FORMING METHOD FOR A VEHICLE SPEAKER GRILLE

Abstract

A forming process for a vehicle speaker grille is disclosed.The disclosed molding process for a vehicle speaker grille comprises a molding process for transferring a printed film onto an injection-molded product; and a post-process for processing the injection-molded product onto which the printed film is transferred, wherein the molding process includes loading a printed film between a first mold and a second mold, closing the first mold and the second mold, injecting a resin between the printed film and a concave section of the irregularity, transferring a section of the printed film, opening the first mold and the second mold, and removing the injection-molded product, and the post-process includes removing the transferred section, which is not the top surface of the injection-molded product, from the transferred printed film by injecting air into the top surface of the removed printed film.

Description

BACKGROUNDField of InterestThe present disclosure relates to a molding method for a vehicle speaker grill, and more particularly, to a molding method for a vehicle speaker grill having improved process efficiency as compared to a painting process.Description of the Prior ArtA vehicle is equipped with an audio system, and a speaker grill is provided inside the vehicle as part of a speaker apparatus. The speaker grill is a cover for a speaker apparatus, and serves to protect a speaker unit and simultaneously emit speaker sounds to the outside.Typically, the vehicle speaker grill is made of plastic or metal, but recently, as the interior of the vehicle has become more important, the speaker grill having improved aesthetic is made by combining plastic and metal. Specifically, an inner cover is made of plastic, an outer cover is made of metal, and the outer cover is stacked on the inner cover to make the vehicle speaker grill.The vehicle speaker grill has conventionally been manufactured by painting (coating) the outer cover on the inner cover. However, the painting process not only includes many process steps, but also generates volatile organic compounds (VOCs) from materials used for painting, which causes health problems for workers and air pollution.Therefore, the present disclosure provides a molding process and a post process that can replace the conventional painting process in the molding method for manufacturing a vehicle speaker grill, thereby increasing the efficiency and stability of the process and providing an eco-friendly molding method.SUMMARYAn object to be achieved by the present disclosure is to provide a molding method for a vehicular speaker grill capable of manufacturing the vehicular speaker grill with improved aesthetic.An object to be achieved by the present disclosure is to provide a molding method for a vehicle speaker grill having improved process efficiency.An object to be achieved by the present disclosure is to provide a molding method for a vehicle speaker grill with improved product completeness.An object to be achieved by the present disclosure is to provide a molding method for a vehicle speaker grill with improved process safety.An object to be achieved by the present disclosure is to provide an environmentally friendly molding method for a vehicle speaker grill.A molding method for a vehicle speaker grill according to an exemplary embodiment of the present disclosure includes a molding process of transferring a printed film to an injection molded product; and a post-process of processing the injection molded product to which the printed film is transferred, the molding process including loading a printed film between a first mold provided with a film molding groove part and a second mold provided with an insert part that faces the film molding groove part and is provided with a plurality of irregularities, mold-closing the first mold and the second mold such that an upper surface of the irregularity is in contact with the printed film, injecting a resin between the printed film and a concave portion of the irregularity, and transferring a portion of the printed film, which is in contact with the injection molded product to the injection molded product side by heat of the injection molded product, and mold-opening the first mold and the second mold and taking out the injection molded product to which the printed film is transferred, and the post process includes removing the transferred portion other than the upper surface of the injection molded product from the transferred printed film by injecting air into the upper surface of the taken out printed film.The post process may further include removing micrograte of the printed film by rubbing the top surface of the removed printed film with a brush.The molding process may further include curing the removed printed film.The forming process may further include vacuum forming the loaded printed film into the film forming groove part.The molding process may include moving a support member provided on an outer side of the second mold to the first mold to press and fix the loaded printed film.The concave portion may be provided in the form of a hole recessed in the second mold, and the molding process may further include processing the transferred printed film such that a size of the hole in the transferred printed film is smaller than that of the hole in the injection molded product.In the molding process, the printed film may be provided with a metallic material.In the molding process, the injection molded product may be made of a resin having a color contrasting with a color of the printed film.The film forming groove part may be recessed