Method for integrally forming a vehicle interior part, vehicle interior part, and vehicle

Abstract

This application provides a method for integrated molding of vehicle interior parts, the vehicle interior parts themselves, and a vehicle, relating to the field of vehicle parts safety technology. The method for integrated molding of vehicle interior parts includes the following steps: S1, preparing a patterned film, the patterned film comprising a substrate layer and an adhesive layer disposed on one side of the substrate layer, the pattern being an identification pattern formed on the substrate layer; S2, fixing the patterned film to a predetermined area within a mold; S3, injecting a molten matrix into the mold, the materials of the matrix and the adhesive layer being fused together, and the matrix and adhesive layer forming an integrated structure after fusion. This application solves the problems of insufficient connection reliability and easy detachment of vehicle interior parts caused by post-assembly methods in the prior art, realizing an integrated molding method that integrally molds the vehicle interior parts with the substrate, eliminating the connection interface, improving the overall structural integrity, and thus ensuring stability and safety during long-term use.

Description

Technical Field

[0001] This application relates to the field of vehicle parts safety technology, and in particular to a method for integrated molding of vehicle interior parts, vehicle interior parts, and a vehicle. Background Technology

[0002] In automotive interior design, some components combine decorative and functional aspects. For example, the patterned film on the steering wheel, the logo, and the control panel not only need to meet aesthetic requirements but also need to fulfill core functions such as brand recognition and operation guidance.

[0003] In the prior art, such components are usually molded independently and then assembled and fixed to the surface or interior of a pre-made substrate by means of adhesive bonding, snap-fit ​​fitting or mechanical locking to form vehicle interior parts.

[0004] However, this post-installation method must withstand the coupling effects of complex working conditions such as high-frequency and wide-frequency vibration, extreme temperature difference cycles, and ultraviolet radiation throughout the vehicle's entire life cycle. This can easily lead to the degradation of the connection interface performance, causing components to loosen, warp, or even fall off. This not only affects the refined feel of the interior, but also poses a safety hazard to occupants in the event of a sudden high-energy release such as airbag deployment, as the detached components may be scattered by the impact force. Summary of the Invention

[0005] This application provides a method for integral molding of vehicle interior parts, vehicle interior parts, and a vehicle, to solve the problems of insufficient connection reliability and easy detachment of vehicle interior parts caused by post-assembly methods in the prior art. It realizes an integral molding method that integrally molds vehicle interior parts with the base body, eliminates the connection interface, improves the overall structure, and thus ensures stability and safety in long-term use.

[0006] This application provides a method for integral molding of vehicle interior parts, comprising: S1, preparing a patterned film, the patterned film comprising a substrate layer and an adhesive layer disposed on one side of the substrate layer, the pattern being an identification pattern formed on the substrate layer; S2, fixing the patterned film in a preset area within a mold; S3, injecting a molten matrix into the mold, the material of the matrix and the material of the adhesive layer being fused together, and the matrix and the adhesive layer forming an integral structure after being fused together.

[0007] According to the integrated molding method for vehicle interior parts provided in the embodiments of this application, step S1 includes: S1.1, adding an antioxidant and a hindered amine light stabilizer to the adhesive layer.

[0008] According to the integrated molding method for vehicle interior parts provided in the embodiments of this application, step S1 includes: S1.2, providing a pattern layer with the pattern on the side of the substrate layer away from the adhesive layer.

[0009] According to the integrated molding method for vehicle interior parts provided in the embodiments of this application, step S1.2 includes: providing at least one of a texture coating, a pattern coating, a text coating, and a color coating on the side of the substrate layer opposite to the adhesive layer.

[0010] According to the integrated molding method for vehicle interior parts provided in the embodiments of this application, after step S1.2, the method further includes: S1.3, providing a protective film on the side of the pattern layer opposite to the substrate layer.

[0011] According to the integrated molding method for vehicle interior parts provided in the embodiments of this application, step S1.3 includes: coating at least one of an ultraviolet curable coating and a wear-resistant coating on the side of the pattern layer opposite to the substrate layer to form the protective film.

[0012] According to the integrated molding method for vehicle interior parts provided in the embodiments of this application, after step S1, the method further includes: coating the surface of the patterned film with at least one of an anti-reflective coating, an anti-fingerprint coating, and an antistatic coating.

