Automobile light-emitting grating plate and manufacturing process

Abstract

The invention discloses an automobile light-emitting grating plate and a manufacturing process, and the process comprises the following steps: preparing a transparent or semitransparent plastic plate with the thickness of 0.5-4.0 mm; performing silk-screen printing on the back surface of the plate to form a design pattern, wherein the design pattern comprises a shading part and a light-transmitting part; the plastic plate is put into a heating device to be heated and softened; the softened plastic plate is put into a mold, the mold shapes the softened plastic plate, and a needed three-dimensional shape is formed on the plate; and then edge cutting is conducted on the plate to form the needed automobile grille. A light-emitting plate is installed on the side with the printed patterns, and a light-emitting controller is arranged in the light-emitting plate. The machining efficiency of new automobile grating plates can be greatly improved, and the machining cost can be greatly reduced.

Description

TECHNICAL FIELD

[0001] The application relates to an automobile light-emitting grille plate and a manufacturing process. BACKGROUND

[0002] With the popularity of electric vehicles, the automobile grille plate has been converted from the traditional air exchange and heat dissipation function to other functions, such as improving the aesthetic degree, increasing the recognition degree, improving the intelligent performance and the like, and these new requirements also bring new challenges to the manufacturing process of the automobile grille. In the prior art, the automobile grille is usually manufactured by an injection molding process, including a two-color injection molding mold process, a paint spraying and laser engraving injection molding process, an IML injection molding process and the like. The commonalities of these processes are that: plastic particles are put into an injection mold to form a grille plate with a required shape by injection molding, and then a required pattern is formed on the injection molded part by a laser engraving, paint spraying or IML process. These prior art technologies have the disadvantages of long mold opening time, expensive mold, and unchangeable mold size. The development of a new product from mold opening to processing completion needs 100-135 days, and due to the many processing procedures, the paint spraying, laser engraving and other processes are unstable, which results in a low success rate of the final product. Usually, the success rate is less than 50%, which leads to the problems of long processing cycle, high cost and inflexibility in the development of the final product. SUMMARY

[0003] Therefore, the application aims to solve the problems of long processing time, high cost, low success rate and inflexible size and shape of the automobile grille in the prior art.

[0004] To solve the above problems, one aspect of the application provides an automobile grille plate manufacturing process, which comprises the following steps: A transparent or translucent plastic plate is prepared, and the thickness of the plate is 0.5-4.0 mm; A design pattern is formed on the back of the plate by silk screen printing, and the design pattern comprises a light shielding part and a light transmitting part; The plastic plate is placed in a heating device to be softened; The softened plastic plate is placed in a mold, and the mold is used to shape the softened plastic plate to form a required three-dimensional shape on the plate; Then, the edge of the plate is cut to form a required automobile grille; A light-emitting plate is installed on the side of the automobile grille with the printed pattern, and the light-emitting plate is provided with a light-emitting controller.

[0005] Another aspect of the application provides an automobile light-emitting grille plate, which comprises: The main body panel is made of transparent or semi-transparent plastic material, with a thickness of 0.5mm-4.0mm. The main body panel constitutes the main supporting structure of the car grille; the main body panel has a three-dimensional shape formed by hot pressing or high pressure molding. The pattern layer is located inside the main body panel and includes both light-transmitting and non-light-transmitting areas. The light-emitting panel is fixed to the back of the main body material. The light-emitting panel is controlled by the light-emitting controller to emit light according to the set mode. The light emitted by the light-emitting panel passes through the light-transmitting area and the non-light-transmitting area of ​​the pattern layer to form a fixed or changing light-emitting area.

[0006] The automotive luminous grille panel and manufacturing process realized in this application do not require injection molds. Suitable shapes can be formed through simple hot pressing or high-pressure molds. The hot pressing or high-pressure mold production cycle is short, which can shorten the processing cycle of new products to 45 days, while repeated processing only takes 3 days, and can achieve a first-pass success rate of 80%. Therefore, compared with the existing technology, there is a great improvement in processing cycle and cost. Attached Figure Description

[0007] Figure 1 This is a schematic diagram of the manufacturing process of an automotive luminous grille provided in one embodiment of this application.

