A molding die for an automobile roof

Abstract

This invention provides a molding die for an automotive roof, comprising a fixed mold, a moving mold, a middle mold, and an injection molding system. The fixed mold has a first molding groove and an injection rib groove, with shearing surfaces at its edges. The moving mold has a second molding groove and punching surfaces at its edges. The middle mold is located between the fixed and moving molds, and is provided with shearing blades matching the shearing surfaces and sharp blades matching the punching surfaces at intervals. The injection molding system connects to the injection rib grooves. During mold closing, the first and second molding grooves form a composite cavity to complete the composite molding of the substrate and the fabric, as well as the injection molding of the ribs. Simultaneously, the moving mold pushes the middle mold to move, the sharp blades and punching surfaces cooperate to punch the edges of the fabric, and the shearing blades and shearing surfaces cooperate to cut the edges of the substrate. This invention integrates molding, injection, composite molding, and cutting processes into a single mold, significantly reducing mold switching, improving production efficiency and cutting accuracy, and lowering production costs.

Description

Technical Field

[0001] This utility model relates to the field of automotive roof processing technology, and more specifically, to a molding die for automotive roofs. Background Technology

[0002] In the automotive headliner manufacturing industry, molding, injection molding, lamination, and cutting are the core manufacturing methods. Molding uses a mold to apply pressure and shape the material, giving the headliner its design. Injection molding uses high temperature and pressure to inject plastic into a mold cavity, molding ribs onto the back of the headliner substrate. Lamination bonds the headliner substrate and fabric together, enhancing both functionality and aesthetics. Cutting is used for precise cutting to ensure dimensions meet edge requirements, specifically that the fabric edge extends 15±0.5mm beyond the substrate edge. However, currently, these processes use separate molds for production.

[0003] With the ever-increasing demand for automotive headliners in the automotive market, headliner production has resulted in extremely cumbersome mold changeover operations. Each mold changeover not only consumes a significant amount of time for disassembly, installation, and debugging, but is also prone to errors during operation, leading to fluctuations in product quality. The wasted production time caused by mold changeovers reduces overall production efficiency. Furthermore, since each process relies on an independent mold, companies need to invest heavily in mold development and maintenance, significantly increasing production costs. Therefore, there is an urgent need for a new technological solution that can optimize the automotive headliner processing flow, reduce the number of mold changeovers, improve production quality and efficiency, and reduce costs. Utility Model Content

[0004] To overcome the shortcomings of the prior art, this application provides a molding die for an automobile roof that improves production efficiency and allows for cutting dimensions that meet edge-wrapping requirements.

[0005] This application provides a molding die for an automotive roof, comprising: a fixed mold having a first molding groove for molding a substrate, the first molding groove having a plurality of injection molding rib grooves on its wall, and the edge of the first molding groove having a shearing surface; a movable mold having a second molding groove for molding a fabric, the edge of the second molding groove having a punching surface; a middle mold being movable between the fixed mold and the movable mold along the moving direction of the movable mold, the middle mold having shearing blades matching the shearing surface and sharp blades matching the punching surface spaced apart; and an injection molding system having its injection outlet end connected to the injection molding rib grooves; wherein, when the movable mold moves toward the fixed mold to close, the first molding groove and the second molding groove together form a composite cavity, the composite cavity being used for the composite molding of the substrate and the fabric; simultaneously, the movable mold pushes the middle mold toward the fixed mold, the sharp blades cooperating with the punching surface to punch the edge of the fabric, and the shearing blades cooperating with the shearing surface to cut the edge of the substrate.

[0006] Compared with existing technologies, the molding die for an automotive roof disclosed in this application has the following advantages: it integrates molding, injection, lamination, and cutting processes into a single die, avoiding the need for switching between traditional independent dies, reducing disassembly, installation, and debugging time, and improving production efficiency; the composite cavity ensures precise lamination of the substrate and fabric, and the shearing surface, punching surface, and die blade of the middle die cooperate to simultaneously complete edge cutting, ensuring that the edge of the fabric is longer than the edge binding requirement of the substrate, and reducing dimensional errors; it reduces the number of dies and lowers development and maintenance costs.

[0007] In one possible implementation, the distance between the pointed blade and the shearing blade is 14.5-15.5 mm. Compared with the prior art, this distance matches the requirement that the edge of the fabric is 15±0.5 mm longer than the edge of the substrate for hemming, ensuring that the dimensions after cutting meet the process standards, avoiding poor hemming due to interval errors, and improving the product qualification rate.