[0013] According to the integrated molding method for vehicle interior parts provided in the embodiments of this application, the mold is provided with a positioning component, which is used to fix the patterned film in a preset area within the mold; the positioning component includes at least one of a positioning pin and a vacuum adsorption device.

[0014] This application also provides a vehicle interior trim piece, which is manufactured by the integrated molding method for vehicle interior trim pieces described in any of the above embodiments. The vehicle interior trim piece includes a patterned film and a substrate, wherein the substrate and the patterned film are integrally molded together.

[0015] This application also provides a vehicle, including: a vehicle body and a vehicle interior component as described in any of the above embodiments, the vehicle interior component being disposed inside the vehicle body.

[0016] This application provides a method for integrated molding of vehicle interior trim, the vehicle interior trim, and a vehicle. This embodiment defines the material of the adhesive layer, enabling it to be fused and bonded to the base material, laying the foundation for interface bonding in subsequent integrated molding. When the molten base is injected into the mold and comes into contact with the adhesive layer, due to the compatibility of the two materials, molecular chains diffuse and entangle at the interface, forming a strong bond. This molecular-level fusion eliminates the physical interface present in traditional after-assembly processes, making the patterned film and the base a continuous whole. Consequently, during long-term use of the vehicle, regardless of high-frequency vibration, extreme temperature changes, or the instantaneous impact of airbag deployment, the integrated structure will not experience loosening, warping, or detachment of the patterned film, improving the connection reliability of the vehicle interior trim and occupant safety, and avoiding the risk of injury from the patterned film scattering during high-energy release events such as airbag deployment. Attached Figure Description

[0017] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.

[0018] Figure 1 A flowchart of a method for integral molding of vehicle interior parts provided in this application embodiment;

[0019] Figure 2 The flowchart is a step S1 in the integrated molding method for vehicle interior parts provided in the embodiments of this application. Detailed Implementation

[0020] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this application. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this application as detailed in the appended claims.

[0021] As described in the background section, some components in automotive interior design serve both decorative and functional purposes. Examples include patterned diaphragms on the steering wheel, logos, and control panels. These components not only need to meet aesthetic requirements but also fulfill core functions such as brand identification and operational guidance. In existing technologies, these components are typically molded independently and then assembled and fixed to a pre-made substrate surface or interior using adhesives, snap-fit ​​fittings, or mechanical locking to form the vehicle's interior trim. However, this post-assembly method, throughout the vehicle's lifespan, is subject to the coupling effects of complex conditions such as high-frequency, wide-bandwidth vibrations, extreme temperature cycles, and ultraviolet radiation. This can easily lead to performance degradation at the connection interfaces, causing components to loosen, warp, or even detach. This not only affects the perceived refinement of the interior but also poses a safety hazard to occupants in the event of a sudden high-energy release, such as airbag deployment, where detached components may scatter with the impact.

[0022] The technical solution of this application and how the technical solution of this application solves the above-mentioned technical problems are described in detail below with specific embodiments. These specific embodiments can be combined with each other, and the same or similar concepts or processes may not be described again in some embodiments. The embodiments of this application will now be described with reference to the accompanying drawings.

[0023] Reference Figure 1 The integrated molding method for vehicle interior parts provided in this application includes the following steps: S1, preparing a patterned film, the patterned film including a substrate layer and an adhesive layer disposed on one side of the substrate layer, the substrate layer having a pattern formed thereon, the pattern being an identification pattern; S2, fixing the patterned film in a preset area within a mold; S3, injecting a molten matrix into the mold, the material of the matrix and the material of the adhesive layer being able to fuse, and the matrix and adhesive layer forming an integrated structure after fusion.

[0024] The substrate layer refers to the basic supporting structure that constitutes the patterned film. It can be a PC (polycarbonate) film or PET (polyethylene terephthalate) film with added UV-resistant modifiers, specifically designed for interior trim films. The adhesive layer is a functional coating applied to one side of the substrate layer (specifically, the bottom surface of the substrate layer, which refers to the opposite side exposed after installation). Its material must be capable of fusing with the subsequently injected thermoplastic elastomer material in a molten state. EVA (ethylene and vinyl acetate monomers polymerized) modified hot melt adhesive can be used. The matrix material is a polymer that softens and flows upon heating and hardens and sets upon cooling. The matrix is ​​the main structure of the final product. Specifically, the matrix material can be TPO (thermoplastic olefin), which possesses high and low temperature resistance, aging resistance, and impact resistance.

