Shaping processing device for air fiber automobile interior trim part buffer material product

Abstract

The utility model discloses a shaping processing device for an air fiber automobile interior trim part buffer material product. The shaping processing device comprises a shaping plate, a shaping sleeve, a stamping and cutting device and a hot die forming device, wherein the shaping plate is arranged between the die head and the spinneret plate, a hollowed-out area profiling a projection outline B is machined in the middle of the shaping plate, and the projection outline B is a relatively complex projection outline perpendicular to the direction of the maximum visual surface A of the buffer material product; the shaping sleeve is arranged under the spinneret plate, the shape of the cross section of the shaping sleeve is similar to that of a hollow area on the shaping plate, and the profile of the shape of a cutting die of the stamping and cutting device is similar to the profile of the projection of the buffer material product in the direction of the maximum visual surface A; and the hot die forming device is used for carrying out die forming on the final product on the maximum visual surface A of the product in the direction perpendicular to the maximum visual surface A. The product prepared by the device meets the requirements of various seats with complicated structures and shapes on the structure, the shape outline and the surface quality of the air fiber material buffer material product.

Description

Technical Field

[0001] The invention belongs to the technical field of automobile interior decoration parts, relates to the processing of automobile interior decoration parts, and specifically relates to a shaping processing device for air fiber automobile interior decoration part cushioning material products. Background Art

[0002] Currently, the cushioning material of automobile seats is still mainly molded polyurethane foam material made by RIM process. The polyurethane foam material is generally a dense thermosetting cross-linked structure. This material is difficult to recycle and the material itself has poor air permeability.

[0003] As the automotive industry pays more and more attention to low-carbon emission reduction and recyclability of automotive products, the material selection in automotive design is increasingly inclined towards the concepts of lightweight, green, recyclable and renewable. At present, domestic automobile OEMs and parts manufacturers are investing in relevant technical research to find corresponding material alternatives.

[0004] Air fiber materials have the advantages of green recyclability, low density, low odor, and high resilience. At present, R&D personnel are studying the use of air fiber materials to replace polyurethane thermosetting buffer layer materials in automotive interior products to improve the environmental protection and recyclability of interior products and vehicles. However, there is no marketable product for the overall application of this technology in automotive seats. The main reason is that the design of the buffer layer structure in automotive seat products needs to consider the appearance after combining with the protective surface on the one hand, and the interface matching with the seat frame and other massage and ventilation structures on the other hand. The relatively complex structure and shape limit the application of air fiber materials. For example, the A-side structure of the buffer layer material structure of the automotive seat is the visible surface of the seat, which needs to meet the requirements of the shape structure, the connection interface structure requirements of massage, ventilation, heating pads, SBR and other components, and the connection structure requirements of the skin; at the same time, there are high requirements for the smoothness and flatness of the A-side plane, which directly affects the appearance quality and comfort of the seat product. The B-side of the buffer layer material structure of the automotive seat is a non-visible surface, which is required to match the seat frame profile and has a certain fixed limit structure. In addition, the buffer layer structure material itself should also maintain excellent buffering performance. However, for the three-dimensional disordered overlapping spinneret structure of air fiber materials, the cross section after cutting will produce sharp protrusions of the vertical cross section and irregular uneven cross sections, which cannot ensure the smoothness of the air fiber material cutting interface; and directly cutting the contour of the buffer material product on the sheet air fiber material and then molding it will seriously affect the material properties of the final air fiber buffer material product, and excessive compression will seriously reduce the rebound performance and comfort of the air fiber product; furthermore, the multi-hardness design of different parts of the product cannot be actively adjusted according to the design requirements, so the development of air fiber material buffer material products that meet the complex structure, shape contour and buffering performance requirements of automobile seats has become a key technical bottleneck for the successful application of this technology.