[0008] In one possible implementation, the blade tip has a triangular cross-section with a cutting edge angle of 25-30 degrees and a rounded tip radius of 0.1-0.3 mm. Compared with existing technologies, the triangular cross-section and specific angle enhance the blade's sharpness, reduce cutting resistance, and result in a smoother fabric edge cut. The rounded tip design prevents the blade from being too sharp, thus avoiding fabric tearing, improving cut quality, and extending the blade's lifespan.

[0009] In one possible implementation, a mold fixing frame is also included, with the fixed mold fixed on the mold fixing frame, and a moving guide structure provided between the moving mold and the fixed mold. Compared with the prior art, the fixing frame and the guide structure ensure the stability and positioning accuracy of the moving mold during movement, avoid deformation of the composite cavity caused by mold closing deviation, ensure the consistency of the composite molding of the substrate and the fabric, and reduce the product defect rate.

[0010] In one possible implementation, a movable structure is also included, comprising a slide rail and a slide block. The slide rail is fixed to the mold mounting frame, and the slide block is slidably disposed on the slide rail. The sliding direction of the slide block is the same as the moving direction of the moving mold, and the intermediate mold is mounted on the slide block. Compared with the prior art, the slide block slides along the slide rail, allowing the intermediate mold to adjust its position synchronously with the moving mold, ensuring precise alignment of the shearing blade with the shearing surface and the sharp blade with the punching surface during mold closing, thus improving the reliability of the cutting process.

[0011] In one possible implementation, the intermediate mold is mounted on a slide block via a push cylinder. The cylinder seat of the push cylinder is fixed to the slide block, and the telescopic rod of the push cylinder is connected to the intermediate mold. The extension and retraction direction of the telescopic rod is perpendicular to the sliding direction of the slide block. Compared with the prior art, the push cylinder can independently drive the intermediate mold to move in a direction perpendicular to the sliding of the slide block, enabling fine-tuning of the intermediate mold during mold closing, ensuring precise matching of the position and force of the shearing action, and improving process controllability.

[0012] In one possible implementation, the slide block is provided with a groove, the extension direction of which is the same as the extension direction of the telescopic rod, and the intermediate mold is provided with a slider that slides and matches the groove. Compared with the prior art, the cooperation between the slider and the groove provides guidance for the intermediate mold, preventing the intermediate mold from shifting when the cylinder is driven, ensuring that the shearing blade and the sharp blade remain stable during the cutting process, and improving cutting accuracy and consistency. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the mold assembly for this application;

[0014] Figure 2 for Figure 1 Enlarged view of point A;

[0015] Figure 3 This is an explosion diagram of this application;

[0016] Figure 4 This is a schematic diagram of the fixed mold structure;

[0017] Figure 5 This is a schematic diagram of the moving mold structure;

[0018] Figure 6 A schematic diagram of the structure for installing the intermediate mold;

[0019] Figure 7 This is a schematic diagram of the intermediate mold structure;

[0020] Explanation of reference numerals in the attached figures:

[0021] 1. Fixed mold; 11. First molding groove; 12. Shearing surface; 13. Injection rib groove; 2. Moving mold; 21. Second molding groove; 22. Punching surface; 3. Middle mold; 31. Pointed blade; 32. Shearing blade; 33. Slider; 4. Push cylinder; 5. Slide block; 51. Slide groove; 10. Top cover; 101. Base material; 102. Fabric. Detailed Implementation

[0022] First, those skilled in the art should understand that these embodiments are merely used to explain the technical principles of the embodiments of this application and are not intended to limit the scope of protection of the embodiments of this application. Those skilled in the art can make adjustments as needed to adapt to specific application scenarios.

[0023] In the description of the embodiments of this application, it should be noted that, unless otherwise explicitly specified and limited, the terms "connected" and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of this application based on the specific circumstances.

[0024] In the embodiments of this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0025] The present application will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0026] See Figures 1 to 7 This application discloses a molding die for an automobile roof, comprising: a fixed mold 1, a moving mold 2, a middle mold 3, and an injection molding system; the fixed mold 1 is provided with a first molding groove 11 for molding a substrate 101, the groove wall of the first molding groove 11 is provided with a plurality of injection molding rib grooves 13, and the edge of the first molding groove 11 is provided with a shearing surface 12; the moving mold 2 is provided with a second molding groove 21 for molding a fabric 102, and the edge of the second molding groove 21 is provided with a punching surface 22; the middle mold 3 is movable and disposed between the fixed mold 1 and the moving mold 2 along the moving direction of the moving mold 2, and the middle mold 3 is provided with a shearing surface 12. The system is equipped with a shearing blade 32 with a matching shearing surface 12 and a sharp blade 31 with a matching punching surface 22. The injection outlet of the injection molding system is connected to the injection molding rib groove 13. When the moving mold 2 moves toward the fixed mold 1 to close the mold, the first molding groove 11 and the second molding groove 21 together form a composite cavity, which is used for the composite molding of the substrate 101 and the fabric 102. At the same time, the moving mold 2 pushes the middle mold 3 to move toward the fixed mold 1, and the sharp blade 31 cooperates with the punching surface 22 to punch the edge of the fabric 102, and the shearing blade 32 cooperates with the shearing surface 12 to cut the edge of the substrate 101.

