Nrog rau kev txhim kho tas mus li ntawm cov neeg siv khoom xav tau rau automotive kev nplij siab thiab zoo nkauj, mos interiors tau maj mam dhau los ua ib qho tseem ceeb hauv kev lag luam tsheb. Lawv tau dav siv nyob rau hauv siab- kawg thiab nruab nrab- mus rau - siab- tsheb kawg, feem ntau yog siv rau cov ntsuas vaj huam sib luag, qhov rooj vaj huam sib luag, nruab nrab armrests thiab lwm yam tseem ceeb ntawm kev sib cuag. Cov txheej txheem molding ntawm cov tawv nqaij tha xim sab hauv ncaj qha txiav txim siab qhov zoo, kev xav ntawm tes thiab durability ntawm cov khoom sab hauv. Tsab ntawv xov xwm no yuav tsom mus rau peb txoj haujlwm tseem ceeb hauv kev molding rau tsheb mos sab hauv tawv nqaij: Fiberglass Reinforced Plastic (FRP) molding, Vacuum Forming thiab Skin Foaming.
Ⅰ Fiberglass Reinforced Plastic (FRP) Moulding
1. Txheej txheem Taw Qhia
Fiberglass Reinforced Plastic (FRP) molding, tseem hu ua iav fiber reinforced composite molding, yog txheej txheem uas tsim cov tawv nqaij sab hauv los ntawm kev sib xyaw iav fiber ntau raws li cov khoom siv ntxiv nrog cov resin ua cov khoom siv matrix. Cov txheej txheem siv qhov zoo toughness ntawm iav fiber ntau thiab cov moldability zoo heev ntawm resin los tsim cov tawv nqaij sab hauv nrog ob txhais tes mos thiab tej yam ntxwv lub zog. Tsis zoo li cov khoom siv tawv tawv FRP, FRP siv rau cov tawv nqaij sab hauv yuav raug kho tshwj xeeb hauv kev faib ua feem ntawm cov khoom siv thiab cov iav fiber ntau, thiab qee zaum hloov tau cov khoom ntxiv yuav raug ntxiv los xyuas kom meej qhov muag ntawm cov khoom nto.
2. Hom khoom
Cov ntaub ntawv rau FRP cov tawv nqaij mos sab hauv feem ntau suav nrog ob lub ntsiab lus: cov khoom siv txhawb zog thiab cov khoom siv matrix. Cov khoom siv txhawb zog yog cov iav fiber ntau, feem ntau yog cov iav fiber ntau los yog iav fiber ntau, uas tuaj yeem txhim kho lub zog tensile thiab hnav tsis kam ntawm daim tawv nqaij. Cov khoom siv matrix feem ntau yog thermosetting resin, xws li unsaturated polyester resin, epoxy resin thiab polyurethane resin. Ntawm lawv, polyurethane resin yog siv dav tshaj plaws vim nws qhov yooj yim thiab adhesion. Tsis tas li ntawd, txhawm rau txhim kho kev ua tau zoo ntawm cov khoom, cov khoom siv ntxiv xws li plasticizers, antioxidants, UV absorbers thiab colorants yuav muab ntxiv rau hauv cov khoom siv matrix.
3. Cov yam ntxwv txheej txheem
Qhov zoo ntawm FRP molding txheej txheem yog pom tseeb: ua ntej, nws muaj moldability zoo heev, uas tuaj yeem hloov mus rau cov duab ntawm lub tsheb sab hauv, xws li qhov nkhaus ntawm qhov ntsuas vaj huam sib luag thiab cov duab tsis zoo ntawm lub qhov rooj vaj huam sib luag. Qhov thib ob, cov khoom lag luam muaj kev ua tau zoo, kev sib txuas ntawm tes zoo li muaj zog, tsis yooj yim rau tawg lossis deform. Thib peb, cov xim thiab qhov chaw zoo nkauj tuaj yeem hloov kho tau yooj yim. Cov xim tuaj yeem muab ntxiv rau hauv cov xim matrix ua ntej, thiab qhov kev ntxhib los mos ntawm qhov chaw tuaj yeem tsim los ntawm pwm kev ntxhib los mos los yog xa tawm - ua. Txawm li cas los xij, cov txheej txheem kuj tseem muaj qee qhov tsis txaus: lub voj voog ntau lawm kuj ntev, uas tsis haum rau loj - nplai ntau lawm; cov txheej txheem kho resin yuav tsim me me ntawm cov tshuaj volatile, thiab kev tiv thaiv ib puag ncig yuav tsum tau kho; tus nqi yog me ntsis siab dua li cov txheej txheem yas tsoos.
