A manufacturing process for an automotive interior dash mat

Abstract

The present application aims to give a manufacturing process of automobile inner front pad, the third starting hard cotton felt layer is put into the interlayer of the shallow cold mold lower mold, the vertical cylinder drives the lifting of the supporting plate to tightly adhere to the top wall in the interlayer, absorbs the heat transferred to the top wall in the interlayer by the k-2 hard cotton felt layer during the heat dissipation process, on the one hand, helps the k-2 hard cotton felt layer to accelerate heat dissipation, on the other hand, makes itself preheated, after preheating, it is unnecessary to soften for a long time in the drying oven, only needs to accept short time drying softening, in this way, the drying oven only needs to set short time drying softening, the k-2 composite layer drying time is shorter, so it is unnecessary to wait for too long after the k-2 hard cotton felt layer completes heat dissipation, the manufacturing efficiency is high.

Description

Technical Field

[0001] This invention relates to the field of automotive interior front bulkhead mat manufacturing. Background Technology

[0002] Patent document CN 114454502 A discloses a method for manufacturing the front bulkhead of an automobile cockpit. This method uses a press to drive the upper molds of both a shallow-cooled mold and a deep-cooled mold to move downwards synchronously. A first rigid cotton felt layer is fed into a heating chamber via a first conveyor belt for individual heating and softening. It then enters the lower mold of the shallow-cooled mold and is hot-pressed by the upper mold. After the upper mold is reset, it remains in the lower mold to dissipate heat. Simultaneously, a second rigid cotton felt layer and the first composite layer are fed into the heating chamber via the first conveyor belt for joint heating and softening. After heating, the first rigid cotton felt layer has dissipated heat and is transferred from the lower mold of the shallow-cooled mold to the lower mold of the deep-cooled mold by an operator. The softened first composite layer is then transferred from the heating chamber to the lower mold of the deep-cooled mold and stacked on top of the softened first rigid cotton felt layer. The softened second rigid cotton felt layer is then transferred from the heating chamber to the lower mold of the shallow-cooled mold. The upper molds of the deep cryogenic mold and the upper mold of the shallow cryogenic mold press down simultaneously. The upper mold of the deep cryogenic mold presses the softened first composite layer onto the already formed first rigid cotton felt layer, while the upper mold of the shallow cryogenic mold heat-presses the second rigid cotton felt layer. Since the second rigid cotton felt layer requires a longer heating time than the first composite layer, the heating chamber is set with a longer heating time to accommodate the second rigid cotton felt layer. As a result, after the k-th rigid cotton felt layer has dissipated heat in the lower mold of the shallow cryogenic mold, it must wait for the k-th composite layer to complete its long heating time in the heating chamber before both layers enter the lower mold of the deep cryogenic mold for pressing. However, the waiting time for the second rigid cotton felt layer is too long, affecting manufacturing efficiency. Summary of the Invention

[0003] The present invention aims to provide a manufacturing process for automotive interior front bulkhead mats, where the time required for the kth rigid cotton felt layer to complete heat dissipation is short and does not affect manufacturing efficiency.