[0005] The existing patent CN 118266716 A discloses "A multi-layer comfortable air fiber structure and preparation method and the prepared cushion, backrest and seat", which specifically discloses a seat cushion product structure, using air fiber material to replace polyurethane cushion material, and improving the comfort of the cushion and back cushion layers through the mechanical connection structure of the comfort upper layer and the support lower layer. However, there is no disclosure on how to achieve a complex shape structure and a smooth surface forming method, and there is no clear method for cutting cross-section processing and complex structure shape problems, so it is impossible to investigate whether the forming requirements of air fiber material automotive seat cushion material products have been solved; in addition, the mechanical connection method of the comfort upper layer and the support lower layer in the multi-layer comfortable air fiber structure provided by it will produce abnormal noise at the connection interface of the two structures, affecting the comfort of the seat product. Summary of the invention

[0006] In view of the above-mentioned technical problems and shortcomings, the purpose of the present invention is to provide a shaping processing device for air fiber automobile interior cushioning material products, to ensure that the performance of the air fiber material is not lost due to mold compression during the forming process of the air fiber product, while meeting the requirements of various types of seats with complex structures and shapes for the structure, shape profile and surface quality of air fiber material cushioning material products, and solving the forming requirements of air fiber material automobile seat cushioning material products; in addition, it can also adjust the hardness of the product through the design of the spinning profile and the forming profile in the forming stage and the design of the solid and / or hollow layout of the spinneret, to achieve one-piece forming, and avoid the abnormal noise problem caused by the mechanical connection of the comfort upper layer and the support lower layer described in the existing patent CN 118266716 A.

[0007] To achieve the above object, the present invention adopts the following technical solution:

[0008] A shaping processing device for air fiber automobile interior parts cushioning material products, the shaping processing device comprises a shaping plate, a shaping sleeve, a stamping and cutting device, and a hot molding device; wherein the shaping plate is arranged between a die head and a spinneret, the shaping plate is fixedly connected to the spinneret, a hollow area in the middle of the shaping plate is processed to imitate a projection profile B, and the projection profile B is a relatively complex projection profile perpendicular to the maximum visible surface A of the cushioning material product; the shaping sleeve is arranged in a cooling and molding device, the shaping sleeve is arranged directly below the spinneret, and the cross-sectional shape of the shaping sleeve is consistent with that on the shaping plate The hollow area is profiled, and the air fiber filaments ejected from the spinneret flow into the shaping sleeve with a set cross-sectional shape at the lower end for cross-entanglement and cooling and accumulation forming according to the set cross-sectional shape; the punching and cutting device is used to perform secondary cutting and forming on the air fiber product initially formed in the shaping sleeve, and the shape contour of the cutting die of the punching and cutting device is profiled with the projection contour of the cushioning material product in the direction of the maximum visible surface A; the hot molding device is used to perform molding and shaping of the final product on the maximum visible surface A of the product along the direction perpendicular to the maximum visible surface A according to the structure and contour of the final cushioning material product.

[0009] As a preferred embodiment of the present invention, the shaping processing device also includes a screw extruder and a drainage device; wherein the screw extruder and the die head are used for polymer melting, the cooling and forming device is arranged close to the screw extruder, and is used for cooling the air fiber filaments ejected from the spinneret; the drainage device is arranged close to the cooling and forming device, and is used for draining the moisture in the air fiber cushioning material product preliminarily formed in the shaping sleeve; the stamping and cutting device is arranged close to the drainage device; the hot molding device is arranged close to the stamping and cutting device.

[0010] As a preferred embodiment of the present invention, the shaping processing device also includes a traction device, which is used to traction and convey the initially formed air fiber cushioning material product in the shaping sleeve to the drainage device, and to traction and convey the initially formed air fiber cushioning material product drained of water in the drainage device to the punching and cutting device area.

[0011] As a preferred embodiment of the present invention, the shaping plate is a hollow metal plate, which is tightly connected to the spinneret and fixed between the die head and the spinneret by bolts. The periphery of the shaping plate is used to block part of the spinneret holes of the spinneret to achieve the effect of spinning according to a fixed contour, thereby cooperating with the shaping sleeve to obtain the expected cross-sectional contour of the air fiber.