[0025] In this embodiment, an adhesive layer is first applied to the bottom surface of the substrate layer. Specifically, when the subsequent substrate is TPO material, the adhesive layer can be an EVA-modified hot melt adhesive with good compatibility. Then, a pre-prepared patterned film containing the substrate layer and adhesive layer is placed in a predetermined area within the injection mold cavity and fixed. Finally, the substrate heated to a molten state is injected into the mold cavity using an injection molding machine at a melting temperature of 180°C to 220°C. After the vehicle interior trim is formed, the surface of the formed vehicle interior trim is lightly polished (only removing possible overflow). During the filling process, the molten substrate material comes into contact with the adhesive layer on the patterned film fixed within the cavity. Under high temperature and pressure, the molecular chain segments at the interface diffuse and entangle with each other. As the mold cools, the adhesive layer and the substrate material fuse together, forming a seamless or interconnected integral structure.

[0026] This embodiment defines the material of the adhesive layer, enabling it to moltenly bond with the substrate material, thus laying the foundation for interfacial bonding in subsequent integrated molding. When the molten substrate is injected into the mold and comes into contact with the adhesive layer, due to the compatibility of the two materials, molecular chains diffuse and entangle at the interface, forming a strong bond. This molecular-level fusion eliminates the physical interface present in traditional post-assembly processes, making the patterned film and the substrate a continuous whole.

[0027] In traditional automotive manufacturing, the patterned diaphragm on the steering wheel is independently molded and then assembled to the airbag cover (i.e., the substrate) using methods such as heat fusion, inserts, or screws. Throughout the vehicle's lifespan, it is subjected to complex conditions including high-frequency, wide-frequency vibrations, extreme temperature cycles, and ultraviolet radiation, which can easily lead to performance degradation at the connection interface, causing the component to loosen, warp, or even detach. This method, however, uses an integrated structural design, allowing the molded patterned diaphragm and airbag cover to simultaneously withstand external loads and environmental stresses. The peel strength reaches or exceeds 50 N / cm, far surpassing the 10 N / cm of existing adhesive-bonded patterned diaphragms. During long-term automotive use, regardless of high-frequency vibrations, extreme temperature changes from -40°C to 80°C, or the instantaneous impact of airbag deployment, the integrated structure will not cause the patterned diaphragm to loosen, warp, or detach. This improves the connection reliability of vehicle interior components and occupant safety, avoiding the risk of injury from the patterned diaphragm scattering during high-energy release events such as airbag deployment.

[0028] Reference Figure 2 In some embodiments of this application, step S1 includes: S1.1, adding an antioxidant and a hindered amine light stabilizer to the adhesive layer.

[0029] Antioxidants are chemical substances that can inhibit or delay the degradation of polymer materials due to reactions with oxygen during processing and use. Antioxidants include Irganox 1010 (primary antioxidant) and Irgafos 168 (secondary antioxidant). Hindered amine light stabilizers are a class of stabilizers that can effectively capture free radicals generated by ultraviolet radiation, thereby inhibiting the photoaging reaction of materials. Specifically, hindered amine light stabilizers can be Tinuvin 622 LD and / or Irganox 1010. Adding these two types of additives to the adhesive layer aims to enhance its aging resistance under high-temperature injection molding and subsequent long-term use conditions through synergistic effects, preventing interfacial delamination under high temperature, high humidity, and ultraviolet radiation conditions.

[0030] When preparing the adhesive layer, antioxidants and hindered amine light stabilizers need to be pre-mixed uniformly into the hot melt adhesive matrix material constituting the adhesive layer. Specifically, EVA-modified hot melt adhesive particles are first dry-mixed with metered amounts of hindered phenolic antioxidants and tetramethylpiperidine hindered amine light stabilizers in a high-speed mixer, ensuring the additive powder adheres uniformly to the particle surface. Subsequently, this mixture is melt-blended and granulated using an extruder to obtain modified hot melt adhesive granules containing a synergistic stabilizing system of antioxidants and hindered amine light stabilizers. Finally, this modified hot melt adhesive is uniformly applied to one side of the substrate layer using a coating or casting process to form an adhesive layer containing antioxidants and hindered amine light stabilizers. The resulting patterned film possesses an inherent ability to resist thermo-oxidative and photo-aging at the material level.