[0004] A manufacturing process for an automotive interior front bulkhead mat utilizes a heating chamber, a press, and a first conveyor belt. Below the press are a shallow cooling mold and a deep cooling mold. The upper molds of the shallow cooling mold and the deep cooling mold are mounted on the bottom wall of the press. The heating chamber contains side-by-side heating positions for rigid cotton felt layers and composite layers. The first conveyor belt also has corresponding side-by-side placement positions for rigid cotton felt layers and composite layers. The upper part of the side wall of the lower mold of the shallow cooling mold has a transverse recess forming a sandwich layer. A vertical cylinder is mounted on the bottom wall of the sandwich layer, and a support plate is mounted on the upper end of the vertical cylinder. This manufacturing process includes the following steps: S1. Multiple rigid cotton felt layers are arranged along the length of the first conveyor belt and placed in the rigid cotton felt layer placement position. Multiple composite layers are arranged along the length of the conveyor belt and placed in the composite layer placement position. The kth composite layer is aligned left and right with the (k+1)th rigid cotton felt layer. k is a positive integer. S2. The first hard cotton felt layer is sent from the hard cotton felt layer placement position to the hard cotton felt layer drying position in the drying box by the first conveyor belt, and is dried and softened by the drying box for a long time. S3. After the first rigid cotton felt layer has been softened by baking, it is sent from the baking oven to the lower mold of the shallow cooling mold. The upper mold of the shallow cooling mold and the upper mold of the deep cooling mold are driven by the press to move down synchronously. The upper mold of the shallow cooling mold heat-presses the first rigid cotton felt layer of the lower mold of the shallow cooling mold into shape. The second rigid cotton felt layer is sent from the rigid cotton felt layer placement position to the rigid cotton felt layer baking position of the baking oven by the first conveyor belt. The first composite layer is sent from the composite layer placement position to the composite layer baking position of the baking oven by the first conveyor belt. They are all simultaneously baked and softened by the baking oven for a long time. S4. After the first rigid cotton felt layer is hot-pressed, it remains in the lower mold of the shallow cold mold to dissipate heat. The third rigid cotton felt layer is sent from the rigid cotton felt layer placement position to the tray of the interlayer. The tray is driven by the vertical cylinder to move upward and lift the third rigid cotton felt layer to be close to the inner top wall of the interlayer. The third rigid cotton felt layer absorbs the heat dissipated by the first rigid cotton felt layer remaining in the lower mold of the shallow cold mold. S5. After the first rigid cotton felt layer has completed heat dissipation in the shallow cooling mold lower mold, it is transferred to the deep cooling mold lower mold. S6. After the first composite layer has been softened by baking, it is sent from the baking oven to the lower mold of the deep cooling mold and stacked on the first hard cotton felt layer. After the second hard cotton felt layer has been softened by baking, it is sent from the baking oven to the lower mold of the shallow cooling mold. The upper mold of the deep cooling mold and the upper mold of the shallow cooling mold are driven by the press to move down synchronously. The upper mold of the deep cooling mold presses the first composite layer onto the first hard cotton felt layer, and the upper mold of the shallow cooling mold heat-presses the second hard cotton felt layer into shape. S7. After the third rigid cotton felt layer completes heat absorption in the interlayer, the pallet is driven by the vertical cylinder to reset and move the third rigid cotton felt layer down away from the top wall of the interlayer; the third rigid cotton felt layer is sent to the original position of the rigid cotton felt layer placement position. S8. The third hard cotton felt layer is sent from the original position of the hard cotton felt layer placement position to the hard cotton felt layer drying position of the drying box by the first conveyor belt, and the second composite layer is sent from the composite layer placement position to the composite layer drying position of the drying box by the first conveyor belt, and together they are dried and softened in the drying box for a short time. S9. Repeat the following steps S91~S95. S91. During the short-term baking of the (k-1)th composite layer (k≥3, the same below) and the kth rigid cotton felt layer in the baking oven, the (k-1)th rigid cotton felt layer remains in the lower mold of the shallow cold mold to dissipate heat after hot pressing; the (k+1)th rigid cotton felt layer is sent from the rigid cotton felt layer placement position to the tray of the interlayer. The tray is driven by the vertical cylinder to move upward and lift the (k+1)th rigid cotton felt layer to be close to the inner top wall of the interlayer. The (k+1)th rigid cotton felt layer absorbs the heat dissipated by the (k-1)th rigid cotton felt layer in the lower mold of the shallow cold mold. S92. After the (k-1)th rigid cotton felt layer has completed heat dissipation in the shallow cooling mold, it is transferred to the deep cooling mold. S93. After the (k-1)th composite layer has been softened by baking, it is sent from the baking oven to the lower mold of the deep cooling mold and stacked on the (k-1)th rigid cotton felt layer. After the (k)th rigid cotton felt layer has been softened by baking, it is sent from the baking oven to the lower mold of the shallow cooling mold. The upper mold of the deep cooling mold and the upper mold of the shallow cooling mold are driven by the press to move down synchronously. The upper mold of the deep cooling mold presses the (k-1)th composite layer onto the (k-1)th rigid cotton felt layer, and the upper mold of the shallow cooling mold heat-presses the (k)th rigid cotton felt layer into shape. S94. After the (k+1)th hard cotton felt layer completes heat absorption in the interlayer, the pallet is driven by the vertical cylinder to reset and move the (k+1)th hard cotton felt layer down away from the top wall of the interlayer; the (k+1)th hard cotton felt layer is sent to the original position of the hard cotton felt layer placement position. S95. The (k+1)th rigid cotton felt layer is transported from its original position to the rigid cotton felt layer drying position in the drying chamber by the first conveyor belt, while the kth composite layer is transported from its composite layer position to the composite layer drying position in the drying chamber by the first conveyor belt, and together they are dried and softened in the drying chamber for a short time.

