Forming process of carbon fiber rearview mirror shell

Abstract

The invention discloses a forming process of a carbon fiber rearview mirror shell, which comprises the following steps: step S1, primary mold pressing: obtaining a preform after first mold pressing equipment is cooled; s2, secondary mold pressing, wherein a carbon fiber main body is obtained after second mold pressing equipment is cooled; s3, primary injection molding is conducted, specifically, a first plastic part is formed on the inner surface of the carbon fiber body through first injection molding equipment in an injection molding mode; and S4, secondary injection molding is conducted, specifically, a second plastic part is formed on the first connecting part through second injection molding equipment in an injection molding mode, and the carbon fiber rearview mirror shell is obtained. The carbon fiber main body is formed in a two-time mold pressing mode, the machining time is short, the machining efficiency is improved, preheating of two-time mold pressing is carried out on the corresponding lower mold, the situation that material forming is affected due to temperature reduction in the material carrying process is avoided, the product quality is better ensured, and the product quality is improved. A first plastic part and a second plastic part are respectively formed in a twice injection molding mode, so that the plastic parts are formed on the carbon fiber main body through injection molding.

Description

Technical Field

[0001] The present invention relates to the field of automobile rearview mirror housing technology, and in particular to a molding process for a carbon fiber rearview mirror housing. Background Art

[0002] Car rearview mirrors are located on the left and right sides of the car's head. They can reflect the situation on the side and below of the car, allowing the driver to indirectly see the situation in these positions, thereby expanding the driver's field of vision. In order to pursue lightweight design, car rearview mirrors usually include a carbon fiber body and plastic parts arranged on the carbon fiber body.

[0003] In the existing technology, the carbon fiber body is made by autoclave molding, which solves the thickness problem of the traditional carbon-clad shell and achieves precise matching of the original vehicle size. However, the autoclave molding process takes a long time to form, resulting in the need to open multiple sets of molds for one product to better meet production volume, which is high in production cost. The plastic parts are fixed to the inner surface of the carbon fiber body by bonding. The plastic parts are used to fix the carbon fiber body to the vehicle body. The bonding method has low structural strength and is easy to fall off under high temperature exposure. In order to achieve rapid prototyping of carbon fiber products, a method of using thermoplastic carbon fiber for compression molding has emerged. However, compression molding can usually only form products with a small curvature. Therefore, how to use thermoplastic carbon fiber to make automotive rearview mirrors to improve production efficiency has become a key research direction in the industry.

[0004] Therefore, it is necessary to design a new technical solution to solve the above problems. Summary of the Invention

[0005] In view of this, the present invention addresses the shortcomings of the prior art, and its main purpose is to provide a molding process for a carbon fiber rearview mirror housing, which uses a first molding device to preheat and pre-press a thermoplastic carbon fiber sheet, and uses a second molding device to preheat and mold the preform and cooperate with the assistance of a slider structure to complete the molding of the carbon fiber body. The molding of the carbon fiber body is achieved by two molding methods. Compared with the traditional autoclave molding method, the processing time is short, the processing efficiency is improved, and the preheating of the two moldings is performed on the corresponding lower mold, avoiding the temperature drop of the material during the transportation process and affecting the molding of the material, thereby better ensuring the quality of the product. In addition, the structure of the plastic part is complex and it is difficult to be directly injection molded on the carbon fiber body. The first plastic part and the second plastic part are formed separately by two injection molding methods, so that the plastic part is injection molded on the carbon fiber body, which enhances the structural strength of the connection with the carbon fiber body. The arrangement of the groove and the insert portion enhances the structural strength of the connection between the first plastic part and the second plastic part, thereby enhancing the structural strength of the entire carbon fiber rearview mirror housing.