[0031] This embodiment provides a long-term guarantee of interfacial bonding performance by introducing antioxidants and hindered amine light stabilizers into the adhesive layer, from the perspective of material chemical modification. When the molten matrix is ​​injected into the mold in subsequent steps, the injection temperature will generate a severe thermal shock to the adhesive layer. At this time, the antioxidants in the adhesive layer first play a role, interrupting the oxidation chain reaction by capturing free radicals generated by the thermal oxidation reaction, effectively inhibiting the oxidative degradation of the adhesive layer material itself at high temperatures, and avoiding the weakening of interfacial bonding due to a sharp decrease in material strength. On the other hand, during vehicle use, if the interior parts are exposed to ultraviolet rays shining through the windows for a long time, the hindered amine light stabilizer can efficiently quench the free radicals generated by photoexcitation, delaying yellowing, chalking, and interfacial peeling of the adhesive layer and the adjacent substrate layer.

[0032] Reference Figure 2 In some embodiments of this application, step S1 includes: S1.2, providing a patterned layer with a pattern on the side of the substrate layer away from the adhesive layer.

[0033] A pattern layer is a layer applied to the surface of a substrate layer to create decorative visual effects or functional markings. Specifically, a pattern layer can be a logo layer or other button marking layer. When a pattern layer needs to be applied to the side of the substrate layer away from the adhesive layer, the substrate layer surface is first subjected to corona or plasma treatment to improve its surface tension and ink adhesion. Subsequently, the printing process is carried out according to design requirements. For example, a base color can be formed on the substrate layer surface using screen printing, and then brand logos or functional symbols can be printed at predetermined positions on the base color layer using ink printing. UV-resistant pigments, such as inorganic pigments like titanium dioxide and carbon black, are used in the printing inks to prevent rapid fading of organic dyes.

[0034] In the above-described steps for preparing the pattern layer, by placing the pattern layer on the side of the substrate layer away from the adhesive layer, the pattern layer is located on the outermost side or below the surface of the final product, allowing it to be directly observed or seen through the protective layer. This structural layout ensures that the pattern layer meets decorative requirements while not participating in the interfacial bonding process with the substrate material, thus avoiding the potential impact of printing inks or pattern textures on the fusion effect between the adhesive layer and the substrate. The pattern layer can be designed and prepared independently, without being limited by the high temperature and high pressure conditions during subsequent injection molding, providing great freedom for the design of complex patterns, multi-color gradients, fine textures, and other high-end visual effects.

[0035] Reference Figure 2 In some embodiments of this application, step S1.2 includes: providing at least one of a texture coating, a pattern coating, a text coating, and a color coating on the side of the substrate layer opposite to the adhesive layer.

[0036] Textured coatings are thin layers formed on the surface of a substrate layer to mimic the texture or decorative patterns of a specific material, such as carbon fiber woven textures, brushed metal textures, or geometric patterns. Patterned coatings are printed layers that form specific graphics or logos, such as brand logos or decorative patterns. Text coatings are printed layers consisting of characters, which can be used to present brand names, functional identifiers, or warning messages. Color coatings are printed layers that impart specific colors or gradient effects to the substrate layer, and can be monochrome, multi-color, or gradient color layers. All of these coatings can be selectively formed on the side of the substrate layer opposite to the adhesive layer, depending on design requirements.

[0037] When setting a pattern layer on the side of the substrate layer away from the adhesive layer, one or more of the following can be selected: textured coating, patterned coating, text coating, and color coating, depending on the final visual effect requirements. For example, a textured coating simulating carbon fiber weaving can be first formed on the surface of the substrate layer by printing, laying the foundation for the overall visual effect. After the textured coating dries, a patterned coating containing the brand logo is formed on top of it by printing. The patterned coating can use ink with a metallic sheen to enhance the visual effect. At the same time, explanatory text coatings, such as brand names or product series logos, can be superimposed at appropriate positions on the patterned coating. In addition, a color coating with a gradient effect can be formed in the background area by printing, making the overall visual effect richer. The above-mentioned coatings can be layered and superimposed to form a complex patterned layer with multiple layers, colors, and textures on the surface of the substrate layer.