[0005] Furthermore, the long-term baking and softening time is 60 seconds, and the short-term baking and softening time is 40 seconds.

[0006] The beneficial effects are as follows: the third and subsequent rigid cotton felt layers are placed in the interlayer of the lower mold of the shallow cooling mold. Driven by a vertical cylinder, the pallet is lifted up to be close to the top wall of the interlayer. This absorbs the heat transferred to the top wall of the interlayer by the (k-2)th rigid cotton felt layer during heat dissipation. On the one hand, this helps the (k-2)th rigid cotton felt layer to accelerate heat dissipation, and on the other hand, it allows itself to be preheated. After preheating, it does not need to undergo long-term heat softening in the baking oven. It only needs to undergo short-term heat softening. In this way, the baking oven only needs to be set to a short-term heat softening time, and the baking time of the (k-2)th composite layer is shorter. Therefore, the (k-2)th rigid cotton felt layer does not need to wait too long after heat dissipation, resulting in high manufacturing efficiency. Attached Figure Description

[0007] Figure 1 This is a front view of the press used in this production process; Figure 2 This is the left view of the press used in this production process; Figure 3 This is a production process flow chart, and the process is at step S1. Figure 4 This is a production process flow chart, and the process is at step S2. Figure 5 This is a production process flow chart, and the process is at step S3. Figure 6 This is a production process flow chart, and the process is at step S4. Figure 7 This is a production process flow chart, and the process is at step S5. Figure 8 This is a production process flow chart, and the process is at step S6. Figure 9 This is a production process flow chart, and the process is at step S7. Figure 10 This is a production process flow chart, and the process is at step S8. Figure 11 This is a production process flow chart, and the process is at step S91. Figure 12 This is a production process flow chart, and the process is at step S92. Figure 13 This is a production process flow chart, and the process is at step S93. Figure 14 This is a production process flow chart, and the process is at step S94. Figure 15 This is a production process flow chart, and the process is at step S95. In the diagram: 1. Shallow cooling mold upper mold; 2. Shallow cooling mold lower mold; 3. Shallow cooling mold; 4. Deep cooling mold upper mold; 5. Deep cooling mold lower mold; 6. Deep cooling mold; 7. Press; 9. Vertical cylinder; 10. Support plate. Detailed Implementation

[0008] The present invention will be further described in detail below with reference to specific embodiments.

[0009] The manufacturing process of the automotive interior front panel mat of this invention uses a first conveyor belt, which has side-by-side placement positions for rigid cotton felt layers and composite layers. A drying chamber is located outside the discharge end of the first conveyor belt, containing corresponding side-by-side drying positions for the rigid cotton felt layers and composite layers. A second and third conveyor belt are located outside the discharge end of the drying chamber. The inlet end of the second conveyor belt connects to the discharge port of the rigid cotton felt layer drying position, and a shallow cooling mold 3 is located outside the discharge end. The inlet end of the third conveyor belt connects to the composite layer drying position, and a deep cooling mold 6 is located outside the discharge end. A press 7 is located above both the shallow cooling mold 3 and the deep cooling mold 6. Figure 1 As shown, the shallow cooling mold upper die 1 and the deep cooling mold upper die 4 are mounted on the bottom wall of the press 7. Figure 2 As shown, the upper part of the front sidewall of the lower mold 2 of the shallow cold mold is laterally recessed to form a sandwich layer. A vertical cylinder 9 is installed on the bottom wall of the sandwich layer, and a support plate 10 is installed on the upper end of the vertical cylinder 9. Figure 3 As shown, a feeding robot and a discharging robot are provided outside the interlayer to dock with the placement position of the rigid cotton felt layer on the first conveyor belt. The steps of this manufacturing process are described in detail below.