in the first mold, and the insert part may protrude toward the first mold, and the film forming groove part is larger than the insert part, and in the molding process, when a resin is injected between the printed film and the concave portion of the irregularity, and when the portion of the printed film in contact with the injection molded product is transferred to the injection molded product side by the heat of the injection molded product, the resin may also be injected between the concave portion provided at an outermost side of the insert part and an inner side surface of the film forming groove part.The molding process may use ultraviolet rays when the removed printed film is cured.The present disclosure provides a molding method for a vehicle speaker grill capable of manufacturing the vehicle speaker grill with improved aesthetic.The present embodiment provides a molding method for a vehicle speaker grill with improved process efficiency.The present embodiment provides a molding method for a vehicle speaker grill with improved product completeness.The present embodiment provides a molding method for a vehicle speaker grill with improved process safety.The present disclosure provides an environmentally friendly molding method for a vehicle speaker grill.The effects of the present disclosure are not limited to the above-mentioned effects, and other effects not mentioned above will be obviously taken from the following description by a person skilled in the art.The objects to be achieved by the present disclosure, the means for achieving the objects, and the effects of the present disclosure described above do not indicate essential features of the claims, and thus the scope of the claims is not limited to the disclosure of the present disclosure.BRIEF DESCRIPTION OF THE DRAWINGSThe above and other aspects, features and other advantages of the present disclosure will become more apparent from the following detailed description taken in conjunction with the accompanying drawings, in which: FIG. 1 is a perspective view illustrating a state before an injection molded product and a printed sheet are assembled in a vehicle speaker grill according to an embodiment of the present disclosure; FIG. 2 is an enlarged view illustrating a surface of the vehicle speaker grill according to an embodiment of the present disclosure when the injection molded product and the printed sheet are assembled; FIG. 3 is a cross-sectional view illustrating a step in which the printed film is loaded during a molding process of the vehicular speaker grill according to an embodiment of the present disclosure; FIG. 4 is a cross-sectional view illustrating a step of vacuum forming the printed film during the forming process of the vehicular speaker grill according to an embodiment of the present disclosure; FIG. 5 is a cross-sectional view illustrating a step of mold-closing a first mold and a second mold during the molding process of the vehicle speaker grill according to an embodiment of the present disclosure; FIG. 6 is a cross-sectional view illustrating a step of injecting a resin and transferring a printed film during the molding process of the vehicular speaker grill according to an embodiment of the present disclosure; FIG. 7 is a cross-sectional view illustrating a step in which the first mold and the second mold are mold-opened during the molding process of the vehicle speaker grill according to an embodiment of the present disclosure; FIG. 8 is a cross-sectional view illustrating a step of curing the removed printed film during the molding process of the vehicular speaker grill according to an embodiment of the present disclosure; FIG. 9 is a cross-sectional view illustrating an air shower step during a post process of the vehicle speaker grill according to an embodiment of the present disclosure; and FIG. 10 is a cross-sectional view illustrating a brushing step during the post process of the vehicular speaker grill according to an embodiment of the present disclosure.DETAILED DESCRIPTION OF THE EMBODIMENTHereinafter, the exemplary embodiment of the present disclosure will be described with reference to the accompanying drawings and exemplary embodiments as follows. Scales of components illustrated in the accompanying drawings are different from the real scales for the purpose of description, so the scales are not limited to those illustrated in the drawings.Hereinafter, embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. The following embodiments are presented to sufficiently convey the spirit of the present disclosure to those skilled in the art. The present disclosure is not limited to only the embodiments illustrated below, but may be embodied in other forms. In order to clarify the present disclosure, parts unrelated to the description may be omitted, and a size of components may be slightly exaggerated to facilitate understanding.FIG. 1 is a perspective view illustrating a state before an injection molded product 100 and a printed sheet 200 are assembled in a vehicle speaker grill 10 according to an embodiment of the present disclosure, and FIG. 2 is an enlarged view illustrating a surface of the vehicle speaker grill 10 according to an embodiment of the present disclosure when the injection molded product 100 and the printed sheet 200 are assembled.Referring to FIGS. 1 and 2, the vehicle speaker grill 10 according to an embodiment of the present disclosure is composed of an outer cover and an inner cover having a plurality of holes. The outer cover is disposed toward a passenger inside the vehicle and is mainly made of a metallic material, and the inner cover is disposed behind