[0038] Specifically, the steps for setting a pattern layer on the side of the PET substrate layer away from the adhesive layer are as follows. First, a textured coating with a metallic brushed texture is formed on the surface of the substrate layer using a gravure printing process. This textured coating uses solvent-based ink containing aluminum powder. The metallic brushed effect is transferred to the surface of the substrate layer by engraving the texture on the gravure roller. After drying, a realistic metallic textured background is formed.

[0039] Subsequently, a patterned coating, featuring the brand logo, is created on top of the textured coating using screen printing. High-octane white ink is selected to ensure the logo remains clearly visible against the metallic background. After the patterned coating dries, a line of text is printed below the logo using inkjet printing.

[0040] Finally, a gradient color coating is evenly sprayed onto the entire surface. This coating uses transparent dye-based ink, and the thickness of the coating is adjusted to create a gradient effect from dark to light, making the overall visual effect richer and more three-dimensional.

[0041] This embodiment constructs a complex pattern layer on the substrate layer by layering and combining texture coating, pattern coating, text coating and color coating. The complex pattern layer has a brushed metal background, a high-contrast brand logo, clear brand text and gradient color effect. This achieves a rich visual effect that traditional single process cannot achieve, and provides a highly recognizable and artistic appearance for the final unibody product.

[0042] Reference Figure 2 In some embodiments of this application, step S1 further includes: S1.3, providing a protective film on the side of the pattern layer away from the substrate layer.

[0043] A protective film is a transparent, thin layer applied to the surface of the pattern layer to provide physical and weather protection. This protective film effectively resists the erosion and damage to the underlying fine pattern layer caused by external environmental factors, forming a physical protective layer that blocks direct ultraviolet radiation from contacting the substrate.

[0044] Specifically, using precision coating equipment, a transparent protective coating is evenly applied to the surface of the pattern layer, forming a liquid coating of uniform thickness. Then, depending on the characteristics of the coating, it is cured by methods such as ultraviolet light irradiation or hot air drying, ultimately forming a strong, transparent solid protective film on top of the pattern layer. This protective film completely covers the pattern layer, isolating it from the external environment and providing protection for subsequent processes and long-term use.

[0045] In the steps described above for preparing the protective film, a physical and chemical protective barrier is constructed by setting a protective film on the surface of the pattern layer. This protective film is located on the outermost side of the interior trim and directly withstands friction and scratches during daily use, as well as the erosion from ultraviolet rays, moisture, and chemicals in the external environment. During the subsequent integrated injection molding process, this protective film also acts as an insulator, preventing the high-temperature molten base material from directly impacting and damaging the delicate pattern layer.

[0046] Meanwhile, the protective film encapsulates the pattern layer in a stable, inert environment, effectively delaying ink aging, fading, and peeling. This ensures that the patterned film maintains a clear and vibrant initial state throughout the entire lifespan of the vehicle, significantly improving the durability and aesthetics of interior components. Traditional processes often expose the patterned film directly or protect it only with simple post-treatment, leading to fading and wear over time. This method, however, uses a protective film to prevent the patterned film from being scratched by everyday abrasions such as fingernails or steering wheel covers, ensuring the pattern remains undamaged and faded.

[0047] In some embodiments of this application, step 1.3 includes coating at least one of an ultraviolet-curable coating and an abrasion-resistant coating on the side of the patterned layer opposite to the substrate layer to form a protective film.

[0048] UV-curable coatings are transparent solid coatings formed by the cross-linking and curing reaction of a liquid resin system triggered by ultraviolet radiation. They are characterized by fast curing speed, high production efficiency, and the ability to form a physical protective layer to block ultraviolet rays. Abrasion-resistant coatings, on the other hand, are transparent coatings with high surface hardness and scratch resistance, effectively resisting minor scratches and wear during daily use.