[0006] To achieve the above object, the present invention adopts the following technical solutions: A molding process for a carbon fiber rearview mirror housing comprises the following steps: Step S1, a primary molding, firstly placing the thermoplastic carbon fiber sheet into the lower mold of a first molding device, wherein the first molding device is provided with a movable first infrared heater, and then driving the first infrared heater to move above the thermoplastic carbon fiber sheet to preheat the thermoplastic carbon fiber sheet. After preheating, the first infrared heater is driven away from the thermoplastic carbon fiber sheet, and then the upper mold and the lower mold of the first molding device are closed, and the preform is obtained after the first molding device is cooled; Step S2, secondary molding, first removes the edge material on the periphery of the preform, then places the preform into the lower mold of a second molding device, the second molding device is provided with a movable second infrared heater, then drives the second infrared heater to move above the preform to preheat the preform, and after preheating, drives the second infrared heater away from the preform, then closes the upper mold and the lower mold of the second molding device, and the second molding device has a slider structure for forming the folded edge. When closing the mold, the slider structure presses the preform, and the carbon fiber body is obtained after the second molding device is cooled; Step S3, single-shot injection molding, first removing the peripheral edge material of the carbon fiber body, then placing the carbon fiber body into a first injection molding device, and injection-molding a first plastic part on the inner surface of the carbon fiber body by the first injection molding device, wherein the first plastic part includes a first mounting portion for connecting to the vehicle body and a first connecting portion for connecting to the second plastic part, the first connecting portion having a first hollow cavity, and a groove being defined between the first connecting portion and the inner surface of the carbon fiber body; Step S4, secondary injection molding, placing the carbon fiber body with the first plastic part into the second injection molding equipment, and injection molding the second plastic part on the first connecting part through the second injection molding equipment, wherein the second plastic part includes a second mounting part for connecting to the vehicle body and a second connecting part connected to the first connecting part, the second connecting part has a second hollow cavity, and the second connecting part is formed with an insertion part extending into the groove, and the second connecting part and the first connecting part together form a ring body to obtain a carbon fiber rearview mirror shell.

[0007] As a preferred solution, the first molding device and the second molding device are both provided with a movable frame, the movable frame includes a frame body and a driving motor for driving the frame body to move, and the first infrared heater and the second infrared heater are provided on the corresponding movable frame.

[0008] As a preferred solution, lateral guide rails are provided on both sides of the first molding device and the second molding device, the frame is provided with a top plate and a left side plate, a rear side plate, and a right side plate connected to the top plate, the left side plate and the right side plate are respectively slidably connected to the corresponding lateral guide rails, the driving motor is provided below the corresponding lower mold, the driving motor is connected to a screw rod, a nut seat is provided on the screw rod, the rear side plate is connected to the nut seat, and the first infrared heater and the second infrared heater are at least provided at the bottom of the top plate.

[0009] As a preferred solution, the first molding device and the second molding device are both extended with a support frame, the top of the support frame is provided with a slide rail, and the bottoms of the left side plate and the right side plate are slidably connected to the slide rail.

[0010] As a preferred solution, the slider structure includes a left slider, a rear slider and a right slider, and the ends of the left slider, the rear slider and the right slider close to the lower mold of the second molding device together constitute a folding forming part for forming the fold.

[0011] As a preferred solution, the front side and bottom side of the carbon fiber body are open, the first connecting part corresponds to the open setting on the front side of the carbon fiber body, the first connecting part is extended with an extension part combined with the inner surface of the carbon fiber body, the first mounting part is arranged on the extension part, and the second mounting part is located below the carbon fiber body.

[0012] As a preferred solution, the bottom of the first connecting portion is higher than the bottom of the carbon fiber main body, and the top outer surface of the second connecting portion is combined with the inner surface of the carbon fiber main body.

[0013] As a preferred solution, the inner surface of the bottom of the carbon fiber main body and the end of the bottom of the first connecting part close to the carbon fiber main body are both concavely provided with recessed positions, and the two recessed positions together form a groove. The insertion part is protruded from the top of the second connecting part, and the top of the second connecting part corresponds to the end of the insertion part close to the carbon fiber main body. The bottom of the carbon fiber main body extends into the recessed position.

[0014] Compared with the prior art, the present invention has obvious advantages and beneficial effects. Specifically, it can be seen from the above technical solution that: Mainly, a first molding device is used to preheat and pre-press the thermoplastic carbon fiber sheet, and a second molding device is used to preheat and shape the preform and cooperate with the assistance of the slider structure to complete the molding of the carbon fiber body. The molding of the carbon fiber body is achieved by two molding methods. Compared with the traditional autoclave molding method, the processing time is short, the processing efficiency is improved, and the preheating of the two moldings is carried out on the corresponding lower mold to avoid the temperature drop of the material during the transportation process and affect the molding of the material, thereby better ensuring the quality of the product. In addition, the structure of the plastic part is complex and it is difficult to be directly injection molded on the carbon fiber body. The two injection molding methods are used to form the first plastic part and the second plastic part respectively, so that the plastic part is injection molded on the carbon fiber body, which enhances the structural strength of the connection with the carbon fiber body. The setting of the groove and the insert enhances the structural strength of the connection between the first plastic part and the second plastic part, thereby enhancing the structural strength of the entire carbon fiber rearview mirror shell.