[0012] As a preferred embodiment of the present invention, the spinneret holes on the spinneret plate are through holes or semi-through holes or a combination of through holes and semi-through holes arranged in a set manner; wherein the through holes are used to spray out solid air fiber filaments, and the semi-through holes are used to spray out hollow air fiber filaments.

[0013] As a preferred embodiment of the present invention, the cooling and forming device includes a cooling water tank and a cooling pool, the forming sleeve is arranged in the cooling pool, and the cooling water tank is used to provide cold water for the cooling pool.

[0014] As a preferred embodiment of the present invention, the driving mechanism of the punching and cutting device is pneumatically driven, electrically driven, hydraulically driven or a combination of any two; and the cutting die is installed and fixed in a detachable manner.

[0015] Advantages and beneficial effects of the present invention:

[0016] (1) The present invention has three forming stages in the preparation of the cushioning material product, and the forming section selection in each stage is particular. In the forming stage of the shaping sleeve (forming stage 1), the shaping plate cooperates with the shaping sleeve to form a specified contour on a plane perpendicular to the traction direction, and the contour section is similar to a more complex projection contour of the cushioning material product in the direction perpendicular to the maximum visible surface; the punching and cutting device cutting and forming (forming stage 2) uses the punching and cutting device to cut the specified contour in the traction direction, and the punching and cutting contour is similar to the projection contour of the product in the direction of the maximum visible surface; the die forming stage (forming stage 3) uses the die forming device according to The final product structure and contour are molded on the maximum visible surface of the product in a direction perpendicular to the maximum visible surface; forming stages 1 and 2 can ensure the smooth surface of the maximum visible surface of the cushioning material product, and at the same time prepare a rough blank contour for the hot molding of forming stage 3. The molding method of forming stage 3 can control the core area of ​​the rough blank to not be molded or to be molded with a compression rate of less than 40%, thereby ensuring the comfort of the core area of ​​the final product and avoiding structural changes caused by air fiber molding and resulting in performance loss, thereby preparing air fiber material cushioning material products that meet the complex structure, shape contour and cushioning performance requirements of automobile seats.

[0017] (2) The present invention can realize the synchronous extrusion of hollow fibers and / or solid fibers by setting the structure and arrangement of the spinneret holes on the spinneret, and it is convenient to adjust the hardness of the product according to the layout of the hollow and / or solid air fibers to achieve one-piece forming without the need for subsequent mechanical connection, thereby avoiding abnormal noise. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0019] Figure 1 is a schematic diagram of a shaping processing device of the present invention;

[0020] Figure 2 It is a schematic diagram of the connection between the shaping plate and the spinneret of the present invention;

[0021] Figure 3 This is a schematic diagram of the installation position of the shaping plate and the shaping sleeve of the present invention;

[0022] Figure 4 A schematic diagram of a spinneret hole on a spinneret of the present invention;

[0023] Figure 5 It is a schematic diagram of the forming process of the seat cushion cushioning material product of the present invention;

[0024] Figure 6 It is a schematic diagram of the forming process of the backrest cushioning material product of the present invention;

[0025] Figure 7 It is a schematic diagram of the forming process of the leg support cushioning material product of the present invention.

[0026] Figure numerals: screw extruder 1, shaping plate 2, spinneret 3, cooling and forming device 4, shaping sleeve 5, draining device 6, punching and cutting device 7, hot molding device 8, hollow area 201, spinneret hole 301, cooling water tank 401, cooling pool 402, through hole 3011, semi-through hole 3012. DETAILED DESCRIPTION

[0027] The following will be combined with the drawings in the embodiments of the present application to clearly and completely describe the technical solutions in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this application.

[0028] In the description of the present application, it should be noted that the terms "upper", "lower", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, or are the orientations or positional relationships in which the product of the application is usually placed when in use. They are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present application.

