A mold for instrument panel foam production

Abstract

The utility model discloses a mould for instrument panel foaming production, including upper die and lower die, upper die is equipped with mould core, and the surface of mould core is provided with the accommodation groove for accommodating skeleton convex bundle, and the surface of mould core is provided with the accommodation groove for accommodating skeleton convex bundle, and the surface of mould core is provided with the accommodation groove for accommodating skeleton convex bundle, and the surface of mould core is provided with the accommodation groove for accommodating skeleton convex bundle, and the surface of mould core is provided with the accommodation groove for accommodating skeleton convex bundle, and the surface of mould core is provided with the accommodation groove for accommodating skeleton convex bundle, and the surface of mould core is provided with the accommodation groove for accommodating skeleton convex bundle, and the surface of mould core is provided with the accommodation groove for accommodating skeleton convex bundle, and the surface of mould core is provided with the accommodation groove for accommodating skeleton convex bundle, and the surface of mould core is provided with the accommodation groove for accommodating skeleton convex bundle, and the surface of mould core is provided with the accommodation groove for accommodating skeleton convex bundle, and the surface of mould core is provided with the accommodation groove for accommodating skeleton convex bundle, and the surface of mould core is provided with the accommodation groove for accommodating skeleton convex bundle, and the surface of mould core is provided with the accommodation groove for accommodating skeleton convex bundle, and the surface of mould core is provided with the accommodation groove for accommodating skeleton convex bundle, and the surface of mould core is provided with the accommodation groove for accommodating skeleton convex bundle, and the surface of mould core is provided

Description

Technical Field

[0001] This utility model relates to the field of automotive interior manufacturing technology, and in particular to a mold for dashboard foam production. Background Technology

[0002] In the manufacturing process of automotive interior dashboards, foam molding is a crucial step in enhancing product comfort and aesthetics. The specific process involves: an upper mold fixing the injection-molded frame, and a lower mold fixing the slush-molded skin. Polyurethane raw material is injected under high pressure into the cavity between the frame and the skin through a mixing head in a foaming device. The mold uses a sealed structure to expel air and maintain constant pressure, allowing the foam to mature and form a dashboard that combines flexibility and support. The core of this process is that the surface of the foamed upper mold must completely adhere to the back of the frame. Insufficient adhesion will lead to seal failure, uneven foam filling, and surface collapse caused by abnormal pressure distribution, severely impacting product yield.

[0003] To meet diverse market demands, dashboards are currently divided into high-end and low-end versions. The essential difference lies in the configuration: the high-end dashboard has a pre-installed head-up display (HUD) within its frame, while the low-end does not. (See also...) Figure 1 , Figure 1 The diagram illustrates the structure of the skeleton in the prior art. Regardless of whether it's a high-end or low-end configuration, the back of skeleton 1 has a skeleton protrusion 11 in the head-up display (HUD) functional area. This protrusion 11 accommodates the HUD insert, ensuring sufficient installation space and heat dissipation for the electronic modules. While the low-end skeleton lacks inserts, it retains the exact same skeleton protrusion 11 to maintain compatibility for platform-based production and future upgrade possibilities. Although this design reduces the development cost of the injection mold, the installation stress of the HUD insert can cause localized warping deformation in the high-end skeleton protrusion 11 area. If the high-end and low-end skeletons are forced to share the same foaming mold, it will lead to problems such as bonding failure or pressure imbalance. Therefore, the prior art employs a separate mold production scheme, developing two sets of foaming molds for the high-end and low-end skeletons respectively. However, this production method suffers from high production costs.

[0004] In addition, in order to enable workers to quickly distinguish between high-end and low-end skeletons, an identification hole is usually drilled in the non-convex hull area of ​​the high-end skeleton, while the low-end skeleton remains a complete plane. The high-end and low-end skeletons can be distinguished by judging whether the skeleton has an identification hole. Utility Model Content

[0005] The technical problem to be solved by this utility model is to provide a mold for the production of dashboard foam, so that high-end products and low-end products can share the same mold by improving the mold, thus solving the problem of high production costs in the past.