[0008] Figure 2 This is a schematic diagram showing the state of a plastic sheet after a pattern has been printed in one embodiment. Figure 3 This is a schematic diagram showing the state of plastic sheets after hot pressing or high-pressure molding. Figure 4 This is a schematic diagram of the final state of an automotive illuminated grille.

[0009] Figure 5 This is a schematic diagram of the final state of the automotive luminous grille in another embodiment. Detailed Implementation

[0010] To make the technical problems, technical solutions, and beneficial effects to be solved by this application clearer and more understandable, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of this application and are not intended to limit the scope of this application.

[0011] In this application, terms referring to orientation, such as up, down, top, bottom, inside, outside, high, low, back, and front, are used with reference to the position of the car grille in normal use.

[0012] All temperature units used in this application are in degrees Celsius.

[0013] One aspect of this application provides a manufacturing process for an automotive grille panel, comprising the following steps: Prepare a transparent or semi-transparent plastic sheet with a thickness of 0.5mm-4.0mm; The design pattern is created by screen printing on the back of the board, and the design pattern includes light-blocking and light-transmitting parts; The plastic sheet is placed in a heating device to soften it. The softened plastic sheet is placed into a mold, and the mold shapes the softened plastic sheet to form the desired three-dimensional shape. The sheet material is then edge-cut to form the desired car grille; A light-emitting panel is installed on the side of the car grille with a printed pattern, and a light-emitting controller is installed inside the panel.

[0014] In at least one embodiment, the molding die used is a high-pressure molding die, and the molding pressure of the die is 10-120 Pa.

[0015] In at least one embodiment, the molding die used is a thermoforming die, which includes an upper die and a lower die; wherein: Upper mold temperature: 100 degrees - 400 degrees; Lower mold temperature: 120°C - 450°C; Heating time: 60S-300S; Molding time: 30S-300S; Mold temperature after mold closing: 60 degrees - 120 degrees.

[0016] In at least one embodiment, the automotive grille manufacturing process further includes the step of: reprinting the pattern of the automotive grille to compensate for defects caused by pattern deformation.

[0017] In at least one embodiment, the ink used for screen printing in the automotive grille manufacturing process is a tensile-resistant and UV-resistant ink.

[0018] In at least one embodiment, a surface treatment layer is provided on the front side of the plastic sheet.

[0019] In at least one embodiment, the surface treatment layer is a paint layer.

[0020] In another aspect, this application proposes an automotive luminous grille, comprising: The main body panel is made of transparent or semi-transparent plastic material, with a thickness of 0.5mm-4.0mm. The main body panel constitutes the main supporting structure of the car grille; the main body panel has a three-dimensional shape formed by hot pressing or high pressure molding. The pattern layer is located inside the main body panel and includes both light-transmitting and non-light-transmitting areas. The light-emitting panel is fixed to the back of the main body material. The light-emitting panel is controlled by the light-emitting controller to emit light according to the set mode. The light emitted by the light-emitting panel passes through the light-transmitting area and the non-light-transmitting area of ​​the pattern layer to form a fixed or changing light-emitting area.

[0021] In at least one embodiment, a surface treatment layer is provided on the front side of the main body plate.

[0022] In at least one embodiment, the surface treatment layer is a paint layer.

[0023] The specific implementation process of this application will be described in detail below with reference to the accompanying drawings.

[0024] like Figure 1 The image shows a manufacturing process for an automotive grille panel provided in one embodiment of this application. The process includes the following steps: S1. Prepare a transparent or semi-transparent plastic sheet with a thickness of 0.5mm-4.0mm; The selected board material can be a complete, non-perforated PC or PMMA, PC+ABS, or ABS resin board. The thickness can be selected from any of the following: 0.8mm, 1.0mm, 1.2mm, 1.5mm, 1.8mm, 2.0mm, 2.2mm, 2.5mm, 3mm, 3.3mm, 3.5mm, etc., between 0.5mm and 4.0mm.