4. txheej txheem ntws
FRP soft interior molding txheej txheem feem ntau suav nrog cov kauj ruam tseem ceeb hauv qab no:
Kev npaj pwm: Ntxuav cov pwm nrog kev ntxhib los mos (feem ntau yog ua los ntawm txhuas lossis hlau), thov tus neeg sawv cev tso tawm tusyees ntawm sab hauv kom ntseeg tau tias cov khoom tuaj yeem demolded smoothly tom qab molding.
Kev npaj khoom siv: Sib tov cov resin matrix, iav fiber, plasticizer thiab lwm yam additives nyob rau hauv ib qho kev faib ua feem. Cov txheej txheem sib tov yuav tsum tsis sib xws kom tsis txhob muaj qhov tshwm sim ntawm cov khoom agglomeration.
Lay- nce thiab Moulding: Ncuav los yog txhuam cov khoom sib xyaw rau hauv pwm, thiab siv cov cuab yeej xws li scrapers kom cov khoom sib npaug ntawm cov pwm sab hauv, kom ntseeg tau tias cov thickness ntawm txhua qhov zoo ib yam. Rau cov khoom uas xav tau lub zog siab dua, ntau txheej ntawm iav fiber ntau tuaj yeem tso tau.
Kho: Muab cov pwm nrog cov ntaub ntawv tso rau hauv qhov cub kho, thiab kho ntawm qhov kub thiab txias (feem ntau 60-80 degree) rau ib lub sijhawm tshwj xeeb (30-60 feeb). Lub curing kub thiab lub sij hawm yuav tsum tau hloov kho raws li hom resin los xyuas kom meej curing tiav ntawm cov khoom.
Demolding thiab Finishing: Tom qab cov khoom tiav lawm, tshem tawm cov pwm, thiab tshem tawm cov burrs, flash thiab lwm yam tsis xws luag ntawm cov khoom siv los ntawm cov cuab yeej trimming. Thaum kawg, ua qhov kev tshuaj xyuas saum npoo kom ntseeg tau tias qhov kev ntxhib los mos thiab xim ua tau raws li qhov xav tau.
5. Cov ntawv thov tseem ceeb
FRP cov tawv nqaij mos sab hauv feem ntau yog siv hauv nruab nrab - mus rau - siab - tsheb kawg uas ua raws li kev nplij siab thiab kev ua haujlwm zoo. Cov ntawv thov feem ntau suav nrog: ntsuas vaj huam sib luag sab saud, qhov rooj vaj huam sib luag armrest thaj chaw, nruab nrab lub console sab vaj huam sib luag, thiab lub rooj zaum nraub qaum. Piv txwv li, qee cov qauv SUV khoom kim heev siv FRP cov tawv nqaij mos hauv qhov chaw kho kom zoo nkauj ntawm lub qhov rooj, uas tsis tsuas yog muaj qhov muag muag, tab sis kuj tuaj yeem tiv taus ntev ntev - siv yam tsis hnav. Tsis tas li ntawd, FRP cov tawv nqaij mos kuj tau siv dav hauv kev tsim kho tsheb sab hauv, vim tias lawv muaj zog moldability, lawv tuaj yeem ua tau raws li tus kheej xav tau ntawm cov neeg siv khoom.
Ⅱ Vacuum Forming
1. Txheej txheem Taw Qhia
Vacuum forming yog ib qho txheej txheem thermoforming rau tsheb mos sab hauv cov tawv nqaij. Nws siv lub hauv paus ntsiab lus ntawm lub tshuab nqus tsev tsis zoo los ua kom cov ntawv rhuab thiab softened thermoplastic zoo haum rau saum npoo ntawm cov pwm, thiab tom qab ntawd tsim cov duab xav tau tom qab txias thiab shaping. Cov txheej txheem yog qhov yooj yim thiab ua tau zoo, thiab tuaj yeem tsim cov tawv nqaij sab hauv nrog cov tuab tuab thiab pom kev zoo nkauj. Raws li hom pwm, lub tshuab nqus tsev sib sau tuaj yeem muab faib ua cov pwm zoo lub tshuab nqus tsev thiab tsis zoo pwm lub tshuab nqus tsev tsim. Ntawm lawv, tsis zoo pwm lub tshuab nqus tsev tsim yog dav siv nyob rau hauv automotive interiors vim hais tias nws muaj peev xwm zoo dua replicate zoo zoo nkauj ntawm cov pwm.