[0049] Specifically, when a protective film is applied to the side of the pattern layer facing away from the substrate layer, a UV-curable coating and a wear-resistant coating can be selectively applied according to performance requirements. For example, firstly, a UV-curable coating containing a photoinitiator and acrylate prepolymer is uniformly applied to the surface of the pattern layer using precision coating equipment. The coated patterned film is then passed under a set of high-power UV lamps, where the liquid coating undergoes an instantaneous polymerization and cross-linking reaction under UV light irradiation, curing into a transparent solid film. If further enhanced wear resistance is required, a polyurethane-type wear-resistant coating can be applied to the surface of the cured UV-curable coating and hardened by hot air drying, ultimately forming a composite protective film composed of the UV-curable coating and the wear-resistant coating on top of the pattern layer.

[0050] In the steps described above for preparing the protective film, the UV-curable coating and the wear-resistant coating work together to form a multi-layered protective system for the pattern layer. The UV-curable coating first forms a dense chemical barrier on the surface of the pattern layer. The UV absorbers in this coating can preferentially absorb or shield the UV energy from external irradiation, significantly reducing the intensity of UV light reaching the underlying ink pattern layer. This effectively slows down the photoaging and degradation process of pigments or resin matrices in the ink, preventing the pattern from fading or yellowing.

[0051] The wear-resistant coating acts as the outermost physical barrier, its high surface hardness resisting physical damage to the pattern layer caused by daily cleaning, fingernail scratches, or friction from fine sand particles. This dual chemical and physical protection mechanism ensures that the pattern layer maintains its color vibrancy, pattern integrity, and smooth surface for a long time in the complex usage environment of automotive interiors, meeting the usage environment requirements of different regions around the world, including cold and tropical regions, and exhibiting excellent resistance to ultraviolet aging.

[0052] In some embodiments of this application, after step S1, the method further includes coating the surface of the patterned film with at least one of an anti-reflective coating, an anti-fingerprint coating, and an antistatic coating.

[0053] Anti-reflective coatings are functional coatings that reduce surface reflection and increase light transmittance. Anti-fingerprint coatings have low surface energy, preventing fingerprints and oils from adhering or making them easy to wipe clean. Antistatic coatings have a certain degree of conductivity, effectively dissipating surface static charges and preventing dust accumulation.

[0054] After the patterned film is prepared, one or more of the aforementioned functional coatings can be applied to the surface of the patterned film, depending on the functional requirements of the final product. For example, for the patterned film area located in the center of the steering wheel, an anti-reflective coating can be applied to its surface using a spraying or vapor deposition process to reduce glare under direct sunlight. To keep the patterned film surface clean and resistant to fingerprints, a transparent anti-fingerprint coating can be applied over the anti-reflective coating. For interior trim surfaces that are prone to attracting dust due to static electricity, an anti-static coating can be applied. These coatings are typically applied after the patterned film is prepared and before it is placed in a mold for injection molding to ensure that the coating completely covers the surface of the final product.

[0055] This embodiment further optimizes and enhances the performance of interior trim by coating the surface of the patterned diaphragm with functional coatings. The anti-reflective coating effectively reduces ambient light reflection on the patterned diaphragm surface, minimizing interference with the driver's vision and improving driving safety. The anti-fingerprint coating gives the surface oleophobic and hydrophobic properties, making it less prone to fingerprints and oil stains, and easy to clean, maintaining the cleanliness and aesthetics of the patterned diaphragm area over the long term. The antistatic coating reduces surface resistivity, allowing static electricity to dissipate rapidly, thereby reducing the adsorption of dust from the air and maintaining the cleanliness of the interior trim. The introduction of these functional coatings significantly improves the perceived quality and user experience of integrated interior trim at a lower cost, making it not only structurally reliable and aesthetically pleasing, but also possessing superior performance in daily use. Traditional aftermarket patterned diaphragms often have assembly gaps that easily accumulate dust, while this method further optimizes surface performance through functional coatings.

[0056] In some embodiments of this application, a positioning component is provided inside the mold. The positioning component is used to fix the patterned film in a preset area inside the mold. The positioning component includes at least one of a positioning pin and a vacuum adsorption device.