[0006] To address the aforementioned technical problems, this utility model discloses a mold for instrument panel foam production, comprising an upper mold and a lower mold. The upper mold has a mold core, and the surface of the mold core has a receiving groove for accommodating the skeleton protrusion. The mold core is equipped with a configuration identification mechanism, a vacuum adsorption mechanism, and an adjustable support mechanism. The configuration identification mechanism includes a sensor, which is fixedly installed on the mold core plane area outside the receiving groove. The sensor is used to align with the identification hole of the high-configuration skeleton. The vacuum adsorption mechanism includes multiple vacuum suction cups, which are evenly distributed circumferentially on the outer edge of the receiving groove. The adjustable support mechanism includes multiple universal support blocks, which are sequentially arranged side by side and detachably installed on the bottom of the receiving groove.

[0007] The sensor is a reflective photoelectric sensor.

[0008] The distance between the sensor and the receiving slot is greater than 20mm.

[0009] The number of vacuum suction cups is four or more, and the multiple vacuum suction cups are arranged in a matrix at intervals.

[0010] The distance between the vacuum suction cup and the edge of the receiving groove is 5mm to 20mm.

[0011] Each of the vacuum suction cups is connected to an external negative pressure device through an independent solenoid valve, and the suction force of each vacuum suction cup is -80 to -95 kPa.

[0012] Specifically, when the sensor identifies the skeleton as high-end, the suction force of the vacuum suction cup is -90±2 kPa; when the sensor identifies the skeleton as low-end, the suction force of the vacuum suction cup is -75±2 kPa.

[0013] Each universal support block has a countersunk mounting hole in the middle, and the bottom of the receiving groove has multiple threaded holes; in the assembled state, the mounting hole of the universal support block is aligned with one of the threaded holes.

[0014] A gasket is provided between the general support block and the bottom of the receiving groove.

[0015] The receiving slot is U-shaped.

[0016] Compared with the prior art, the embodiments of this utility model have the following beneficial effects: (1) By setting up sensors, it is possible to accurately identify high-end and low-end skeletons, achieve zero-misjudgment production, and provide a guarantee for subsequent foaming.

[0017] (2) Multiple vacuum suction cups are evenly distributed around the outer edge of the receiving groove to form a balanced adsorption force field, which compensates for the local warping deformation of the high-end frame caused by the installation of the head-up display insert, reduces the fitting gap, and reduces the foam leakage rate.

[0018] (3) A single mold is compatible with both high-end and low-end skeleton foaming production, which greatly reduces costs and increases efficiency, solving the problem of high production costs in the past.

[0019] (4) The universal support block can be detachably installed at the bottom of the receiving groove. The split and detachable structure allows for partial replacement of worn parts or partial adjustment of the support for the skeleton protrusion. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of this utility model, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 This is a schematic diagram of the skeleton structure in the prior art; Figure 2 This is a schematic diagram of the mold structure in the embodiment; Figure 3 This is a schematic diagram of the upper mold in the embodiment; Figure 4 This is a schematic diagram of the structure of the general support block in the embodiment. Detailed Implementation

[0022] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0023] The terms "first," "second," etc., in the specification, claims, and accompanying drawings of this utility model are used to distinguish different objects, not to describe a specific order. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion. For example, a process, method, mechanism, product, or end that includes a series of steps or units is not limited to the listed steps or units, but may optionally include steps or units not listed, or may optionally include other steps or units inherent to these processes, methods, products, or ends.

[0024] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of the present invention. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0025] This utility model discloses a specific embodiment of a mold used in the production of instrument panel foam. Please see [link to relevant documentation]. Figures 2 to 4 The mold includes an upper mold 2 and a lower mold 3. The upper mold 2 is provided with a mold core 21, and the surface of the mold core 21 has a receiving groove 23 for accommodating the skeleton protrusion. Optionally, the receiving groove 23 is U-shaped. In other embodiments, the shape of the receiving groove 23 can be selectively set according to the outer contour of the skeleton protrusion or the head-up display insert. It should be noted that the depth of the receiving groove 23 is greater than the maximum height of the skeleton protrusion to ensure that the protrusions of both high-end and low-end skeletons can be inserted without interference.