2. Hom khoom
Cov ntaub ntawv tsim nyog rau lub tshuab nqus tsev ntawm cov tawv nqaij mos hauv tsheb yog cov khoom siv thermoplastic zoo nrog cov thermoplasticity zoo thiab yooj, xws li: Polyvinyl Chloride (PVC), Thermoplastic Olefin (TPO), Acrylonitrile-Butadiene-Styrene (ABS) thiab Thermoplastic Polyurethane (PU). PVC yog cov khoom siv ntau tshaj plaws vim nws tus nqi qis, kev yooj yim thiab xim yooj yim. TPO muaj qhov zoo ntawm kev tiv thaiv ib puag ncig, kub tsis kam thiab tiv thaiv kev laus, thiab maj mam hloov PVC hauv cov qauv siab - kawg. TPU muaj kev hnav zoo heev thiab elasticity, thiab feem ntau yog siv rau hauv qhov chaw sab hauv uas yuav tsum tau hnav tsis kam, xws li armrests thiab lub log npog.
3. Cov yam ntxwv txheej txheem
Lub tshuab nqus tsev tsim cov txheej txheem muaj cov yam ntxwv hauv qab no: Ua ntej, kev ua haujlwm siab ntau lawm, lub voj voog ntawm ib qho khoom lag luam feem ntau tsuas yog 1-3 feeb, uas yog tsim rau loj- nplai loj ntawm cov tsheb sab hauv. Thib ob, cov cuab yeej siv qis qis, piv nrog 搪塑 (slush molding) cov txheej txheem, kev nqis peev hauv lub tshuab nqus tsev yog qis dua, uas yog qhov zoo rau cov lag luam me thiab nruab nrab los txais yuav. Thib peb, qhov zoo ntawm qhov chaw yog qhov zoo, cov khoom lag luam tuaj yeem ua raws li qhov kev ntxhib los mos ntawm cov pwm, thiab qhov saum npoo yog du yam tsis muaj qhov tsis xws luag. Plaub, kev siv cov khoom siv yog siab, cov khoom seem tom qab kev tsim tuaj yeem rov ua dua thiab rov siv dua. Txawm li cas los xij, cov txheej txheem kuj tseem muaj kev txwv: nws tsis tsim nyog rau kev tsim cov khoom nrog cov kab noj hniav sib sib zog nqus los yog txoj hauv kev undercuts; lub zog ntawm cov khoom yog qhov tsawg, thiab nws feem ntau yuav tsum tau muab sib xyaw nrog cov khoom siv pob txha siv.
4. txheej txheem ntws
Lub tshuab nqus tsev tsim cov txheej txheem ntawm automotive mos sab hauv cov tawv nqaij yog qhov paub tab, thiab cov kauj ruam tshwj xeeb yog raws li hauv qab no:
Pwm Installation: Txhim kho cov txheej txheem pwm (feem ntau yog txhuas pwm) ntawm qhov chaw ua haujlwm ntawm lub tshuab nqus tsev, thiab txuas lub tshuab nqus tsev rau cov pwm.
Daim ntawv kho thiab cua sov: Txiav cov ntawv thermoplastic rau hauv ib qho me me, kho nws ntawm lub clamping thav duab ntawm lub tshuab, thiab txav lub phaj cua sov mus rau txoj hauj lwm saum daim ntawv. Thaum tshav kub kub ntawm daim ntawv rau qhov softening kub (cov ntaub ntawv sib txawv muaj qhov sib txawv, xws li PVC yog 120-150 degree, TPO yog 150-180 degree) kom txog rau thaum daim ntawv yuav mos thiab zoo ductility.
Nqus adsorption: Txav mus rau hauv daim ntawv softened los npog cov pwm, thiab pib lub tshuab nqus tsev twj tam sim ntawd kom tshem tawm cov huab cua ntawm daim ntawv thiab cov pwm. Nyob rau hauv qhov kev txiav txim ntawm atmospheric siab, daim ntawv yog ze rau lub puab nto ntawm pwm, thiab kev ntxhib los mos thiab cov duab ntawm cov pwm yog replicated.
Txias thiab ua kom zoo: Siv cua txias lossis dej txias kom txias rau daim ntawv. Thaum qhov kub ntawm daim ntawv poob rau hauv chav tsev kub, cov duab ntawm cov khoom yog tsau.
Demolding thiab Trimming: Nres lub tshuab nqus tsev twj tso kua mis, tshem cov khoom tawm ntawm pwm, thiab siv lub tshuab txiav los txiav cov khoom seem ntawm cov khoom kom tau txais cov tawv nqaij sab hauv kawg.
