High-rigidity sun visor for automobile sunroof and manufacturing method thereof

Abstract

The application discloses a high-rigidity automobile sunroof sun visor and a manufacturing method thereof, and belongs to the technical field of automobile interiors. The sun visor adopts a multilayer composite integrated structure, and from bottom to top, the sun visor is sequentially provided with a non-woven fabric layer, a double-layer glass fiber felt layer one, a PU plate core layer, a double-layer glass fiber felt layer two, a hot-rolled cloth layer and a fabric layer, and is formed by high-temperature hot pressing of special glue, and replaces a traditional PP glass fiber plate single base material structure. The application adopts layered glue and water spraying pretreatment, and combines with quantitative temperature control, pressure control hot pressing forming, tool precision punching, and an automatic edge turning and edge covering standardized process to prepare a finished product, and solves the defects of insufficient rigidity of a traditional sun visor, easy sagging and cracking of a large size, poor heat and sound insulation, and low yield. The product is high in rigidity, stable in size, good in driving and riding adaptability, excellent in heat and sound insulation performance, stable in production process, controllable in cost, green and environment-friendly, and has extremely high industrialization application value.

Description

Technical Field

[0001] This invention belongs to the field of automotive interior parts manufacturing technology, and specifically relates to a high-rigidity automotive sunroof sun visor and its manufacturing method. Background Technology

[0002] The sunroof sunshade is a core interior accessory installed inside the sunroof assembly. It mainly serves to insulate heat, sound, block strong light, and beautify the interior environment. Its structural strength, dimensional stability, and appearance quality directly affect the user's driving experience.

[0003] Currently, mainstream automotive sunroof sunshades in the industry are generally made using PP fiberglass board substrates combined with dry molding processes. The conventional process is as follows: after the cut PP fiberglass board substrate is heated and softened in an oven, it is placed into a mold cavity, a fabric layer is attached to the surface of the substrate, and then it is pressed into shape. Finally, excess waste is removed by manual cutting, water jet cutting, or punching.

[0004] The traditional process and product structure have obvious technical defects: the PP fiberglass substrate itself is not rigid enough, and for large-size sunroof sunshade products, long-term use is prone to cracking, sagging and deformation, resulting in poor product dimensional stability; in addition, the single PP fiberglass structure has weak heat insulation and sound insulation performance, which cannot meet the interior comfort requirements of mid-to-high-end models.

[0005] Given the numerous shortcomings of existing technologies, there is an urgent need to develop a rigid, dimensionally stable, heat-insulating and sound-insulating automotive sunroof visor with mature technology and controllable cost, as well as its preparation method. Summary of the Invention

[0006] The purpose of this invention is to provide a high-rigidity automotive sunroof sun visor and its manufacturing method, so as to solve the problems of poor rigidity, easy deformation and cracking, poor heat insulation and sound insulation effect, and high scrap rate of traditional sun visors, and to achieve industrialized production of products with high strength, high stability, low cost and high quality.

[0007] To solve the above-mentioned technical problems, the present invention provides a high-rigidity automotive sunroof sunshade. The sunshade is a multi-layer composite integrated structure, which includes, from bottom to top, a non-woven fabric layer, a double-layer fiberglass felt layer one, a PU board core layer, a double-layer fiberglass felt layer two, a hot-rolled fabric layer, and a fabric layer. Each structural layer is bonded together into an integrated structure by hot pressing with adhesive.

[0008] Preferably, the nonwoven fabric layer has a basis weight of 180 g / m², the fiberglass felt layer has a basis weight of 300 g / m², the hot-rolled fabric layer has a basis weight of 45 g / m², and the PU core layer is a low-density PU board with a thickness of 8 mm.

[0009] This invention also provides a method for manufacturing a high-rigidity automotive sunroof sun visor, comprising the following steps:

[0010] Step A: Substrate pretreatment: The double-layer fiberglass felt layer one, PU board core layer, double-layer fiberglass felt layer two, and hot-rolled cloth layer are laid flat in sequence and sprayed with adhesive and water on both sides; and the raw materials of each layer after being sprayed with adhesive and water are stacked on top of the non-woven cloth layer to complete the substrate pretreatment.