[0029] In the description of this application, it should also be noted that, unless otherwise clearly specified and limited, the terms "disposed" and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection, a direct connection, or an indirect connection through an intermediate medium, or it can be the internal communication of two elements. For ordinary technicians in this field, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0030] Example 1

[0031] like Figures 1 to 4 As shown, this embodiment also provides a shaping processing device for air fiber automotive interior cushioning material products, the shaping processing device includes a screw extruder 1, a shaping plate 2, a cooling and forming device 4, a shaping sleeve 5, a draining device 6, a punching and cutting device 7, and a hot molding device 8; wherein the screw extruder 1 and the die head are used to melt the polymer,

[0032] The shaping plate 2 is arranged between the die head and the spinneret 3, the shaping plate 2 is fixedly connected to the spinneret 3, and a hollow area 201 which is shaped like a projection profile B is processed in the middle of the shaping plate 2, and the projection profile B is a relatively complex projection profile perpendicular to the maximum visible surface A of the cushioning material product;

[0033] The cooling and forming device 4 is arranged close to the screw extruder 1 and is used to cool the air fiber filaments ejected from the spinneret 3;

[0034] The shaping sleeve 5 is arranged in the cooling and forming device 4, and the shaping sleeve 5 is arranged directly below the spinneret 3. The cross-sectional shape of the shaping sleeve 5 is similar to the hollow area 201 on the shaping plate 2. The air fiber filaments ejected from the spinneret 3 flow into the shaping sleeve 5 with the set cross-sectional shape at the lower end according to the set cross-sectional shape to be cross-entangled and cooled and deposited.

[0035] The draining device 6 is arranged near the cooling and forming device 4 and is used to drain the water in the air fiber cushioning material product initially formed in the shaping sleeve 5;

[0036] The punching and cutting device 7 is arranged near the draining device 6, and is used to perform secondary cutting and forming on the air-fiber product initially formed in the shaping sleeve 5. The cutting die shape profile of the punching and cutting device 7 is similar to the projection profile of the cushioning material product in the direction of the maximum visible surface A.

[0037] The hot molding device 8 is arranged close to the punching and cutting device 7, and is used for molding and shaping the final product on the maximum visible surface A of the product along the direction perpendicular to the maximum visible surface A according to the structure and contour of the final cushioning material product.

[0038] Furthermore, in this embodiment, the shaping processing device also includes a traction device (not shown), which is used to pull and transport the initially formed air fiber cushioning material product in the shaping sleeve 5 to the draining device 6, and to pull and transport the initially formed air fiber cushioning material product drained from the draining device 6 to the stamping and cutting device 7 area.

[0039] In this embodiment, the shaping plate 2 is a hollow metal plate, which is tightly connected to the spinneret 3 and fixed between the die head and the spinneret 3 by bolts. The periphery of the shaping plate 2 is used to block part of the spinneret holes 301 of the spinneret 3 to achieve the effect of spinning according to a fixed contour, thereby cooperating with the shaping sleeve 5 to obtain the expected cross-sectional contour of the air fiber; the spinneret holes 301 on the spinneret 3 are through holes 3011 or semi-through holes 3012 or through holes and semi-through holes are arranged and combined in a set manner; wherein the through holes 3011 are used to spray out solid air fiber filaments, and the semi-through holes 3012 are used to spray out hollow air fiber filaments.

[0040] In this embodiment, the cooling and forming device 4 includes a cooling water tank 401 and a cooling pool 402 . The forming sleeve 5 is arranged in the cooling pool 402 . The cooling water tank 401 is used to provide cold water for the cooling pool 402 .

[0041] In this embodiment, the driving mechanism of the punching and cutting device 7 is pneumatically driven, electrically driven, hydraulically driven or any combination of the two; and the cutting die is installed and fixed in a detachable manner and can be replaced.

[0042] It should be noted that the screw extruder 1, cooling and forming device 4, drainage device 6, stamping and cutting device 7, and hot molding device 8 in the shaping processing device provided in this application can all adopt existing equipment, and this application does not impose any limitation on the specific structure of the above-mentioned equipment.