[0057] A positioning component refers to a mechanism located inside the mold used to precisely fix a patterned diaphragm within a pre-defined area of ​​the mold cavity. A positioning pin is a columnar structure located inside the mold that engages with positioning holes on the patterned diaphragm to provide rigid constraint. A vacuum adsorption device is a mechanism that connects to a vacuum system through suction holes on the surface of the mold cavity, using negative pressure to adsorb and fix the patterned diaphragm.

[0058] Specifically, multiple positioning pins can be set in the pre-defined area of ​​the patterned diaphragm in the mold cavity, and positioning holes can be pre-defined at corresponding positions during the preparation of the patterned diaphragm. When the patterned diaphragm is placed into the mold cavity, the positioning holes are aligned with the positioning pins and inserted to achieve initial rigid positioning. Simultaneously or alternatively, suction holes can be opened on the surface of the mold cavity and connected to a vacuum system. After the patterned diaphragm is placed in position, a vacuum adsorption device is activated, using negative pressure to smoothly adsorb it onto the cavity surface, achieving flexible fixation. Through at least one of the positioning pins and the vacuum adsorption device, it is ensured that the patterned diaphragm is accurately and securely positioned in the pre-defined area before injection molding.

[0059] In the above positioning method, the locating pins, through rigid constraint, ensure that the basic position of the patterned diaphragm within the mold does not shift macroscopically. Their fitting clearance can be precisely controlled, ensuring that the patterned diaphragm will not move significantly due to the high-speed impact of the injection molten material. The vacuum adsorption device eliminates the air gap between the patterned diaphragm and the cavity surface through negative pressure, ensuring a tight fit between the diaphragm and the cavity, preventing molten material from penetrating the back of the patterned diaphragm under high pressure, causing displacement or flash.

[0060] When used in conjunction, the locating pin provides initial positioning and error prevention, while vacuum adsorption further eliminates minute displacements and warping, achieving precise positioning that combines rigidity and flexibility. This positioning mechanism allows the positional deviation of the patterned diaphragm on the final molded product to be controlled within ±0.2mm, fully meeting the high-precision assembly requirements of automotive interior parts. It avoids visual defects or assembly interference caused by the offset or skew of the patterned diaphragm, providing a reliable guarantee for the stable mass production of high-quality products.

[0061] This application also provides a vehicle interior trim component, which is manufactured by the integrated molding method of vehicle interior trim components in any of the above embodiments. The vehicle interior trim component includes a patterned film and a substrate, and the substrate and the patterned film are integrally molded together.

[0062] Vehicle interior trim parts refer to finished components manufactured using the aforementioned integrated molding method for vehicle interior trim parts. These include two parts: a patterned diaphragm and an airbag cover (specifically, an airbag cover). The patterned diaphragm is a pre-prepared insert containing a substrate layer and an adhesive layer. The airbag cover is the structural body formed after the airbag cover is injected into a mold and cooled. The patterned diaphragm is fused to the airbag cover via the adhesive layer, forming a seamless, integrated structure.

[0063] The aforementioned vehicle interior components, employing a one-piece molded structure and material system, eliminate the connection interfaces inherent in traditional after-assembly structures. This interface-free structure allows the patterned diaphragm and airbag cover to function as a continuous whole, jointly bearing external loads and environmental stresses. Throughout the vehicle's entire lifespan, regardless of high-frequency vibrations or extreme temperature variations from -40°C to 80°C, the patterned diaphragm will not loosen, warp, or detach. Especially during airbag deployment, the impact force of the airbag can cause traditional independent patterned diaphragms to easily break and fly out, injuring occupants. The integrated structure of this application, lacking separable independent components, completely eliminates the safety hazard of flying parts causing injury.

[0064] Meanwhile, because the patterned layer of the patterned membrane is prepared before molding and protected by a protective film or functional coating, the final product can achieve complex patterns, multi-color gradients, and fine textures that are difficult to achieve with traditional processes, presenting an extremely high level of appearance and brand recognition. The positional deviation of the patterned membrane is no more than 0.2mm, the surface is flat and gapless, it is not easy for dust to accumulate, and the IML protective layer can resist daily scratches. The patterned membrane will not fade even after long-term use.