[0011] Step B: Substrate molding: The laminated raw materials are placed into the molding mold cavity and hot-pressed under high temperature and high pressure to obtain the sunshade substrate;

[0012] Step C: Secondary adhesive spraying: Apply adhesive evenly to the composite surface of the molded sunshade substrate fabric.

[0013] Step D: Fabric lamination: Position and fix the substrate after spraying adhesive, fix the fabric layer with positioning pins, and use a press to hot press and laminate the fabric layer to make the fabric layer and the sunshade substrate fit tightly together.

[0014] Step E: Edge trimming and punching: Using a special punching tool, the semi-finished product after composite fabrication is processed by cutting the waste material on all four sides and punching handle holes.

[0015] Step F: Flanging and applying glue: Fix the punched product, apply folding glue evenly to the non-woven fabric side of the folded area, and let it stand until the glue surface dries.

[0016] Step G: Automatic edge binding: Place the product after the glue has dried into the edge-folding machine to complete the automated edge-folding and binding operation;

[0017] Step H: Product Finishing: Clean oil stains and dirt from the surface of the product fabric, and remove rough edges caused by punching at the product edges;

[0018] Step 1: Finished Product Inspection: Conduct a comprehensive inspection of the finished products, including appearance, structure, and bonding strength, and select qualified products.

[0019] Step J: Packaging and Warehousing: Standardize the packaging of qualified products and register them for warehousing.

[0020] Preferably, in step A, the total amount of adhesive used for molding the substrate of a single product is 180g~220g, and the total amount of water sprayed is 180g~220g; the amount of adhesive and water sprayed per layer of the double-layer fiberglass felt layer one, PU board core layer, double-layer fiberglass felt layer two, and hot-rolled cloth layer is 30g.

[0021] Preferably, in step B, the substrate molding process parameters are: upper mold temperature 115℃~135℃, lower mold temperature 125℃~145℃, molding pressure 7~8Mpa, and holding time 60s.

[0022] Preferably, in step C, the amount of adhesive applied to the substrate surface composite spray is 30g~50g.

[0023] Preferably, in step D, the fabric composite process parameters are: upper mold temperature 100℃~120℃, lower mold temperature 100℃~120℃, composite pressure 5~6Mpa, and pressure holding time 60s.

[0024] Preferably, in step F, the amount of adhesive used for flanging the product is 15g~20g.

[0025] Preferably, in step H, a clean cloth soaked in dichloromethane is used to wipe away oil stains and dirt from the fabric surface, and scissors are used to trim away rough edges of the product.

[0026] Preferably, the inspection items in step I include fabric flatness, surface cleanliness, product edge smoothness, interlayer bonding status, and edge bonding firmness. Unqualified products with defects such as stains, delamination, edge peeling, and excessive burrs are rejected.

[0027] In summary, the beneficial effects of the above-described technical solutions conceived by this invention compared with the prior art include:

[0028] 1. This invention uses a PU core combined with a multi-layer fiberglass felt composite structure to replace the traditional single base material of PP fiberglass board, which greatly improves the overall rigidity and bending resistance of the sun visor, and completely solves the problems of easy cracking and sagging deformation of large-size products. The product has a stable shape after long-term use. Moreover, the multi-layer composite structure forms a sealed sound and heat insulation cavity, which significantly improves the heat insulation and sound insulation performance compared with traditional products. It can effectively block heat conduction and noise transmission at the sunroof location, improve the comfort of the car interior, and the product has a high matching precision with the car roof, resulting in an aesthetically pleasing assembly effect.