[0026] As an improvement, the core 21 is equipped with a configuration identification mechanism, a vacuum adsorption mechanism, and an adjustable support mechanism.

[0027] In this embodiment, the identification mechanism includes a sensor 24, which is fixedly installed on the planar area of ​​the mold core 21 outside the receiving groove 23. Its main function is to align with the identification hole of the high-end frame. Preferably, the sensor 24 is a reflective photoelectric sensor, preferably the Keyence FU-35M model. The sensor 24 is fixedly installed on the planar area of ​​the mold core 21 outside the receiving groove 23, and its installation position is strictly limited to a distance of more than 20mm from the edge of the receiving groove 23, preferably 25mm, to avoid the stress concentration area during mold closing. The detection direction of the sensor 24 can be selected at different tilt angles according to actual needs, for example, aligning with the identification hole of the high-end frame at a 30° tilt angle. Generally, the diameter of the identification hole is Ø2.0±0.1mm, and the hole depth penetrates the thickness of the frame. The sensor 24 is calibrated to the center of the identification hole. When a weak reflection signal (hole) is detected, it is determined to be a high-end frame; when a strong reflection signal (plane) is detected, it is determined to be a low-end frame; when there is no reflection signal, it is determined that no product has been placed, and the machine is stopped and the mold is locked.

[0028] In this embodiment, the vacuum adsorption mechanism includes four vacuum suction cups 26 arranged in a 2×2 matrix. The four vacuum suction cups 26 are evenly distributed circumferentially at a distance of 5mm to 20mm from the outer edge of the receiving groove 23. Optionally, each suction cup is connected to an external negative pressure device via an independent solenoid valve. The solenoid valve can be an SMCITV3050 model, thereby enabling dynamic adjustment of the adsorption force of each vacuum suction cup 26. The adsorption force of each vacuum suction cup 26 is -80 to -95 kPa. During use, when the sensor 24 identifies a high-configuration frame, the adsorption force of the vacuum suction cup 26 is -90±2 kPa, which can compensate for the 0.3mm warping deformation caused by the installation of the insert; when the sensor 24 identifies a low-configuration frame, the adsorption force of the vacuum suction cup 26 is -75±2 kPa, which can maintain basic adhesion in energy-saving mode.

[0029] In this embodiment, the adjustable support mechanism includes multiple universal support blocks 25, which are sequentially arranged side-by-side and detachably installed on the bottom of the receiving groove 23. Specifically, the adjustable support mechanism consists of three universal support blocks 25 arranged side-by-side, with the width of each support block 25 being similar to the width of the receiving groove 23, and the three universal support blocks 25 covering the bottom of the receiving groove 23. It should be noted that screws are preferred as the connecting parts for the detachable installation method. A countersunk mounting hole 251 is provided in the center of the support block 25, and multiple threaded holes are provided on the bottom of the receiving groove 23. In the assembled state, the mounting hole 251 of the universal support block 25 is aligned with one of the threaded holes and fixed to the pre-machined threaded hole on the bottom of the groove by an internal hexagon screw. Stainless steel shims (with thicknesses of 0.1 / 0.2 / 0.3 / 0.5 mm) can be placed between the support block 25 and the bottom of the groove to compensate for cumulative manufacturing errors. The number of shims can be increased or decreased to specifically adjust one of the universal support blocks 25.

[0030] In addition, the mold also includes a controller, which is electrically connected to the sensor 24, the external negative pressure device, and the solenoid valve.