[0015] In order to more clearly illustrate the structural features and effects of the present invention, the present invention is described in detail below with reference to the accompanying drawings and specific embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a process flow chart of a preferred embodiment of the present invention; Figure 2 Schematic diagram of the molding process of the carbon fiber body according to a preferred embodiment of the present invention; Figure 3 1 is a schematic diagram of the installation of a mobile rack according to a preferred embodiment of the present invention; Figure 4 Schematic diagram of a mold of a first molding device according to a preferred embodiment of the present invention; Figure 5 Schematic diagram of the mold of the second molding device of the preferred embodiment of the present invention; Figure 6 1 is a perspective schematic diagram of a carbon fiber rearview mirror housing according to a preferred embodiment of the present invention; Figure 7 is a cross-sectional schematic diagram of a carbon fiber rearview mirror housing according to a preferred embodiment of the present invention; Figure 8 It is a schematic diagram of the cooperation between the inserting portion and the groove of a preferred embodiment of the present invention.

[0017] Description of the accompanying drawings: 10. Thermoplastic carbon fiber sheet; 20. First molding equipment; 30. preform; 40. second molding device; 41. Slider structure; 411. Left slider; 412, rear slider; 413, right slider; 50. Carbon fiber main body; 60. First plastic part; 61. First mounting portion; 62. First connecting portion; 621, first hollow cavity; 63, extension portion; 70. groove; 80. second plastic part; 81. Second mounting portion; 82. Second connecting portion; 821, second hollow cavity; 822, insertion portion; 823, recess; 90, mobile rack; 91, frame; 911, top plate; 912, left side panel; 913, right side panel; 100. Lateral guide rail; 110. Support frame. DETAILED DESCRIPTION

[0018] First of all, it should be noted that in the description of the present invention, the terms "up", "down", "left", "right", etc. indicate directions or positional relationships based on the directions or positional relationships shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operated in a specific direction. Therefore, they cannot be understood as limiting the present invention.

[0019] Please refer to Figures 1 to 8 As shown, it shows the specific structure of a preferred embodiment of the present invention, including the following steps: Step S1, one-time molding, first, the thermoplastic carbon fiber sheet 10 is placed in the lower mold of the first molding device 20, the first molding device 20 is provided with a movable first infrared heater, and then the first infrared heater (not shown in the figure) is driven to move above the thermoplastic carbon fiber sheet 10 to preheat the thermoplastic carbon fiber sheet 10. After preheating, the first infrared heater is driven away from the thermoplastic carbon fiber sheet 10, and then the upper mold and the lower mold of the first molding device 20 are closed. After the first molding device 20 is cooled, a preform 30 is obtained.

[0020] Step S2, secondary molding, first removes the edge material on the periphery of the preform 30, then places the preform 30 into the lower mold of the second molding device 40, the second molding device 40 is provided with a movable second infrared heater (not shown in the figure), then drives the second infrared heater to move above the preform 30 to preheat the preform 30, and after preheating, drives the second infrared heater away from the preform 30, then closes the upper mold and the lower mold of the second molding device 40, and the second molding device 40 has a slider structure 41 for forming the folded edge. When closing the mold, the slider structure 41 presses the preform 30, and after the second molding device 40 cools down, a carbon fiber body 50 is obtained, the front side and the bottom side of the carbon fiber body 50 are open, and the cross section of the carbon fiber body 50 is an upward arched arc; refer to Figure 5 As shown, the slider structure 41 includes a left slider 411, a rear slider 412 and a right slider 413. The left slider 411, the rear slider 412 and the right slider 413, one end of which is close to the lower mold of the second molding device 40, together constitute a folding forming part for forming folds.

[0021] Step S3, one-step injection molding, first remove the edge material on the periphery of the carbon fiber body 50, then place the carbon fiber body 50 into a first injection molding device (not shown in the figure), and use the first injection molding device to injection mold a first plastic part 60 on the inner surface of the carbon fiber body 50. The first plastic part 60 includes a first mounting portion 61 for connecting to the vehicle body and a first connecting portion 62 for connecting to the second plastic part 80. The first connecting portion 62 has a first hollow cavity 621. A groove 70 is formed between the first connecting portion 62 and the inner surface of the carbon fiber body 50. For details, see Figure 6 As shown, the first connecting portion 62 is extended with an extending portion 63 that is combined with the inner surface of the carbon fiber body 50 , and the first mounting portion 61 is disposed on the extending portion 63 .