[0010] Step S1 as follows Figure 3As shown, multiple rigid cotton felt layers are arranged along the length of the first conveyor belt and placed in the rigid cotton felt layer placement position, and multiple composite layers are arranged along the length of the conveyor belt and placed in the composite layer placement position. The kth composite layer is aligned left and right with the (k+1)th rigid cotton felt layer, where k is a positive integer.

[0011] Step S2 as follows Figure 4 As shown, the first layer of rigid cotton felt is transported from the placement position to the drying position of the drying chamber by the first conveyor belt. It undergoes a long-term softening process of 60 seconds in the drying chamber. After the long-term softening is complete, it enters the drying chamber... Figure 5 In step S3, the material is conveyed from the drying oven to the lower mold 2 of the shallow cooling mold via the second conveyor belt. The upper mold 1 of the shallow cooling mold, together with the upper mold 4 of the deep cooling mold, is driven downward synchronously by the press 7. The upper mold 1 of the shallow cooling mold heats and presses the first rigid cotton felt layer of the lower mold 2 into shape. The second rigid cotton felt layer is conveyed from the rigid cotton felt layer placement position to the rigid cotton felt layer drying position in the drying oven via the first conveyor belt. The first composite layer is conveyed from the composite layer placement position to the composite layer drying position in the drying oven via the first conveyor belt. Together, they are subjected to a long-term heating and softening process of 60 seconds in the drying oven.

[0012] Step S4 as follows Figure 6 As shown, after the first rigid cotton felt layer is hot-pressed, it remains in the lower mold 2 of the shallow cooling mold to dissipate heat. The upper mold 1 of the shallow cooling mold and the upper mold 4 of the deep cooling mold are driven upwards and reset by the press 7. The third rigid cotton felt layer is delivered from the rigid cotton felt layer placement position to the tray 10 of the interlayer by the feeding robot. The tray 10 is driven upwards by the vertical cylinder 9 to lift the third rigid cotton felt layer to be close to the inner top wall of the interlayer. The third rigid cotton felt layer absorbs the heat dissipated by the first rigid cotton felt layer left in the lower mold 2 of the shallow cooling mold for preheating.

[0013] Step S5 as follows Figure 7 As shown, after the first rigid cotton felt layer has completed heat dissipation in the shallow cooling mold 2, it is transferred by the operator to the deep cooling mold 5.

[0014] Step S6 as follows Figure 8 As shown, after the first composite layer has been softened by baking, it is conveyed from the baking chamber to the lower mold 5 of the cryogenic mold by the third conveyor belt and stacked onto the first rigid cotton felt layer. After the second rigid cotton felt layer has been softened by baking, it is conveyed from the baking chamber to the lower mold 2 of the shallow cryogenic mold by the second conveyor belt. The upper mold 4 of the cryogenic mold and the upper mold 1 of the shallow cryogenic mold are driven by the press 7 to move down synchronously. The upper mold 4 of the cryogenic mold presses the first composite layer onto the first rigid cotton felt layer, while the upper mold 1 of the shallow cryogenic mold heat-presses the second rigid cotton felt layer into shape.

[0015] Step S7 as follows Figure 9 As shown, after the third rigid cotton felt layer completes heat absorption within the interlayer, the pallet 10 is driven to reset by the vertical cylinder 9, causing the third rigid cotton felt layer to move downwards and away from the top wall of the interlayer. The third rigid cotton felt layer is then returned to its original position by the discharge robot, and then enters the... Figure 10 In step S8, the first conveyor belt moves the first composite layer from its original position at the placement location to the drying location of the rigid cotton felt layer in the drying chamber. The second composite layer is then moved from its placement location to the drying location of the drying chamber by the first conveyor belt, and together with the third rigid cotton felt layer, it undergoes a short 40-second drying softening process in the drying chamber.

[0016] Step S9: Repeat steps S91 to S95.

[0017] Step S91 as follows Figure 11 As shown, during the short-term baking of the (k-1)th composite layer (k≥3, the same below) and the kth rigid cotton felt layer in the baking oven for 40 seconds, the (k-1)th rigid cotton felt layer remains in the lower mold 2 of the shallow cooling mold for heat dissipation after hot pressing. The (k+1)th rigid cotton felt layer is delivered from the rigid cotton felt layer placement position to the tray 10 of the interlayer by the feeding robot. The tray 10 is driven by the vertical cylinder 9 to move upward and lift the (k+1)th rigid cotton felt layer to be close to the inner top wall of the interlayer. The (k+1)th rigid cotton felt layer absorbs the heat dissipated by the (k-1)th rigid cotton felt layer in the lower mold 2 of the shallow cooling mold for preheating.