[0029] 2. This invention adopts a standardized and tooled production process. The parameters of processes such as layered glue spraying, hot pressing, and automatic edge wrapping are precisely controllable, resulting in strong production stability and effectively reducing the product scrap rate. At the same time, automated equipment replaces a large number of manual operations, simplifies post-processing procedures, and significantly reduces labor and production costs. Moreover, the entire production process of the molded product does not generate any toxic or harmful substances. The raw materials are environmentally friendly and pollution-free, and the finished product is odorless, meeting the environmental protection testing standards for automotive interiors. Dedicated punching and flanging tooling ensures precise operation, high safety, and effectively improves production efficiency. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the stacked structure of the high-rigidity automotive sunroof sunshade of the present invention;

[0031] Figure 2 This is a flowchart illustrating the manufacturing process of the high-rigidity automotive sunroof sunshade of this invention.

[0032] The meanings of the markings in the attached diagram are as follows:

[0033] In the diagram: 1. Non-woven fabric layer; 2. Double-layer fiberglass felt layer one; 3. PU board core layer; 4. Double-layer fiberglass felt layer two; 5. Hot-rolled fabric layer; 6. Fabric layer. Detailed Implementation

[0034] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. The advantages and features of the present invention will become clearer from the following description and claims. It should be noted that the drawings are all in a very simplified form and use non-precise proportions, and are only used to facilitate and clarify the illustration of the embodiments of the present invention.

[0035] In the description of this invention, it should be understood that the terms "center", "longitudinal", "lateral", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0036] Example

[0037] This invention provides a high-rigidity automotive sunroof sunshade; please refer to [link / reference]. Figure 1 All raw materials are uniformly processed to a size of 850mm*600mm; the non-woven fabric layer 1 has a weight of 180g / m², the single fiberglass felt in double-layer fiberglass felt layer 1 2 and double-layer fiberglass felt layer 2 4 each has a weight of 300g / m², the PU board core layer 3 uses a low-density PU board with a thickness of 8mm, the hot-rolled fabric layer 5 has a weight of 45g / m², and the fabric layer 6 uses a special knitted fabric for automotive interiors.

[0038] This invention also provides a method for manufacturing a high-rigidity automotive sunroof sun visor; please refer to [link / reference]. Figure 2 The specific preparation process is as follows:

[0039] Step A: Substrate Pretreatment: Lay the two layers of fiberglass felt (layer 1) flat on the adhesive spraying table, and spray 30g of adhesive and 30g of tap water evenly on each layer in a single application. Flip the double-layer fiberglass felt layer 180° and lay it flat again to secure it. Lay the PU core layer 3 flat on top of the double-layer fiberglass felt layer 2, and spray 30g of adhesive and 30g of water on both sides of the PU core layer 3. Then, lay the two layers of fiberglass felt (layer 2) flat on top of the PU core layer 3, and spray 30g of adhesive and 30g of water on each layer in a single application. Finally, lay the hot-rolled fabric layer 5 flat and complete the single application of 30g of adhesive and 30g of water. In this step, the total amount of adhesive and water used for substrate molding of a single product is 210g, which falls within the standard parameter range of 180g~220g. The double-layer fiberglass felt layer 1, PU core layer 3, double-layer fiberglass felt layer 2, and hot-rolled cloth layer 5, which have undergone the above-mentioned adhesive and water spraying treatment, are stacked in an orderly manner from top to bottom and placed on top of the non-woven fabric layer 1 to complete the overall substrate layering pretreatment.

[0040] Step B: Substrate molding: The laminated substrate is placed smoothly into the lower mold cavity of the molding mold, and the mold is closed for high temperature and high pressure hot pressing molding. Specific process parameters: upper mold temperature 125℃, lower mold temperature 135℃, molding pressure 8Mpa, holding pressure time 60s. After the holding pressure and curing is completed, the mold is opened and the multi-layer composite integrated sunshade substrate is taken out.

[0041] Step C: Secondary glue spraying: Place the molded sunshade substrate fabric composite side up on the glue spraying workbench, use 02SA(B) type glue with a 77 type glue spray gun to spray glue evenly, the glue amount for a single product is 35g, which is within the parameter range of 30g~50g, to complete the substrate fabric composite pretreatment.