the outer cover and is mainly made of a plastic material.When the inner cover and the outer cover are coupled, an inner circumferential surface of a hole in the inner cover may be seen through a hole in the outer cover, as illustrated in FIG. 2. In other words, a hole 110 in the injection molded product is exposed to passengers of the vehicle through a hole 210 in the printed film, which will be described later. Therefore, a color of the inner cover may be provided to contrast with a color of the outer cover, thereby improving the aesthetic of the speaker grill 10.Conventionally, the outer cover has been manufactured on the inner cover by a painting process, but this process is complex and generates volatile organic compounds (VOCs), which causes health problems for workers and air pollution. Therefore, embodiments of the present disclosure solve the conventional problems by a molding process and a post process replacing the painting process.The molding method for the vehicle speaker grill 10 according to an embodiment of the present disclosure largely includes the molding process and the post process. The molding process is a process of transferring the printed film 200 that becomes the outer cover to the injection molded product 100 that becomes the inner cover, and the post process is a process of enhancing the completeness of the products by processing the injection molded product 100 to which the printed film 200 is transferred after the molding process.FIGS. 3 to 8 illustrate the molding process of the vehicular speaker grill 10 according to an embodiment of the present disclosure, and FIGS. 9 and 10 illustrate the post-process of the vehicular speaker grill 10 according to an embodiment of the present disclosure.FIG. 3 is a cross-sectional view illustrating a step in which the printed film 200 is loaded during the molding process of the vehicular speaker grill 10 according to an embodiment of the present disclosure.Referring to FIG. 3, the components for forming the vehicle speaker grill 10 according to an embodiment of the present disclosure include a first mold 300 and a second mold 400.One of the first mold 300 and the second mold 400 is a fixed mold and the other is a movable mold. In an embodiment of the present disclosure, the first mold 300 is provided as a fixed mold and the second mold 400 is provided as a movable mold.The first mold 300 includes a film molding groove part 310 recessed on a mold clamping surface, and the second mold 400 includes an insert part 410 protruding on a mold clamping surface. The insert part 410 faces the film forming groove part 310, but is provided with a plurality of irregularities 411. The irregularity 411 includes a convex portion 411B protruding toward the first mold 300 and a concave portion 411A recessed toward the second mold 400, based on the insert part 410.When the first mold 300 and the second mold 400 are opened, the printed film 200 is loaded between the first mold 300 and the second mold 400. The printed film 200 may be provided in a roll-to-roll manner on the mold closing surface of the first mold 300. The printed film 200 may be made of a metallic material. The metallic material refers to a metal material mainly composed of metal elements or metal alloys, and therefore, a metallic foil refers to a thin foil composed of metal layers. However, the printed film 200 of the present disclosure is not limited to the metal material, and includes nonmetallic materials or nonmetallic materials that look like metal materials.The printed film 200 may be formed by stacking a plurality of layers. Specifically, the printed film 200 may be laminated with a carrier film, a release layer, a colored layer, and an adhesive layer, and the adhesive layer may serve to increase adhesion strength with the injection molded product 100, and the release layer may serve to separate the transferred printed film 200 from the carrier film.FIG. 4 is a cross-sectional view illustrating a step of vacuum forming the printed film 200 during the forming process of the vehicular speaker grill 10 according to an embodiment of the present disclosure.Referring to FIG. 4, the loaded printed film 200 may be vacuum-formed into the film forming groove part 310. In this case, the printed film 200 may be vacuum-formed to adhere to an inner surface of the film forming groove part 310 and conform to the shape of the inner surface.The loaded printed film 200 may be pressed and fixed with a support member 420 provided on an outer side of the second mold 400 before or simultaneously with the vacuum forming. In particular, the support member 420 may pressurize and fix the loaded printed film 200 by moving toward the first mold 300 by a mechanical or electronic method. Therefore, the next process can be stably performed by fixing the position of the loaded printed film 200 on the mold clamping surface of the first mold 300.FIG. 5 is a cross-sectional view illustrating the mold closing step of the first mold 300 and the second mold 400 during the molding process of the vehicle speaker grill 10 according to an embodiment of the present disclosure, and FIG. 6 is a cross-sectional view illustrating a step of injecting a resin and transferring the printed film 200 during the molding process of the vehicle speaker grill 10 according to an embodiment of the present disclosure.Referring to FIGS. 5 and 6, the second mold 400, which is a movable mold, moves toward the first mold 300, which is a fixed mold, and the first mold 300 and the second mold 400 are mold-locked. In this case, the support member 420 is inserted into a receiving portion provided in the second mold 400, so