[0043] Example 2

[0044] This embodiment provides a shaping method for an air fiber automotive interior cushioning material product, the method using the above-mentioned shaping device, the method comprising the following steps:

[0045] Step 1. Determine the maximum visible surface A of the cushioning material product and a relatively complex projection profile B perpendicular to the maximum visible surface A;

[0046] Step 2. A shaping plate is arranged between the die head and the spinneret, the shaping plate is fixedly connected to the spinneret, and a hollow area in the middle of the shaping plate is processed to imitate the projection contour B. The air fiber material is polymer melted through a screw extruder and a die head, and the molten air fiber material is melted and spun according to a set cross-sectional shape through the shaping plate and the spinneret; the spinneret holes on the spinneret are through holes or semi-through holes or through holes and semi-through holes are arranged and combined in a set manner; wherein the through holes are used to spray out solid air fiber filaments, and the semi-through holes are used to spray out hollow air fiber filaments.

[0047] Step 3. A shaping sleeve is arranged in the cooling and forming device. The shaping sleeve is arranged directly below the spinneret. The cross-sectional shape of the shaping sleeve is in line with the hollow area on the shaping plate. The air fiber filaments ejected from the spinneret flow into the shaping sleeve with a set cross-sectional shape at the lower end according to the set cross-sectional shape to be cross-entangled and cooled and accumulated to form. The air fiber cushioning material product initially formed in the shaping sleeve is continuously produced under the action of the traction device in a direction perpendicular to the cross-sectional direction of the shaping sleeve;

[0048] Step 4. Drain the water in the initially formed air fiber cushion material product through a draining device, and use a traction device to pull the initially formed air fiber cushion material product to the punching and cutting device area for secondary cutting and forming;

[0049] Step 5. The air fiber cushioning material product initially formed in the shaping sleeve is subjected to secondary cutting and shaping by using a punching and cutting device; wherein the cutting die shape profile of the punching and cutting device is contoured with the projection profile of the cushioning material product in the direction of the maximum visible surface A;

[0050] Step 6. The final air fiber cushioning material product is molded and shaped by a hot molding device. Before molding and shaping, inserts (inserts include steel wires, bayonet, etc.) are embedded in the rough blank formed by secondary cutting, and the final product is molded and shaped on the maximum visible surface A of the product in a direction perpendicular to the maximum visible surface A according to the structure and contour of the final cushioning material product. At the same time, the core area of ​​the cushioning material product is not molded or is molded with a compression rate of less than 40%. After molding and shaping, the edge hardened area is modified to obtain the final air fiber cushioning material product.

[0051] Further, in this embodiment, the hot molding device described in step 6 includes a mold body, a liquid heating pool, and a liquid cooling pool; wherein, the mold body includes an upper mold and a lower mold, and the cylinder controls the upper mold and the lower mold to separate and close. After the upper mold and the lower mold are closed, the mold body is controlled by the cylinder to fall into the liquid heating pool for secondary heating and shaping (the shaping time can be set by countdown control, and the heating method of the liquid heating pool is resistance heating, with temperature display function and controllable temperature). After the heating and shaping is completed, the mold body enters the liquid cooling pool in a closed state for cooling (the cooling time can be set by countdown control, and the liquid cooling pool has a temperature display function and controllable temperature), then drains the water, opens the upper and lower molds, and takes out the air fiber cushioning material formed product after the molding is completed.

[0052] This embodiment uses the above method to prepare seat cushion cushioning material products, back cushioning material products, and leg support cushioning material products, wherein the specific forming process of the seat cushion cushioning material product is shown in the figure. Figure 5 As shown, the specific forming process diagram of the backrest cushioning material product is as follows Figure 6 As shown, the specific forming process diagram of the leg support cushioning material product is as follows Figure 7 As shown, Figures 5 to 7 In the figure, the first figure is a schematic diagram of the product in the forming stage of the finalizing sleeve (forming stage 1), the second figure is a schematic diagram of the product in the cutting forming stage of the punching and cutting device (forming stage 2), and the third figure is a schematic diagram of the product in the compression molding stage (forming stage 3). Through the three forming stages and the special design of the forming section in each stage, it is ensured that the air fiber material cushioning material product that meets the complex structure, shape contour and cushioning performance requirements of the automobile seat is prepared.