[0042] Step D: Fabric lamination: The substrate with the second adhesive spraying completed is precisely positioned and fixed in the lower mold cavity of the lamination mold. The fabric layer 6 is flattened and fixed on the upper surface of the substrate by the positioning pins at the four corners of the mold, ensuring no displacement and no wrinkles. Then, the mold is closed and hot-pressed for lamination. Process parameters: the temperature of the upper and lower molds is 110℃, the lamination pressure is 6Mpa, and the holding time is 60s, so that the fabric layer 6 is tightly attached to the sunshade substrate without gaps or delamination.

[0043] Step E: Trimming and punching: The semi-finished product after the composite fabric layer 6 is precisely placed into the lower mold cavity of the special punching die for positioning and fixing. The special punching tool is started to complete the punching of excess waste material on all four sides of the product and the punching of the handle hole for the sunroof assembly in one go, ensuring that the product's external dimensions and hole dimensions are accurate and compliant.

[0044] Step F: Flanging and Glue Application: Fix the die-cut product onto a special glue application fixture. Use a brush to apply the matching flanging glue evenly to the non-woven fabric side of the product where the flanging is to be applied. The amount of glue applied to a single product is 20g, which is within the standard range of 15g to 20g. After application, let it stand and air dry until the glue surface is completely non-sticky to avoid bonding defects in subsequent edge binding.

[0045] Step G: Automatic edge binding: After the glue has dried, place the product stably on the dedicated station of the edge-binding machine, calibrate and position it, and start the equipment to complete the automated edge-binding operation, ensuring that the edge binding is flat and smooth, the corners are neat, and the initial bonding is tight.

[0046] Step H: Product finishing: Use a clean cloth dampened with an appropriate amount of dichloromethane to repeatedly wipe the surface of the product fabric layer 6 to thoroughly remove oil stains and dirt generated during the production process; use special scissors to finely trim the edges of the product to remove any remaining fine burrs, ensuring a smooth and flat product appearance; isolate products with incomplete cleaning, excessive burrs, or serious appearance defects separately and dispose of them as scrap.

[0047] Step 1: Finished Product Inspection: Conduct comprehensive quality inspection on the finished products. The inspection items strictly correspond to the process standards, including: the flatness and cleanliness of the fabric layer 6 surface, the overall edge smoothness of the product, the bonding status between each structural layer and the absence of delamination, and the adhesion of the folded edges and the absence of edge lifting or falling off. Strictly reject unqualified products with stains, delamination, edge falling off, or excessive rough edges, and retain only compliant and good products.

[0048] Step J: Packaging and Warehousing: Place the qualified products into special plastic protective bags, pack them neatly into boxes according to standardized specifications, with 25 products in each box. Clearly affix labels such as product specifications, production batch, and qualification mark to the surface of the carton. After registration and filing, store the products in the warehouse.

[0049] In this embodiment, the dimensions of all raw materials are uniformly 850mm*600mm, with the fiberglass felt having a basis weight of 300g / m², the PU board core being an 8mm thick low-density PU board, the hot-rolled cloth having a basis weight of 45g / m², the non-woven fabric having a basis weight of 180g / m², and the fabric being a special knitted fabric for automotive interiors.

[0050] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A high-rigidity automotive sunroof sunshade, characterized in that, The sunshade is a multi-layer composite integrated structure, which includes, from bottom to top, a non-woven fabric layer (1), a double-layer fiberglass felt layer one (2), a PU board core layer (3), a double-layer fiberglass felt layer two (4), a hot-rolled fabric layer (5), and a fabric layer (6). Each structural layer is bonded together into an integrated structure by hot pressing with adhesive.

2. The high-rigidity automotive sunroof sunshade according to claim 1, characterized in that, The nonwoven fabric layer has a basis weight of 180 g / m², the fiberglass felt layer has a basis weight of 300 g / m², the hot-rolled fabric layer has a basis weight of 45 g / m², and the PU board core layer is a low-density PU board with a thickness of 8 mm.