[0065] Furthermore, when the vehicle interior trim parts of this application are applied to the steering wheel, there is no need to modify the existing steering wheel frame or the airbag installation interface. They can directly replace the existing aftermarket airbag cover without investing in new tooling, thus reducing the cost of technology upgrades. In addition, the TPO material of the substrate is recyclable, which meets the "green manufacturing" requirements of the automotive industry and reduces waste emissions.

[0066] This application also provides a vehicle, including a vehicle body and vehicle interior trim as described in any of the above embodiments, wherein the vehicle interior trim is disposed inside the vehicle body.

[0067] The vehicle body refers to the basic structure that constitutes the main body of a vehicle, including core components such as the body, chassis, and powertrain. Interior trim refers to components installed inside the vehicle body for decoration, functional operation, or occupant protection.

[0068] The vehicle provided in this application includes a vehicle body and interior trim components disposed inside the vehicle body. The interior trim components are integrated structural parts manufactured using the aforementioned integrated molding method for interior trim components, as described above. The interior trim components are securely installed in predetermined locations inside the vehicle body, such as the steering wheel, dashboard, door panels, or center console, through their patterned film and integrated structure with the airbag cover.

[0069] Other embodiments of this application will readily occur to those skilled in the art upon consideration of the specification and practice of the invention disclosed herein. This application is intended to cover any variations, uses, or adaptations of this application that follow the general principles of this application and include common knowledge or customary techniques in the art not disclosed herein. The specification and examples are to be considered exemplary only, and the true scope and spirit of this application are indicated by the claims.

[0070] It should be understood that this application is not limited to the precise structure described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of this application is limited only by the appended claims.

Claims

1. A method for integral molding of vehicle interior parts, characterized in that, include: A patterned film is prepared, the patterned film comprising a substrate layer and an adhesive layer disposed on one side of the substrate layer, wherein the pattern is formed on the substrate layer, and the pattern is an identification pattern; The patterned film is fixed in a preset area within the mold; A molten matrix is ​​injected into the mold, the materials of the matrix and the adhesive layer are fused together, and the matrix and the adhesive layer can form an integrated structure after being fused together.

2. The integrated molding method for vehicle interior parts according to claim 1, characterized in that, The preparation of the patterned film includes adding an antioxidant and a hindered amine light stabilizer to the adhesive layer.

3. The method for integrated molding of vehicle interior parts according to claim 1, characterized in that, The preparation of the patterned film includes: providing a patterned layer with the pattern on the side of the substrate layer opposite to the adhesive layer.

4. The method for integrated molding of vehicle interior parts according to claim 3, characterized in that, The provision of a pattern layer with the pattern on the side of the substrate layer opposite to the adhesive layer includes: providing at least one of a texture coating, a pattern coating, a text coating, and a color coating on the side of the substrate layer opposite to the adhesive layer.

5. The method for integrated molding of vehicle interior parts according to claim 3, characterized in that, After the pattern layer with the pattern is provided on the side of the substrate layer opposite to the adhesive layer, the method further includes: providing a protective film on the side of the pattern layer opposite to the substrate layer.

6. The method for integrated molding of vehicle interior parts according to claim 5, characterized in that, The provision of a protective film on the side of the pattern layer opposite to the substrate layer includes: coating the side of the pattern layer opposite to the substrate layer with at least one of an ultraviolet curable coating and an abrasion-resistant coating to form the protective film.

7. The method for integral molding of vehicle interior parts according to any one of claims 1-6, characterized in that, After the step of preparing the patterned film, the method further includes coating the surface of the patterned film with at least one of an anti-reflective coating, an anti-fingerprint coating, and an antistatic coating.

8. The method for integral molding of vehicle interior parts according to any one of claims 1-6, characterized in that, The mold is equipped with a positioning component, which is used to fix the patterned film in a preset area within the mold; the positioning component includes at least one of a positioning pin and a vacuum adsorption device.

9. A vehicle interior trim component, characterized in that, The vehicle interior trim component is manufactured by the integrated molding method of any one of claims 1-8, wherein the vehicle interior trim component comprises: A patterned membrane; The substrate is integrally formed with the patterned membrane.

10. A vehicle, characterized in that, include: Vehicle body; The vehicle interior trim as described in claim 9 is disposed inside the vehicle body.

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