that a surface of the support member 420 forms the same surface as the mold closing surface of the second mold 400.Thereafter, the resin is injected between the printed film 200 and a concave portion 411A of the irregularity 411 to become the injection molded product 100. The resin may be a plastic resin formed by a polymerization reaction, and the injected molten resin has high heat. Accordingly, the part of the printed film 200 in contact with the injection molded product 100 in the printed film 200 is transferred to the injection molded product 100 by the heat of the injection molded product 100.A concave portion 411A of the irregularity 411 serves as a cavity into which the resin is injected, and a convex portion 411B of the irregularity 411 serves to block between the concave portion 411A and the concave portion 411A. When the concave portion 411A is provided in the form of a hole recessed in the second mold 400, the injection molded product 100 is formed with a hole 110 in the injection molded product, and the transferred printed film 200 is also provided with a hole 210 in the printed film.The film forming groove part 310 is recessed in the first mold 300 and the insert part 410 is formed to protrude toward the first mold 300, but the film forming groove part 310 may be provided to be larger than the insert part 410. Therefore, the resin can also be injected between the concave portion 411A provided at an outermost side of the insert part 410 and an inner side surface of the film forming groove part 310, so that the outermost side of the injection molded product 100 and the outermost side of the transferred printed film 200 can be provided in a curved shape.The injection molded product 100 may be manufactured with a resin having a color contrasting with a color of the printed film 200. For example, the printed film 200 may be a metallic paint made of a metallic material, and the injection molded product 100 may be a single paint such as yellow, blue, or red. Therefore, when the inner cover and the outer cover are coupled, as illustrated in FIG. 2, the metallic colored surface of the printed film 200 can be seen, and the monochromatic inner circumferential surface of the injection hole can be seen through the hole 210 in the printed film, thereby improving the aesthetic of the speaker grill 10.FIG. 7 is a cross-sectional view illustrating a step in which the first mold 300 and the second mold 400 are mold-opened during the molding process of the vehicular speaker grill 10 according to an embodiment of the present disclosure.Referring to FIG. 7, after the first mold 300 and the second mold 400 are mold-opened, the injection molded product 100 to which the printed film 200 is transferred may be taken out.When the concave portion 411A of the irregularity 411 has a hole shape recessed in the second mold 400, the injection molded product 100 and the transferred printed sheet 200 have the hole 110 in the injection molded product and the hole 210 in the printed sheet, respectively. In this case, since the hole 110 in the injection molded product and the hole 210 in the printed film have the same size, after the extraction of the injection molded product 100 to which the printed film 200 has been transferred, the transferred printed film 200 can be processed so that the size of the hole 210 in the transferred printed film is smaller than the size of the hole 110 in the injection molded product. The processing process may be performed after the injection molded product 100 to which the printed film 200 has been transferred is taken out or before being cured, or after being taken out and cured. Although a separate process is added to largely process the hole 210 in the transferred printed film, the aesthetic can be improved by further exposing the injection molded product 100, which is the inner cover, to the outside.FIG. 8 is a cross-sectional view illustrating a step of curing the removed printed film 200 during the molding process of the vehicular speaker grill 10 according to an embodiment of the present disclosure.Referring to FIG. 8, after the take-out of the injection molded product 100 to which the printed film 200 is transferred, a step of curing the taken-out printed film 200 may be further included. In this case, the curing apparatus 500 used may use ultraviolet rays.The molding process according to an embodiment of the present disclosure transfers the printed film 200 by the heat of the injection molded product 100. The purpose of the molding process is to form the hole 210 in the printed film 200 to correspond to the hole 110 in the injection molded product, but the heat transferred from the injection molded product 100 to the printed film 200 cannot be fully controlled, so that a problem occurs in which the hole 210 in the printed film is not properly formed. In other words, the printed film 200 may cover the hole 110 in the injection molded product without providing the hole 210 in the printed film. Therefore, in order to avoid such problems, the embodiment of the present disclosure provides the post process to improve the completeness of the product after the molding process.FIG. 9 is a cross-sectional view illustrating an air shower step during the post process of the vehicle speaker grill 10 according to an embodiment of the present disclosure.Referring to FIG. 9, in the air shower step, by injecting air into the upper surface of the removed printed film 200, the transferred portion other than the upper surface of the injection molded product 100 may be removed from the transferred printed film 200.An air shower apparatus 600 used in the air shower may be