3. A method for manufacturing a high-rigidity automotive sunroof sun visor, used to prepare the automotive sunroof sun visor according to any one of claims 1-2, characterized in that, Includes the following steps: Step A: Substrate pretreatment: The double-layer fiberglass felt layer 1 (2), PU board core layer (3), double-layer fiberglass felt layer 2 (4), and hot-rolled cloth layer (5) are laid flat in layers and sprayed with adhesive and water on both sides in sequence; The raw materials that have been sprayed with adhesive and water are stacked on top of the nonwoven fabric layer (1) to complete the substrate stacking pretreatment; Step B: Substrate molding: The laminated raw materials are placed into the molding mold cavity and hot-pressed under high temperature and high pressure to obtain the sunshade substrate; Step C: Secondary adhesive spraying: Apply adhesive evenly to the composite surface of the molded sunshade substrate fabric. Step D: Fabric lamination: Position and fix the substrate after spraying glue, fix the fabric layer (6) with positioning pins, and use a press to hot press and laminate the fabric layer (6) to make the sunshade substrate tightly bonded. Step E: Edge trimming and punching: Using a special punching tool, the semi-finished product after composite fabrication is processed by cutting the waste material on all four sides and punching handle holes. Step F: Flanging and applying glue: Fix the punched product, apply folding glue evenly to the non-woven fabric side of the folded area, and let it stand until the glue surface dries. Step G: Automatic edge binding: Place the product after the glue has dried into the edge-folding machine to complete the automated edge-folding and binding operation; Step H: Product Finishing: Clean oil stains and dirt from the surface of the product fabric, and remove rough edges caused by punching at the product edges; Step 1: Finished Product Inspection: Conduct a comprehensive inspection of the finished products, including appearance, structure, and bonding strength, and select qualified products. Step J: Packaging and Warehousing: Standardize the packaging of qualified products and register them for warehousing.

4. The manufacturing method of a high-rigidity automotive sunroof sun visor according to claim 3, characterized in that, In step A, the total amount of glue used for molding the substrate of a single product is 180g~220g, and the total amount of water sprayed is 180g~220g; the amount of glue sprayed and the amount of water sprayed per layer of the double-layer fiberglass felt layer (2), PU board core layer (3), double-layer fiberglass felt layer (4), and hot-rolled cloth layer (5) are all 30g.

5. A method for manufacturing a high-rigidity automotive sunroof sun visor according to claim 3, characterized in that, In step B, the substrate molding process parameters are: upper mold temperature 115℃~135℃, lower mold temperature 125℃~145℃, molding pressure 7~8Mpa, and holding time 60s.

6. A method for manufacturing a high-rigidity automotive sunroof sun visor according to claim 3, characterized in that, In step C, the amount of adhesive applied to the substrate surface composite spray is 30g~50g.

7. A method for manufacturing a high-rigidity automotive sunroof sun visor according to claim 3, characterized in that, In step D, the fabric lamination process parameters are: upper mold temperature 100℃~120℃, lower mold temperature 100℃~120℃, lamination pressure 5~6Mpa, and pressure holding time 60s.

8. A method for manufacturing a high-rigidity automotive sunroof sun visor according to claim 3, characterized in that, In step F, the amount of adhesive used for flanging the product is 15g~20g.

9. A method for manufacturing a high-rigidity automotive sunroof sun visor according to claim 3, characterized in that, In step H, use a clean cloth soaked in dichloromethane to wipe away oil stains and dirt from the fabric surface, and use scissors to trim away the rough edges of the product.

10. A method for manufacturing a high-rigidity automotive sunroof sun visor according to claim 3, characterized in that, The inspection items in step I include fabric flatness, surface cleanliness, product edge smoothness, interlayer bonding status, and edge bonding firmness. Unqualified products with stains, delamination, edge peeling, or excessive burrs are rejected.

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