5. Cov ntawv thov tseem ceeb
Kev tsim lub tshuab nqus tsev yog ib qho ntawm cov txheej txheem siv ntau tshaj plaws hauv cov tawv nqaij mos sab hauv tsheb, thiab nws cov khoom siv npog feem ntau ntawm cov mos thab sab hauv ntawm lub tsheb, suav nrog: lub qhov rooj vaj huam sib luag sab sauv ntawm daim tawv nqaij, ntsuas vaj huam sib luag qis dua, nruab nrab console kho vaj huam sib luag, lub cev sab hauv vaj huam sib luag thiab lub rooj zaum rov qab vaj huam sib luag. Piv txwv li, feem ntau cov qauv kev lag luam thiab kev cog lus siv PVC lub tshuab nqus tsev- tsim cov tawv nqaij rau lub qhov rooj vaj huam sib luag, uas tsis yog tsuas yog ua tau raws li qhov yuav tsum tau ua ntawm qhov muag muag, tab sis kuj tswj cov nqi tsim khoom. Tsis tas li ntawd, lub tshuab nqus tsev tsim cov tawv nqaij kuj feem ntau siv rau sab hauv ntawm cov tsheb lag luam, vim tias lawv cov khoom siv ntau lawm thiab tuaj yeem ua tau raws li qhov xav tau loj rau kev lag luam tsheb sab hauv.
Ⅲ Daim tawv nqaij Foaming
1. Txheej txheem Taw Qhia
Daim tawv nqaij foaming yog txheej txheem tshwj xeeb rau kev tsim cov tawv nqaij mos sab hauv. It forms a dense surface layer (skin layer) and a porous inner layer (foaming layer) on the surface of the substrate through chemical foaming or physical foaming. Cov tawv nqaij tawv txheej muab lub ntsej muag du thiab muag tes zoo li, thaum lub qhov ntxeem tau foaming muab cov elasticity zoo thiab tsis ua haujlwm. Cov txheej txheem tuaj yeem ua ke cov tawv nqaij thiab cov txheej txheem tsis sib xws rau hauv ib qho, txo cov txheej txheem sib dhos. Raws li cov txheej txheem foaming, nws tuaj yeem muab faib ua polyurethane (PU) foaming, polypropylene (PP) foaming, thiab lwm yam, ntawm cov PU tawv foaming yog qhov dav siv hauv tsheb sab hauv.
2. Hom khoom
Cov ntaub ntawv tseem ceeb ntawm cov txheej txheem ntawm daim tawv nqaij muaj xws li cov ntaub ntawv substrate thiab cov ntaub ntawv foaming. Cov khoom siv substrate feem ntau yog cov phaj yas nyuaj (xws li PP, ABS) lossis cov ntaub, uas ua lub luag haujlwm txhawb nqa. Cov khoom siv foaming feem ntau yog polyurethane (PU) cov khoom sib xyaw, uas yog tsim los ntawm ob yam: Cov khoom siv 1 yog cov khoom siv polyol, uas yog tov nrog catalysts, antioxidants, surfactants thiab UV absorbers; Cheebtsam 2 yog isocyanate. Tsis tas li ntawd, rau qhov kev ua tau zoo sib txawv, lwm cov ntaub ntawv tuaj yeem muab ntxiv, xws li ntxiv cov iav fiber ntau rau lub substrate los txhim kho lub zog, lossis ntxiv cov xim pleev xim rau cov khoom foaming los kho cov xim ntawm daim tawv nqaij.
3. Cov yam ntxwv txheej txheem
Cov txheej txheem ntawm daim tawv nqaij foaming muaj qhov tshwj xeeb zoo: Ua ntej, cov khoom muaj kev nplij siab zoo, cov tawv nqaij tawv txheej muaj qhov muag muag, thiab cov txheej foaming muaj elasticity zoo, uas tuaj yeem txhim kho kev nplij siab zoo. Qhov thib ob, nws muaj kev sib koom ua ke zoo, thiab txheej txheej ntawm daim tawv nqaij thiab txheej txheej foaming yog tsim nyob rau hauv ib lub sij hawm, uas tsis txhob muaj teeb meem ntawm delamination ntawm daim tawv nqaij thiab cov txheej txheem tsis nyob rau hauv cov txheej txheem ib txwm muaj. Qhov thib peb, zoo ib puag ncig adaptability, PU cov ntaub ntawv tom qab foaming muaj zoo siab thiab tsis kub tsis kam, thiab tsis yooj yim rau hnub nyoog los yog harden nyob rau hauv hnyav ib puag ncig tej yam kev mob. Plaub, kev tsim qauv yooj yim, lub thickness ntawm daim tawv nqaij txheej thiab txheej foaming tuaj yeem hloov kho los ntawm kev tswj cov foaming tsis. Qhov tsis zoo yog tias cov txheej txheem foaming yog rhiab rau qhov kub thiab txias, thiab qhov chaw tsim khoom yuav tsum tau tswj nruj me ntsis; lub voj voog ntau lawm ntev dua li ntawm lub tshuab nqus tsev.