[0031] The working process of the mold in this embodiment is as follows: First, the skeleton is placed with its back side facing up in the upper mold 2, with the convex bulge precisely aligned with the receiving groove 23. Second, the sensor 24 scans and identifies the hole area. If a hole is detected, it is determined to be a high-configuration skeleton; if a complete plane is detected, it is determined to be a low-configuration skeleton. Third, according to the identified configuration information, the vacuum suction cup 26 adsorbs the skeleton with a preset adsorption force. Fourth, the mold is closed for foaming. The upper mold 2 and lower mold 3 are closed, the universal support block 25 presses the back of the skeleton, and polyurethane raw material is injected into the cavity at a specific flow rate. After holding the pressure for 180 seconds, the mold is opened, and the ejection mechanism demolds the foamed dashboard, thus completing the entire foaming process of the automotive interior parts.

[0032] In this embodiment, the mold, equipped with sensor 24, can accurately identify high- and low-configuration skeletons, achieving zero-misjudgment production and ensuring the success of subsequent foaming. Multiple vacuum suction cups 26 are evenly distributed circumferentially on the outer edge of the receiving groove 23, forming a balanced adsorption force field to compensate for localized warping deformation of the high-configuration skeleton caused by the installation of the head-up display insert, reducing the fitting gap and lowering the foaming leakage rate. A single mold set is compatible with the foaming production of both high- and low-configuration skeletons, significantly reducing costs and increasing efficiency, solving the problem of high production costs in the past. A universal support block 25 is detachably installed at the bottom of the receiving groove 23; the split, detachable structure allows for partial replacement of worn parts or partial adjustment of the support for the skeleton protrusions.

[0033] The technical means disclosed in this utility model are not limited to those disclosed in the above embodiments, but also include technical solutions composed of any combination of the above technical features. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principle of this utility model, and these improvements and modifications are also considered within the scope of protection of this utility model.

Claims

1. A mold for producing foamed dashboard panels, comprising an upper mold and a lower mold, characterized in that, The upper mold is provided with a mold core, and the surface of the mold core is provided with a receiving groove for accommodating the skeleton protrusion; The mold core is equipped with a configuration identification mechanism, a vacuum adsorption mechanism, and an adjustable support mechanism; The configuration identification mechanism includes a sensor, which is fixedly installed on the mold core plane area outside the receiving groove, and the sensor is used to align with the identification hole of the high-configuration skeleton; The vacuum adsorption mechanism includes multiple vacuum suction cups, which are circumferentially distributed on the outer edge of the receiving groove. The adjustable support mechanism includes multiple universal support blocks, which are sequentially arranged side by side and detachably installed at the bottom of the receiving groove.

2. The mold for instrument panel foam production according to claim 1, characterized in that, The sensor is a reflective photoelectric sensor.

3. A mold for instrument panel foam production according to claim 2, characterized in that, The distance between the sensor and the receiving groove is greater than 20mm.

4. A mold for instrument panel foam production according to claim 1, characterized in that, The number of vacuum suction cups is four or more, and the multiple vacuum suction cups are arranged at intervals in a matrix.

5. A mold for instrument panel foam production according to claim 4, characterized in that, The distance between the vacuum suction cup and the edge of the receiving groove is 5mm to 20mm.

6. A mold for instrument panel foam production according to claim 1, characterized in that, Each of the vacuum suction cups is connected to an external negative pressure device through an independent solenoid valve, and the suction force of each vacuum suction cup is -80~-95 kPa.

7. A mold for instrument panel foam production according to claim 6, characterized in that, When the sensor identifies the frame as high-end, the suction force of the vacuum suction cup is -90±2 kPa. When the sensor identifies the skeleton as low-spec, the suction force of the vacuum suction cup is -75±2 kPa.

8. A mold for instrument panel foam production according to any one of claims 1-7, characterized in that, Each of the general support blocks has a countersunk mounting hole in the middle, and the bottom of the receiving groove has multiple threaded holes. In the assembled state, the mounting holes of the universal support block are aligned with one of the threaded holes.

9. A mold for instrument panel foam production according to claim 1, characterized in that, A gasket is provided between the universal support block and the bottom of the receiving groove.

10. A mold for instrument panel foam production according to claim 1, characterized in that, The receiving groove is U-shaped.

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