[0018] Step S92 as follows Figure 12 As shown, after the (k-1)th rigid cotton felt layer has completed heat dissipation in the shallow cooling mold 2, it is transferred by the operator to the deep cooling mold 5.

[0019] Step S93 as follows Figure 13 As shown, after the (k-1)th composite layer has been softened by baking, it is conveyed from the baking chamber to the lower mold 5 of the deep cooling mold by the third conveyor belt and stacked onto the (k-1)th rigid cotton felt layer. After the kth rigid cotton felt layer has been softened by baking, it is conveyed from the baking chamber to the lower mold 2 of the shallow cooling mold. The upper mold 4 of the deep cooling mold and the upper mold 1 of the shallow cooling mold are driven by the press 7 to move down synchronously. The upper mold 4 of the deep cooling mold presses the (k-1)th composite layer onto the (k-1)th rigid cotton felt layer, and the upper mold 1 of the shallow cooling mold heat-presses the kth rigid cotton felt layer into shape.

[0020] Step S94 as follows Figure 14 As shown, after the (k+1)th rigid cotton felt layer completes heat absorption within the interlayer, the pallet 10 is driven by the vertical cylinder 9 to reset, causing the (k+1)th rigid cotton felt layer to move downwards and away from the top wall of the interlayer. The (k+1)th rigid cotton felt layer is then returned to its original position by the discharge robot, and then enters the... Figure 15 In step S95, the first conveyor belt moves the rigid cotton felt layer from its original position to the rigid cotton felt layer drying position in the drying chamber, while the kth composite layer is moved from its composite layer position to the composite layer drying position in the drying chamber by the first conveyor belt. Together, they are subjected to a short-term drying and softening process of 40 seconds in the drying chamber.

[0021] The above description is merely an embodiment of the present invention and does not limit the scope of patent protection. Any non-substantial changes or substitutions made by those skilled in the art based on the present invention still fall within the scope of patent protection.