[0027] Among them, the fixed mold 1 serves as the fixed base of the mold, and its first forming groove 11 is made with high-precision CNC machining technology to ensure the accuracy of the forming of the substrate 101. Several injection rib grooves 13 are opened on the groove wall of the first forming groove 11. The shape, size and distribution of these grooves are designed according to the mechanical properties and structural strength required by the substrate 101 of the car roof 10. The injection rib grooves 13 are connected to the injection outlet end of the injection system through a sealed pipe to ensure that the plastic melt can be injected into the groove stably and efficiently during the injection process. The shearing surface 12 is set on the edge of the first forming groove 11. The extension direction of the shearing surface 12 is the same as the movement direction of the middle mold 3. It is finely ground and the surface roughness is controlled at a low level to ensure the flatness and accuracy when shearing the edge of the substrate 101. The moving mold 2 moves toward the fixed mold 1 via a hydraulic drive system. The second forming groove 21 is also CNC machined, and its shape matches the forming requirements of the fabric 102 of the car roof 10. A punching surface 22 is provided on the edge of the second forming groove 21, extending perpendicularly to the moving direction of the intermediate mold 3. It is made of high-strength, wear-resistant material and can withstand multiple punching operations on the edge of the fabric 102 without damage. The intermediate mold 3 is positioned between the fixed mold 1 and the moving mold 2, and moves along the moving direction of the moving mold 2 via a moving structure, ensuring the stability and accuracy of the movement. Shearing blades 32 and sharp blades 31 are spaced apart on the intermediate mold 3, precisely matching the shearing surface 12 of the fixed mold 1 and the punching surface 22 of the moving mold 2, respectively. Strict tool setting and adjustment are required before processing. When the moving mold 2 moves toward the fixed mold 1 and closes, the first molding groove 11 and the second molding groove 21 together form a composite cavity; the injection molding system starts and injects the high-temperature and high-pressure plastic melt into the injection molding rib groove 13 to complete the molding of the injection rib strip on the back of the substrate 101; at the same time, the moving mold 2 pushes the middle mold 3 toward the fixed mold 1, and the sharp blade 31 and the punching surface 22 cooperate to abut against each other, punching the edge of the fabric 102 with a certain punching pressure and speed; when the mold is fully closed, the shearing blade 32 cooperates with the shearing surface 12 to cut the edge of the substrate 101, thereby realizing the composite molding of the substrate 101 and the fabric 102 and the precise edge cutting.

[0028] In this embodiment, the distance between the pointed blade 31 and the shearing blade 32 is 14.5-15.5 mm. Specifically, during the mold manufacturing process, high-precision processing equipment, such as a CNC machining center, is used to ensure the accurate processing position of the pointed blade 31 and the shearing blade 32, so as to ensure that the distance between them meets the requirements. By precisely controlling this distance, it can be ensured that during the cutting process, the edge of the fabric 102 is 15 ± 0.5 mm longer than the edge of the substrate 101, which meets the design requirements and ensures the accuracy and quality of the cutting.

[0029] In this embodiment, the cross-section of the blade 31 is triangular, with a cutting edge inclination angle of 25-30 degrees and a blade tip rounding radius of 0.1-0.3 mm. Specifically, to achieve a good cutting effect, the cutting edge inclination angle is limited to the range of 25-30 degrees. During the manufacturing process, a precision grinding process, such as a CNC grinder, is used to accurately control the cutting edge inclination angle, ensuring that the cutting edge inclination angle of each blade 31 is within the specified range. Simultaneously, the blade tip rounding radius of 0.1-0.3 mm is achieved through fine polishing and grinding processes. This design ensures the sharpness of the blade 31 while improving its wear resistance and service life, avoiding problems such as blade tip breakage during punching, and ensuring the punching quality of the fabric 102 edge. This design of the blade 31 ensures sufficient sharpness when punching the fabric 102 edge while avoiding punching damage due to an excessively sharp blade tip, thus improving the service life of the blade 31.