[0022] Step S4, secondary injection molding, places the carbon fiber body 50 with the first plastic part 60 into a second injection molding machine (not shown). The second injection molding machine then injection molds a second plastic part 80 onto the first connecting portion 62. The second plastic part 80 includes a second mounting portion 81 for connecting to the vehicle body and a second connecting portion 82 connected to the first connecting portion 62. The second connecting portion 82 has a second hollow cavity 821 and an insertion portion 822 extending into the groove 70. The second connecting portion 82 and the first connecting portion 62 together form an annular body, thereby obtaining a carbon fiber rearview mirror housing. The second mounting portion 81 is located below the carbon fiber body 50. The hollow structures of the first hollow cavity 621 and the second hollow cavity 821 can both be directly molded using corresponding injection molding equipment. This is a mature existing technology and will not be described in detail here.

[0023] The first molding device 20 and the second molding device 40 are both provided with a movable frame 90, and the movable frame 90 includes a frame body 91 and a driving motor (not shown in the figure) for driving the frame body 91 to move. The first infrared heater and the second infrared heater are provided on the corresponding movable frame 90; specifically, see Figure 3As shown, both sides of the first molding device 20 and the second molding device 40 are provided with lateral guide rails 100, and the frame 91 is provided with a top plate 911 and a left side plate 912, a rear side plate (not shown in the figure), and a right side plate 913 connected to the top plate 911. The left side plate 912 and the right side plate 913 are respectively slidably connected to the corresponding lateral guide rails 100, and the driving motor is arranged below the corresponding lower mold. The driving motor is connected to a screw rod, and a nut seat is provided on the screw rod. The rear side plate is connected to the nut seat. The screw rod and nut drive is an existing mature technology and will not be described in detail here. The first infrared heater and the second infrared heater are at least arranged at the bottom of the top plate 911. The first infrared heater and the second infrared heater are both existing mature technologies and will not be described in detail here. Preferably, the first molding device 20 and the second molding device 40 are both extended with a support frame 110, and a slide rail (not shown in the figure) is provided on the top of the support frame 110, and the bottom of the left plate 912 and the right plate 913 are slidably connected to the slide rail.

[0024] See Figure 8 As shown, the bottom of the first connecting portion 62 is higher than the bottom of the carbon fiber body 50, and the top outer surface of the second connecting portion 82 is combined with the inner surface of the carbon fiber body 50. The inner surface of the bottom of the carbon fiber body 50 and the end of the bottom of the first connecting portion 62 close to the carbon fiber body 50 are both concave. The two concave positions together form a groove 70. The insertion portion is protruded from the top of the second connecting portion 82, and the top of the second connecting portion 82 corresponds to the end of the insertion portion 822 close to the carbon fiber body 50 and is concave with a recess 823, and the bottom of the carbon fiber body 50 extends into the recess 823.

[0025] The design emphasis of the present invention is: Mainly, a first molding device is used to preheat and pre-press the thermoplastic carbon fiber sheet, and a second molding device is used to preheat and shape the preform and cooperate with the assistance of the slider structure to complete the molding of the carbon fiber body. The molding of the carbon fiber body is achieved by two molding methods. Compared with the traditional autoclave molding method, the processing time is short, the processing efficiency is improved, and the preheating of the two moldings is carried out on the corresponding lower mold to avoid the temperature drop of the material during the transportation process and affect the molding of the material, thereby better ensuring the quality of the product. In addition, the structure of the plastic part is complex and it is difficult to be directly injection molded on the carbon fiber body. The two injection molding methods are used to form the first plastic part and the second plastic part respectively, so that the plastic part is injection molded on the carbon fiber body, which enhances the structural strength of the connection with the carbon fiber body. The setting of the groove and the insert enhances the structural strength of the connection between the first plastic part and the second plastic part, thereby enhancing the structural strength of the entire carbon fiber rearview mirror shell.

[0026] The above description is merely a preferred embodiment of the present invention and does not limit the technical scope of the present invention. Therefore, any minor modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention are still within the scope of the technical solution of the present invention.