Claims

1. A manufacturing process for an automotive interior front bulkhead mat, comprising a heating chamber, a press, and a first conveyor belt, wherein a shallow cooling mold (3) and a deep cooling mold (6) are provided below the press, the upper mold of the shallow cooling mold (1) and the upper mold of the deep cooling mold (4) are mounted on the bottom wall of the press, the heating chamber is provided with side-by-side heating positions for rigid cotton felt layers and composite layers, and the first conveyor belt is provided with corresponding side-by-side placement positions for rigid cotton felt layers and composite layers, characterized in that: The upper part of the side wall of the lower mold (2) of the shallow cold mold is laterally recessed to form a sandwich layer (11). The bottom wall of the sandwich layer (11) is equipped with a vertical cylinder (9), and the upper end of the vertical cylinder (9) is equipped with a support plate (10). This manufacturing process includes the following steps: S1. Multiple rigid cotton felt layers are arranged along the length of the first conveyor belt and placed in the rigid cotton felt layer placement position. Multiple composite layers are arranged along the length of the conveyor belt and placed in the composite layer placement position. The kth composite layer is aligned left and right with the (k+1)th rigid cotton felt layer. k is a positive integer. S2. The first hard cotton felt layer is sent from the hard cotton felt layer placement position to the hard cotton felt layer drying position in the drying box by the first conveyor belt, and is dried and softened in the drying box for a long time. S3. After the first hard cotton felt layer is softened by baking, it is sent from the baking oven to the lower mold of the shallow cooling mold (2). The upper mold of the shallow cooling mold (1) and the upper mold of the deep cooling mold (4) are driven by the press (7) to move down synchronously. The upper mold of the shallow cooling mold (1) heat-presses the first hard cotton felt layer of the lower mold of the shallow cooling mold (2) into shape. The second hard cotton felt layer is sent from the hard cotton felt layer placement position to the hard cotton felt layer baking position of the baking oven by the first conveyor belt. The first composite layer is sent from the composite layer placement position to the composite layer baking position of the baking oven by the first conveyor belt. They are all simultaneously baked and softened by the baking oven for a long time. S4. After the first hard cotton felt layer is hot-pressed, it remains in the lower mold (2) of the shallow cold mold to dissipate heat. The third hard cotton felt layer is sent from the hard cotton felt layer placement position to the tray (10) of the interlayer (11). The tray (10) is driven by the vertical cylinder (9) to lift the third hard cotton felt layer to the inner top wall of the interlayer. The third hard cotton felt layer absorbs the heat dissipated by the first hard cotton felt layer remaining in the lower mold (2) of the shallow cold mold. S5. After the first hard cotton felt layer has completed heat dissipation in the shallow cold mold lower mold (2), it is transferred to the deep cold mold lower mold (5). S6. After the first composite layer is softened by baking, it is sent from the baking oven to the lower mold of the deep cold mold (5) and stacked on the first hard cotton felt layer. After the second hard cotton felt layer is softened by baking, it is sent from the baking oven to the lower mold of the shallow cold mold (2). The upper mold of the deep cold mold (4) and the upper mold of the shallow cold mold (1) are driven by the press (7) to move down synchronously. The upper mold of the deep cold mold (4) presses the first composite layer onto the first hard cotton felt layer, and the upper mold of the shallow cold mold (1) hot-presses the second hard cotton felt layer. S7. After the third hard cotton felt layer completes heat absorption in the interlayer (11), the tray (10) is driven by the vertical cylinder (9) to reset and move the third hard cotton felt layer down away from the top wall of the interlayer; the third hard cotton felt layer is sent to the original position of the hard cotton felt layer placement position. S8. The third hard cotton felt layer is sent from the original position of the hard cotton felt layer placement position to the hard cotton felt layer drying position of the drying box by the first conveyor belt, and the second composite layer is sent from the composite layer placement position to the composite layer drying position of the drying box by the first conveyor belt, and together they are dried and softened in the drying box for a short time. S9. Repeat the following steps S91~S95. S91. During the short-term baking of the k-1th composite layer (k≥3, the same below) and the kth hard cotton felt layer in the baking oven, the k-1th hard cotton felt layer is left in the lower mold (2) of the shallow cold mold after hot pressing to dissipate heat; the k+1th hard cotton felt layer is sent from the hard cotton felt layer placement position to the tray (10) of the interlayer. The tray (10) is driven by the vertical cylinder (9) to move upward to lift the k+1th hard cotton felt layer to be close to the inner top wall of the interlayer. The k+1th hard cotton felt layer absorbs the heat dissipated by the k-1th hard cotton felt layer in the lower mold (2) of the shallow cold mold. S92. After the (k-1)th hard cotton felt layer has completed heat dissipation in the shallow cold mold lower mold (2), it is transferred to the deep cold mold lower mold (5). S93. After the (k-1)th composite layer is softened by baking, it is sent from the baking oven to the lower mold of the deep cold mold (5) and stacked on the (k-1)th hard cotton felt layer. After the (k)th hard cotton felt layer is softened by baking, it is sent from the baking oven to the lower mold of the shallow cold mold (2). The upper mold of the deep cold mold (4) and the upper mold of the shallow cold mold (1) are driven by the press (7) to move down synchronously. The upper mold of the deep cold mold (4) presses the (k-1)th composite layer onto the (k-1)th hard cotton felt layer, and the upper mold of the shallow cold mold (1) hot-presses the (k)th hard cotton felt layer. S94. After the (k+1)th hard cotton felt layer completes heat absorption in the interlayer (11), the tray (10) is driven by the vertical cylinder (9) to reset and move the (k+1)th hard cotton felt layer down away from the top wall of the interlayer; the (k+1)th hard cotton felt layer is sent to the original position of the hard cotton felt layer placement position. S95. The (k+1)th rigid cotton felt layer is transported from its original position to the rigid cotton felt layer drying position in the drying chamber by the first conveyor belt, while the kth composite layer is transported from its composite layer position to the composite layer drying position in the drying chamber by the first conveyor belt, and together they are dried and softened in the drying chamber for a short time.

2. The manufacturing process of an automotive interior front bulkhead mat as described in claim 1, characterized in that: The long-term baking and softening time is 60 seconds, and the short-term baking and softening time is 40 seconds.

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