[0030] In this embodiment, a mold fixing frame is also included. The fixed mold 1 is fixed on the mold fixing frame, and a moving guide structure is provided between the moving mold 2 and the fixed mold 1. Specifically, the mold fixing frame, as the supporting structure of the entire mold, is made of high-strength metal material to ensure sufficient strength and stability. The fixed mold 1 is firmly fixed to the mold fixing frame by bolts, nuts, and other connecting parts to ensure stability during processing and prevent displacement. The moving guide structure between the moving mold 2 and the fixed mold 1 can take various forms, such as a guide post and guide sleeve structure. When the mold is working, the moving guide structure can ensure that the moving mold 2 moves smoothly and accurately, improving the working accuracy and reliability of the mold.

[0031] In this embodiment, a movable structure is also included, comprising a slide rail and a slide block 5. The slide rail is fixed to the mold fixing frame, and the slide block 5 is slidably mounted on the slide rail. The sliding direction of the slide block 5 is the same as the moving direction of the moving mold 2. The intermediate mold 3 is mounted on the slide block 5. Specifically, the slide rail in the movable structure is a high-precision linear slide rail, which is fixed to the mold fixing frame by bolts, etc. When fixing the slide rail, measuring tools such as a level and dial indicator are used to precisely adjust the installation level and straightness of the slide rail to ensure the installation accuracy of the slide rail. The slide block 5 is slidably connected to the slide rail, and the sliding direction of the slide block 5 is the same as the moving direction of the moving mold 2, which is achieved by adjusting the installation angle and position of the slide rail. During the installation process, the installation position of the intermediate mold 3 is precisely adjusted to ensure that the shearing blade 32 and the pointed blade 31 on the intermediate mold 3 can accurately cooperate with the shearing surface 12 of the fixed mold 1 and the punching surface 22 of the moving mold 2.

[0032] In this embodiment, the intermediate mold 3 is mounted on the slide block 5 via a push cylinder 4. The cylinder seat of the push cylinder 4 is fixed to the slide block 5, and the telescopic rod of the push cylinder 4 is connected to the intermediate mold 3. The extension and retraction direction of the telescopic rod is perpendicular to the sliding direction of the slide block 5. Specifically, the intermediate mold 3 is mounted on the slide block 5 via the push cylinder 4, which is a high-precision and high-stability servo electric cylinder. The cylinder seat of the push cylinder 4 is fixed to the slide block 5 with bolts to ensure a tight fit between the two. The telescopic rod of the push cylinder 4 is connected to the intermediate mold 3, and the extension and retraction direction of the telescopic rod is perpendicular to the sliding direction of the slide block 5. This is achieved by adjusting the installation angle and position of the push cylinder 4. In actual use, the extension and retraction stroke of the push cylinder 4's telescopic rod is precisely controlled by the control system to achieve accurate control of the positional accuracy of the intermediate mold 3, ensuring the accuracy and reliability of the mold cutting operation.

[0033] In this embodiment, the slide block 5 is provided with a sliding groove 51, the extension direction of which is the same as the extension direction of the telescopic rod. The intermediate mold 3 is provided with a slider 33 that slides and matches the sliding groove 51. Specifically, the slide block 5 is provided with two parallel sliding grooves 51, the extension direction of which is the same as the extension direction of the telescopic rod. The slider 33 on the intermediate mold 3 and the sliding groove 51 are fitted with a clearance. The size of the clearance is controlled within a suitable range to ensure the smooth sliding of the slider 33 in the sliding groove 51, and to prevent the intermediate mold 3 from shaking during movement due to excessive clearance. The slider 33 and the intermediate mold 3 are integrally formed to ensure that the intermediate mold 3 can move accurately along the sliding groove 51, coordinating with the extension and retraction of the push cylinder 4 to achieve precise cutting operation.

[0034] This embodiment describes a molding die for a car roof. During operation, the moving mold 2 moves towards the fixed mold 1 to close, simultaneously pushing the intermediate mold 3 to move. The first molding groove 11 of the fixed mold 1 and the second molding groove 21 of the moving mold 2 form a composite cavity for the composite molding of the substrate 101 and the fabric 102. Simultaneously, the injection molding system injects melt into the back of the substrate 101 through the injection rib groove 13 to form ribs. The sharp blade 31 of the intermediate mold 3 and the cutting surface 22 of the moving mold 2 first abut against each other to cut the edge of the fabric 102, and then the shearing blade 32 of the intermediate mold 3 and the shearing surface 12 of the fixed mold 1 cooperate to shear the edge of the substrate 101. The beneficial effects include:

[0035] I. Process integration improves efficiency: By integrating the four processes of molding, injection molding, composite molding and cutting into a single mold, the composite molding of the substrate 101 and the fabric 102, the injection molding of the back ribs of the substrate 101, and the edge cutting of the substrate 101 and the fabric 102 are completed simultaneously when the mold is closed, avoiding the cumbersome process of traditional multi-mold switching; significantly reducing disassembly, installation and debugging time, and greatly improving production efficiency.