[0025] S2. Screen printing is performed on the back of the board to form a design pattern, which includes light-blocking and light-transmitting parts; The inks used in screen printing are tensile-resistant and UV-resistant. Pattern designs include radiating cutout patterns and cutout patterns forming specific symbols or designs. Screen printing involves multiple layers to create a light-blocking area with a thickness between 0.005 and 0.2 mm. A variety of ink colors can be used. The number of printing layers is adjusted according to the depth of the ink color. Generally, lighter inks require more printing layers than darker inks. A single color of ink or multiple colors can be used to create a wider range of effects. Figure 2 The image shows the state of the board after the pattern has been printed.

[0026] S3. Place the plastic sheet into a heating device to soften it; Heating devices include, but are not limited to, ovens.

[0027] S4. Place the softened plastic sheet into the mold, and the mold shapes the softened plastic sheet to form the required three-dimensional shape on the sheet; The mold can be a high-pressure molding mold with a molding pressure of 10-120 Pa. The high-pressure molding process is as follows: the sheet is heated by both upper and lower baking pans, and the plastic sheet is heated to a softened state simultaneously. After the upper and lower molds are closed, the upper mold pushes the plastic sheet tightly against the surface of the lower mold by high-pressure air blowing. After the molding is stable, the mold is opened and the part is removed.

[0028] The mold can also be a thermoforming mold, which includes an upper mold and a lower mold; Upper mold temperature: 100 degrees - 400 degrees; Lower mold temperature: 120°C - 450°C; Heating time: 60S-300S; Molding time: 30S-300S; Mold temperature after mold closing: 60 degrees - 120 degrees.

[0029] The thermoforming process: After the sheet material is heated from the top, it is placed between the upper and lower molds. After the molds are closed, the molds continue to apply temperature to the sheet material and apply mechanical pressure based on the shape of the mold itself, pressing the sheet material to conform to the mold contour and forming the shape. After completion, the mold is opened and the product is removed. Figure 3 As shown, this is the state of the sheet material after it has been shaped by a mold, resulting in a three-dimensional shape.

[0030] After the molding is completed, in order to ensure the aesthetics of the pattern design, the pattern of the car grille can be reprinted to make up for the defects caused by the deformation of the pattern.

[0031] S5. Then the sheet metal is edge-cut to form the desired car grille; Cutting methods include CNC cutting or laser cutting.

[0032] S6. Install a light-emitting panel on the side of the car grille with the printed pattern, and install a light-emitting controller inside the light-emitting panel.

[0033] The light-emitting controller can control the light emission mode, color, and range through a built-in program. For example... Figure 4 The image shown is a schematic diagram of the final car grille. The back is illuminated by a light-emitting panel, and light passing through the translucent areas of the pattern creates a unique visual effect. New car grille designs can be quickly created by selecting different patterns, printing colors, and effects, such as... Figure 5 The diagram shown is a schematic representation of the state of the car grille in another embodiment.

[0034] Depending on the requirements, the front of the plastic sheet may be provided with a surface treatment layer, such as a paint layer, to make the color and texture of the car grille match the overall color and texture of the car.

[0035] In another embodiment, this application provides an automotive luminous grille, such as... Figure 4 Or as shown in 5, including: The main body panel 1 is made of transparent or semi-transparent plastic material, with a thickness of 0.5mm-4.0mm. The main body panel constitutes the main support structure of the car grille. The main body panel has a three-dimensional shape formed by hot pressing or high pressure molding. The three-dimensional shape includes a streamlined contour, convex and concave surfaces, and curved edges.