4. txheej txheem ntws
Noj cov txheej txheem PU feem ntau ua npuas ncauj ua piv txwv, nws cov khoom ntws yog raws li hauv qab no:
Substrate Pretreatment: Ntxuav lub ntsej muag ntawm lub substrate (xws li PP phaj) kom tshem tawm cov roj thiab hmoov av, thiab siv cov primer yog tias tsim nyog los txhim kho qhov adhesion ntawm substrate thiab foaming txheej.
Kev npaj pwm: Ntxuav lub foaming pwm, thov ib tug tso tawm neeg sawv cev ntawm lub puab nto, thiab preheat lub pwm mus rau ib tug tej yam kub thiab txias (feem ntau 40-60 degree) los xyuas kom meej cov nyhuv foaming.
Foaming Material Npaj: Siv lub ntsuas ntsuas ntsuas kom raug ntsuas Cov Khoom Siv 1 (polyol cov khoom sib xyaw) thiab Cov Khoom Siv 2 (isocyanate) hauv ib qho kev faib ua feem, thiab sib tov sib npaug hauv qhov siab.
Pouring thiab Foaming: Muab cov khoom sib xyaw PU foaming rau hauv lub substrate, sai sai muab lub substrate rau hauv pwm, thiab kaw lub pwm. Cov khoom siv PU tau dhau los ua cov tshuaj tiv thaiv hauv pwm, thiab maj mam foams thiab kho kom tsim cov tawv nqaij txheej thiab txheej foaming.
Curing thiab Demolding: Khaws cov pwm kaw thiab kho rau ib lub sijhawm (feem ntau 15-30 feeb) kom txog rau thaum cov khoom siv PU kho tau zoo. Tom qab ntawd qhib lub pwm thiab tshem tawm cov khoom.
Tshaj tawm - kev ua haujlwm: Txiav cov burrs ntawm cov khoom, thiab ua qhov kev soj ntsuam zoo ntawm qhov chaw zoo nkauj, thickness thiab adhesion ntawm cov khoom.
5. Cov ntawv thov tseem ceeb
Cov txheej txheem ntawm daim tawv nqaij yog tsuas yog siv nyob rau hauv lub tsheb sab hauv qhov chaw uas muaj kev xav tau siab rau kev nplij siab thiab tsis ua hauj lwm, xws li: ntsuas vaj huam sib luag lub ntsiab lub cev, lub qhov rooj vaj huam sib luag armrest, nruab nrab console armrest, lub rooj zaum headrest thiab steering wheel cover. Piv txwv li, feem ntau nruab nrab - mus rau - siab - kawg sedans siv PU tawv foaming tshuab rau lub ntsuas vaj huam sib luag, uas tsis yog tsuas yog muaj lub ntsej muag zoo nkauj xwb, tab sis kuj tuaj yeem nqus tau lub zog thaum sib tsoo, txhim kho kev nyab xeeb. Tsis tas li ntawd, daim tawv nqaij foaming kuj tseem siv rau sab hauv ntawm lub tsheb tshiab, vim tias cov khoom siv PU muaj lub suab rwb thaiv tsev zoo, uas tuaj yeem txo cov suab nrov hauv lub tsheb thiab txhim kho kev caij tsheb.
Xaus
FRP molding, lub tshuab nqus tsev tsim thiab daim tawv nqaij foaming yog peb cov txheej txheem tseem ceeb rau tsheb mos sab hauv tawv nqaij, txhua tus muaj cov yam ntxwv tshwj xeeb thiab daim ntawv thov scenarios. FRP molding yog tsim rau nruab nrab - mus rau - siab - cov qauv kawg thiab kev kho sab hauv vim nws qhov kev ua tau zoo thiab kev tsim pwm; Lub tshuab nqus tsev yog siv dav hauv huab hwm coj- cov qauv tsim vim nws qhov ua tau zoo thiab tus nqi qis; daim tawv nqaij foaming yog nyiam los ntawm nruab nrab - mus rau - siab - qauv kawg rau nws txoj kev nplij siab thiab kev sib koom ua ke. Nrog rau kev txhim kho txuas ntxiv ntawm kev tsim kho tsheb sab hauv, cov txheej txheem no yuav ua kom zoo dua qub thiab txhim kho kom tau raws li cov kev xav tau ntawm cov neeg siv khoom ntau ntxiv rau kev nplij siab, kev tiv thaiv ib puag ncig thiab tus kheej.