[0036] II. Precise Cutting, Ensuring Quality: The distance between the sharp blade 31 and the shearing blade 32 on the middle die 3 is designed to be 14.5–15.5mm, ensuring that the edge of the fabric 102 is 15±0.5mm longer than the edge of the substrate 101 after cutting, accurately meeting the requirements of the binding process and reducing dimensional errors; the sharp blade 31 adopts a triangular cross section with a blade inclination angle of 25–30° and a blade tip rounding radius of 0.1–0.3mm, which ensures both sharpness for a smooth cut and avoids wear, improving cut quality and blade life.

[0037] III. Structural Coordination, Stability and Reliability: The fixed mold 1 and the moving mold 2 are guided by a guide structure to ensure the mold closing accuracy and avoid deformation of the composite cavity; the middle mold 3 is driven by the slide rail mechanism and the push cylinder 4 to achieve bidirectional fine adjustment, so that the blade and the shearing surface 12 / punching surface 22 are precisely matched, improving the cutting consistency and process controllability.

[0038] IV. Cost Reduction: Reducing the number of molds directly lowers development, maintenance, and management costs, while the improved yield rate further reduces scrap losses.

[0039] In the description of the embodiments of this application, it should be noted that the terms "inner" and "outer" and other terms indicating direction or positional relationship are based on the direction or positional relationship shown in the drawings. This is only for the convenience of description and does not indicate or imply that the device or component must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation of this application.

[0040] In the description of this application, the references to terms such as "an embodiment," "some embodiments," "in this embodiment," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in a suitable manner in any one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0041] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A molding die for an automobile roof, characterized in that, include: A fixed mold is provided with a first molding groove for molding a substrate. The groove wall of the first molding groove is provided with a plurality of injection molding rib grooves, and the edge of the first molding groove is provided with a shearing surface. A moving mold is provided with a second forming groove for forming fabric, and the edge of the second forming groove is provided with a punching surface; The intermediate mold is moved and positioned between the fixed mold and the moving mold along the moving direction of the moving mold. The intermediate mold is provided with shearing blades that match the shearing surface and sharp blades that match the punching surface at intervals. The injection molding system has its injection outlet end connected to the injection rib groove; When the moving mold moves toward the fixed mold to close, the first forming groove and the second forming groove together form a composite cavity, which is used for the composite molding of the substrate and the fabric. At the same time, the moving mold pushes the middle mold to move toward the fixed mold, and the pointed blade cooperates with the punching surface to punch the edge of the fabric, and the shearing blade cooperates with the shearing surface to shear the edge of the substrate.

2. The molding die for the car roof according to claim 1, characterized in that, The distance between the pointed blade and the shearing blade is 14.5-15.5 mm.

3. The molding die for the car roof according to claim 1, characterized in that, The blade has a triangular cross-section with a cutting edge angle of 25-30 degrees and a blade tip rounding radius of 0.1-0.3 mm.

4. The molding die for the car roof according to claim 1, characterized in that, It also includes a mold fixing frame, the fixed mold is fixed on the mold fixing frame, and a moving guide structure is provided between the moving mold and the fixed mold.

5. The molding die for an automobile roof according to claim 4, characterized in that, It also includes a movable structure, which includes a slide rail and a slide block. The slide rail is fixed on the mold fixing frame, and the slide block is slidably disposed on the slide rail. The sliding direction of the slide block is the same as the moving direction of the moving mold, and the intermediate mold is mounted on the slide block.

6. The molding die for an automobile roof according to claim 5, characterized in that, The intermediate mold is mounted on the slide block via a push cylinder. The cylinder seat of the push cylinder is fixed on the slide block. The telescopic rod of the push cylinder is connected to the intermediate mold. The extension and retraction direction of the telescopic rod is perpendicular to the sliding direction of the slide block.

7. The molding die for an automobile roof according to claim 6, characterized in that, The slide block is provided with a sliding groove, the extension direction of which is the same as the extension direction of the telescopic rod, and the middle mold is provided with a slider that slides and matches the sliding groove.

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