[0053] The above are specific embodiments of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art who is familiar with the technical field can easily think of changes or substitutions within the technical scope disclosed by the present invention, which should be included in the protection scope of the present invention. Therefore, the protection scope of the present invention should be based on the protection scope of the claims.

Claims

1. A shaping processing device for air fiber automotive interior cushioning material products, characterized in that: The shaping processing device comprises a shaping plate, a shaping sleeve, a punching and cutting device, and a hot molding device; wherein the shaping plate is arranged between the die head and the spinneret, the shaping plate is fixedly connected to the spinneret, and a hollow area in the middle of the shaping plate is processed to imitate the projection profile B, and the projection profile B is a relatively complex projection profile perpendicular to the maximum visible surface A of the cushioning material product; the shaping sleeve is arranged in the cooling and molding device, the shaping sleeve is arranged directly below the spinneret, the cross-sectional shape of the shaping sleeve imitates the hollow area on the shaping plate, and the spinneret sprays out The air fiber filaments flow into a shaping sleeve with a set cross-sectional shape at the lower end according to a set cross-sectional shape to be cross-entangled and cooled and stacked to form; the punching and cutting device is used to perform secondary cutting and forming on the air fiber product initially formed in the shaping sleeve, and the shape contour of the cutting knife die of the punching and cutting device is similar to the projection contour of the cushioning material product in the direction of the maximum visible surface A; the hot molding device is used to perform molding and shaping of the final product on the maximum visible surface A of the product along the direction perpendicular to the maximum visible surface A according to the structure and contour of the final cushioning material product.

2. The shaping processing device of the air fiber automobile interior decoration cushioning material product according to claim 1 is characterized in that: The shaping processing device also includes a screw extruder and a drainage device; wherein the screw extruder and the die head are used for polymer melting, the cooling and forming device is arranged close to the screw extruder, and is used for cooling the air fiber filaments ejected from the spinneret; the drainage device is arranged close to the cooling and forming device, and is used for draining the moisture in the air fiber cushioning material product initially formed in the shaping sleeve; the stamping and cutting device is arranged close to the drainage device; the hot molding device is arranged close to the stamping and cutting device.

3. The shaping processing device of the air fiber automobile interior decoration cushioning material product according to claim 1 is characterized in that: The shaping processing device also includes a traction device, which is used to traction and convey the initially formed air fiber cushioning material product in the shaping sleeve to the drainage device, and to traction and convey the initially formed air fiber cushioning material product drained of water in the drainage device to the punching and cutting device area.

4. A shaping processing device for air fiber automotive interior cushioning material products according to claim 1, 2 or 3, characterized in that: The shaping plate is a hollow metal plate, which is tightly connected to the spinneret and fixed between the die head and the spinneret by bolts.

5. A shaping processing device for air fiber automotive interior cushioning material products according to claim 1, 2 or 3, characterized in that: The spinneret holes on the spinneret plate are through holes or semi-through holes or a combination of through holes and semi-through holes arranged in a set manner; wherein the through holes are used to spray out solid air fiber filaments, and the semi-through holes are used to spray out hollow air fiber filaments.

6. A shaping processing device for air fiber automotive interior cushioning material products according to claim 1, 2 or 3, characterized in that: The cooling and forming device comprises a cooling water tank and a cooling pool. The forming sleeve is arranged in the cooling pool. The cooling water tank is used to provide cold water for the cooling pool.

7. A shaping processing device for air fiber automotive interior cushioning material products according to claim 1, 2 or 3, characterized in that: The driving mechanism of the punching and cutting device is pneumatically driven, electrically driven, hydraulically driven or a combination of the two; and the cutting die is installed and fixed in a detachable manner.

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