Claims

1. A molding process for a carbon fiber rearview mirror housing, characterized in that: The steps include: Step S1, a primary molding, firstly placing the thermoplastic carbon fiber sheet into the lower mold of a first molding device, wherein the first molding device is provided with a movable first infrared heater, and then driving the first infrared heater to move above the thermoplastic carbon fiber sheet to preheat the thermoplastic carbon fiber sheet. After preheating, the first infrared heater is driven away from the thermoplastic carbon fiber sheet, and then the upper mold and the lower mold of the first molding device are closed, and the preform is obtained after the first molding device is cooled; Step S2, secondary molding, first removes the edge material on the periphery of the preform, then places the preform into the lower mold of a second molding device, the second molding device is provided with a movable second infrared heater, then drives the second infrared heater to move above the preform to preheat the preform, and after preheating, drives the second infrared heater away from the preform, then closes the upper mold and the lower mold of the second molding device, and the second molding device has a slider structure for forming the folded edge. When closing the mold, the slider structure presses the preform, and the carbon fiber body is obtained after the second molding device is cooled; Step S3, single-shot injection molding, first removing the peripheral edge material of the carbon fiber body, then placing the carbon fiber body into a first injection molding device, and injection-molding a first plastic part on the inner surface of the carbon fiber body by the first injection molding device, wherein the first plastic part includes a first mounting portion for connecting to the vehicle body and a first connecting portion for connecting to the second plastic part, the first connecting portion having a first hollow cavity, and a groove being defined between the first connecting portion and the inner surface of the carbon fiber body; Step S4, secondary injection molding, placing the carbon fiber body with the first plastic part into the second injection molding equipment, and injection molding the second plastic part on the first connecting part through the second injection molding equipment, wherein the second plastic part includes a second mounting part for connecting to the vehicle body and a second connecting part connected to the first connecting part, the second connecting part has a second hollow cavity, and the second connecting part is formed with an insertion part extending into the groove, and the second connecting part and the first connecting part together form a ring body to obtain a carbon fiber rearview mirror shell.

2. The molding process of a carbon fiber rearview mirror housing according to claim 1, characterized in that: The first molding device and the second molding device are both provided with a movable frame, and the movable frame includes a frame body and a driving motor for driving the frame body to move. The first infrared heater and the second infrared heater are provided on the corresponding movable frame.

3. The molding process of a carbon fiber rearview mirror housing according to claim 2, characterized in that: Both sides of the first molding device and the second molding device are provided with lateral guide rails, the frame is provided with a top plate and a left side plate, a rear side plate and a right side plate connected to the top plate, the left side plate and the right side plate are respectively slidably connected to the corresponding lateral guide rails, the driving motor is arranged below the corresponding lower mold, the driving motor is connected to a screw rod, a nut seat is provided on the screw rod, the rear side plate is connected to the nut seat, and the first infrared heater and the second infrared heater are at least arranged at the bottom of the top plate.

4. The molding process of a carbon fiber rearview mirror housing according to claim 3, characterized in that: The first molding device and the second molding device are both extended with a support frame, the top of the support frame is provided with a slide rail, and the bottoms of the left side plate and the right side plate are slidably connected to the slide rail.

5. The molding process of a carbon fiber rearview mirror housing according to claim 1, characterized in that: The slider structure includes a left slider, a rear slider and a right slider, and the ends of the left slider, the rear slider and the right slider close to the lower mold of the second molding device together constitute a folding forming part for forming folds.

6. The molding process of a carbon fiber rearview mirror housing according to claim 1, characterized in that: The front and bottom sides of the carbon fiber body are open, the first connecting portion corresponds to the open front side of the carbon fiber body, the first connecting portion is extended with an extension portion combined with the inner surface of the carbon fiber body, the first mounting portion is arranged on the extension portion, and the second mounting portion is located below the carbon fiber body.

7. The molding process of a carbon fiber rearview mirror housing according to claim 1, characterized in that: The bottom of the first connecting portion is higher than the bottom of the carbon fiber body, and the top outer surface of the second connecting portion is combined with the inner surface of the carbon fiber body.

8. The molding process of a carbon fiber rearview mirror housing according to claim 7, characterized in that: The inner surface of the bottom of the carbon fiber body and the end of the bottom of the first connecting part close to the carbon fiber body are both concavely provided with recessed positions, and the two recessed positions together form a groove. The insertion part is protruded from the top of the second connecting part, and the top of the second connecting part corresponds to the end of the insertion part close to the carbon fiber body. The bottom of the carbon fiber body extends into the recessed position.

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