEG C, wherein the shape of the baking plate is also a curved surface of the contour clamp, and the clamp maintains uniform equidistance;

[0011] S3: The INS film heated in the contour is placed on the plastic mold, and the plastic mold pressure frame surface is also a contour curve, and the contour film is uniformly attached to the contour pressure frame surface;

[0012] S4: The upper and lower molds of the plastic mold are closed, the film is sealed, and the film is stretched into the shaped INS film required by the product by negative pressure;

[0013] S5: The formed film is cut to obtain an INS insert with the same appearance as the product; S6: The insert is installed in the cavity of the injection mold fixed mold plate, the fixed mold plate and the movable mold plate are closed, and the molten material is injected into the cavity, and the final INS product, i.e. the automobile interior INS product, is obtained after cooling.

[0014] Compared with the prior art, the beneficial effects are as follows: 1. The design pattern texture is restored to the maximum visual effect on the real object, the product texture positioning accuracy is improved, and the higher demand of the product and customer for the pattern texture is greatly met. 2. Improve product quality: through the modification of the plastic equipment and mold, the parts with complex shape, large stretching and regular curved surface can be better processed, especially those parts that are often touched or easily contaminated, thereby reducing the stretching and uneven stretching of the INS film, improving the appearance and performance of the product, and also improving the problems of not wear-resistant, easy to discolor, ink layer delamination and other problems caused by the thinning of the base layer, ink layer and touch layer. 3. The INS automobile interior of the present application can be applied to more complex modeling curved surface requirements that cannot be met by conventional INS process, so that the application of INS is not limited by the stretching limit, and can be more widely applied. BRIEF DESCRIPTION OF DRAWINGS

[0015] Figure 1 The flowchart of the method for making the contour INS product in the embodiment of the present application is shown;

[0016] Figure 2 The initial state of the INS film in the embodiment of the present application is shown;

[0017] Figure 3 The initial state of the INS film in the embodiment of the present application is shown;

[0018] Figure 4 Fig. 1 is a schematic diagram of the position relationship between the preformed INS film and the heating baking plate in the embodiment of the present application;

[0019] Figure 5 Fig. 1 is a schematic diagram of the position relationship between the preformed INS film and the heating baking plate in the embodiment of the present application;

[0020] Figure 6 Fig. 1 is a schematic diagram of the position relationship between the preformed INS film and the heating baking plate in the embodiment of the present application;

[0021] Figure 7 Fig. 1 is a schematic diagram of the position relationship between the preformed INS film and the heating baking plate in the embodiment of the present application;

[0022] Figure 8 Fig. 1 is a schematic diagram of the position relationship between the preformed INS film and the heating baking plate in the embodiment of the present application;

[0023] Figure 9 Fig. 1 is a schematic diagram of the position relationship between the preformed INS film and the heating baking plate in the embodiment of the present application;

[0024] BRIEF DESCRIPTION OF THE DRAWINGS

[0025] 1, INS film, 2, upper clamp plate, 3, lower clamp plate, 4, preformed INS film, 5, upper baking plate, 6, lower baking plate, 7, upper mold plate of the suction mold, 8, lower mold plate of the suction mold, 9, lower mold plate fixing plate of the suction mold, 10, area to be formed by suction molding, 11, formed INS film, 12, movable mold plate, 13, punched formed INS film, 14, fixed mold plate, 15, shaped INS product DETAILED DESCRIPTION

[0026] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative work fall within the scope of protection of the present application.

[0027] As Figure 1 An INS shaped suction molding method, comprising the following steps:

[0028] S1: In the process of suction molding or high-pressure forming, a 0.5 / 0.8 mm thick printed INS film 1 is pre-clamped and fixed by a specific shaped clamp plate, and the planar printed film is fixed according to the curved shape closest to the product shape, and the shaped clamp plate is divided into an upper clamp plate 2 and a lower clamp plate 3;

[0029] S2: heating on the baking plate in the range of 200-250 DEG C, so that the film is uniformly heated to 120-180 DEG C, wherein the shape of the baking plate is also the same as the curved surface of the shaped clamp plate, and the baking plate is uniformly equidistant from the clamp plate, and the baking plate is divided into upper baking plate 5 and lower baking plate 6;

[0030] S3: the preformed INS film 4 is placed on the suction mold, and the suction mold pressure frame surface is also a shaped curved surface, and the shaped film is uniformly attached to the shaped pressure frame surface. Figure 4 , various curved preformed INS films 4.1, 4.2, 4.3, 4.4.

[0031] S4: the upper mold plate 7 and the lower mold plate 8 of the suction mold are combined, the film is closed, negative pressure is extracted, the film is stretched into the shaped INS film 11 required by the product, the lower mold plate 8 is fixed by the suction mold lower mold fixed plate 9, and the preformed INS film and the suction mold lower mold plate 8 are in the suction molding area 10.

[0032] S5: the shaped film is cut to obtain an INS insert that is the same as the product appearance, that is, the cut-shaped INS film 13.

[0033] S6: the insert is installed in the cavity of the injection mold fixed mold plate, the fixed mold plate 14 and the movable mold plate 12 are combined, the molten material is injected into the cavity, and the final shaped INS product 15 is obtained after cooling, that is: the automotive interior INS product.

[0034] The existing traditional suction molding technology method, regardless of the complexity of the product shape, the number of curved surfaces, and the large difference between high and low, all are shaped into the required product shape, and for products with large stretching and large difference between high and low, the base material layer, ink layer and touch layer of the INS film are easily thinned to the limit, even beyond the stretching limit of the printed film, resulting in cracking, and finally leading to distortion of the texture pattern of the INS product, poor wear resistance and scratch resistance of the texture pattern, and even cracks, peeling and discoloration of the texture pattern.

[0035] Compared with the existing traditional technology, the embodiment of the present application considers the curved surface characteristics of each product, customizes multiple standardized shaped design schemes, and makes each film conform to the product curved surface trend to the greatest extent, so that the film is pre-bent and formed, and the stretching and distortion of the film during suction molding / high pressure forming are minimized.

[0036] Finally, it should be noted that the above only describes the preferred embodiments of the present application and is not intended to limit the present application. Although the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art will appreciate that the technical solutions described in the foregoing embodiments can be modified or some technical features thereof can be replaced by equivalent features, and any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. An INS conformal vacuum forming method, characterized in that: The method comprises the following steps: S1: in the process of plastic forming or high pressure forming, the INS film is pre-clamped and fixed by a special contour clamp according to the curved surface shape closest to the product shape; S2: heating on a baking plate in the range of 200-250 DEG C, so that the film is uniformly heated to the range of 120-180 DEG C, wherein the shape of the baking plate is also the same as the curved surface of the contour clamp, and the baking plate maintains uniform equidistance with the clamp; S3: placing the contour heated INS film on the plastic mold, and the plastic mold pressing frame surface is also a contour curved surface, and the contour film is uniformly attached to the contour pressing frame surface; S4: the upper and lower molds of the plastic mold are closed, the film is sealed, negative pressure is drawn, and the film is stretched into the shaped INS film required by the product; S5: the shaped film is cut to obtain the INS insert piece with the same appearance as the product; S6: the insert piece is installed in the cavity of the injection mold fixed mold plate, the fixed mold plate and the movable mold plate are closed, the molten material is injected into the cavity, and the final INS product, i.e. the automotive interior INS product, is obtained after cooling.

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