[0036] Pattern layer 2, located inside the main body panel, includes both translucent and opaque areas. The ink used for screen printing is tensile-resistant and UV-resistant. Pattern designs include radiating cutout patterns and cutout patterns forming specific symbols or patterns. Multiple layers are screen printed to form a light-blocking area with a thickness between 0.005 and 0.2 mm. Various ink colors can be used. The number of printing layers is adjusted according to the ink color intensity. Generally, lighter inks require more printing layers than darker inks. A single color of ink or multiple colors can be used to create different effects. Figure 2 The image shows the state of the board after the pattern has been printed.

[0037] The light-emitting panel is fixed to the back of the main body material. Controlled by a light-emitting controller, it emits light according to a set pattern. The light emitted by the panel passes through the translucent and opaque areas of the pattern layer, forming fixed or variable light-emitting areas. Generally, after light passes through the translucent and opaque areas of the pattern layer, the translucent areas allow the light to pass through, while the opaque areas block the light, thus creating the designed light-emitting pattern. The translucent areas may also include designs that allow specific colors of light to pass through, or semi-translucent designs.

[0038] The front side of the main body panel 1 can also be provided with a surface treatment layer, such as a paint layer, so that the color and texture of the car grille match the overall color and texture of the car.

[0039] The preferred embodiments of the present invention have been described above with reference to the accompanying drawings, but this does not limit the scope of the invention. Those skilled in the art can implement the present invention in various modifications without departing from its scope and spirit; for example, a feature of one embodiment can be used in another embodiment to obtain yet another embodiment. Any modifications, equivalent substitutions, and improvements made within the scope of the present invention should be within the scope of the present invention.

Claims

1. A manufacturing process of automobile grille plate, comprising the following steps: preparing a transparent or translucent plastic plate material, the thickness of the plate material being 0.5mm-4.0mm; screen printing a design pattern on the back of the plate material, the design pattern including light-shielding part and light-transmitting part; putting the plastic plate material into a heating device to soften it; putting the softened plastic plate material into a mold to shape it, so that the required three-dimensional shape is formed on the plate material; then cutting the edges of the plate material to form the required automobile grille; installing a light-emitting plate on the back of the automobile grille with printed pattern, the light-emitting plate being provided with a light-emitting controller.

2. The process of claim 1, wherein: The mold is a high-pressure forming mold, and the forming pressure of the mold is 10-120 Pa.

3. The process of claim 1, wherein: The mold is a hot-press forming mold, which includes an upper mold and a lower mold; wherein: the temperature of the upper mold is 100-400 degrees; the temperature of the lower mold is 120-450 degrees; heating time: 60S-300S; pressing forming time: 30S-300S; mold temperature after closing: 60-120 degrees.

4. The process of claim 1, wherein: It also includes the step of re-printing the pattern on the back of the automobile grille to compensate for the defects caused by the deformation of the pattern after high-pressure or hot-press forming of the plastic plate material.

5. The process of claim 1, wherein: The ink used in the screen printing is stretch-resistant and UV-resistant.

6. The process of claim 1, wherein: The front surface of the plastic plate material is provided with a surface treatment layer.

7. The process of claim 1, wherein: The surface treatment layer is a paint layer.

8. An automotive light emitting grille plate characterized by It includes: a main plate made of transparent or translucent plastic material, the thickness of the main plate being 0.5mm-4.0mm, the main plate constituting the main support structure of the automobile grille; the main plate having a three-dimensional shape formed by hot-press forming or high-pressure forming; a pattern layer on the back of the main plate, the pattern layer being formed by screen printing and including light-transmitting area and non-light-transmitting area; a light-emitting plate fixed to the back of the main plate, the light-emitting plate being controlled by a light-emitting controller to emit light according to the set mode, the light emitted by the light-emitting plate forming fixed or changing light-emitting area after passing through the light-transmitting area and non-light-transmitting area of the pattern layer.

9. The light emitting lattice sheet of claim 8, wherein: The front surface of the main plate is provided with a surface treatment layer.

10. The light emitting lattice sheet of claim 9, wherein: The surface treatment layer is a paint layer.

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