provided with an inlet port through which air flows in on one side and an outlet port through which air flows out on a surface opposite to the transferred printed film 200. A plurality of exhaust ports may be provided, and the exhaust port may be provided smaller than the intake port such that the pressure of the outflow air is greater than the air pressure of the inflow air.FIG. 10 is a cross-sectional view illustrating a brushing step during the post process of the vehicular speaker grill 10 according to an embodiment of the present disclosure.Referring to FIG. 10, in the brushing step, the microgravities of the printed film 200 may be removed by rubbing the upper surface of the removed printed film 200 with the brush of the brushing device 700. In this case, the micro flash is a thin ridge-shaped surplus portion occurring in processing metal, etc. In an embodiment of the present disclosure, the injection molded product 100 is exposed to the outside through the printed film hole 210 to improve the aesthetic of the vehicle interior. Accordingly, the process of removing the micro burrs so that the size of the hole 210 in the plurality of printed films is constant and the size of the hole 210 in the single printed film is not larger than the size of the hole 110 in the injection molded product plays an important role in improving the aesthetic of the vehicle interior. Brushing may be performed after air showering.The molding method for the vehicular speaker grill 10 according to the embodiment of the present disclosure includes a molding process of transferring the printed film 200 to the injection molded product 100 by the heat of the injection molded product 100, so that it is possible to improve the efficiency of the process as compared with the painting process, improve the stability of the process, and simultaneously implement the environmentally friendly process because the volatile organic compounds generated from the painting material are not generated, and improve the completeness of the vehicular speaker grill 10 by the air shower device 600 and the brush device 700 after the molding process. The vehicle speaker grill 10 manufactured in this manner not only improves the aesthetic appearance of the vehicle interior but also increases the marketability of the vehicle.

Claims

A molding method for a vehicle speaker grill, comprising: a molding process of transferring a printed film to an injection molded product; and a post-process of processing the injection molded product to which the printed film is transferred, the molding process including loading a printed film between a first mold provided with a film molding groove part and a second mold provided with an insert part that faces the film molding groove part and is provided with a plurality of irregularities, mold-closing the first mold and the second mold such that an upper surface of the irregularity is in contact with the printed film, injecting a resin between the printed film and a concave portion of the irregularity, and transferring a portion of the printed film that is in contact with the injection molded product, on the injection molded product side by heat of the injection molded product, and mold-opening the first mold and the second mold and taking out the injection molded product to which the printed film is transferred, and the post process includes removing the transferred portion other than the upper surface of the injection molded product from the transferred printed film by injecting air into the upper surface of the taken out printed film.The method of claim 1, wherein the post process further includes removing microgratches of the printed film by rubbing the top surface of the removed printed film with a brush.The method of claim 1, wherein the molding process further includes curing the removed printed film.The method of claim 1, wherein the forming process further includes vacuum forming the charged printed film into the film forming groove portion.The method of claim 1, wherein the forming process includes moving a support member provided on an outer side of the second die to the first die to press and fix the loaded printed film.The method according to claim 1, wherein the concave portion is provided in the form of a hole recessed in the second mold, and the molding process further includes processing the transferred printed film such that a size of the hole in the transferred printed film is smaller than that of the hole in the injection molded product.The method according to claim 1, wherein in the forming process, the printed film is provided with a metallic material.The method according to claim 1, wherein in the molding process, the injection molded product is made of a resin having a color contrasting with a color of the printed film.The method according to claim 1, wherein the film forming groove part is recessed in the first mold, and the insert part protrudes toward the first mold, and the film forming groove part is larger than the insert part, and in the molding process, when a resin is injected between the printed film and the concave portion of the irregularity, and when the portion of the printed film in contact with the injection molded product is transferred to the injection molded product side by the heat of the injection molded product, the resin is also injected between the concave portion provided at an outermost side of the insert part and an inner side surface of the film forming groove part.The method according to claim 3, wherein the molding process uses ultraviolet rays when the removed printed film is cured.

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