汽车饰件微孔发泡/模内装饰一体化注塑成型技术基础研究

Automobile interior and exterior decoration is one of the indispensable automotive parts. And key technical issues for decorations to be solved are the improvements of the material utilization and product quality. This project intends to adopt microcellular injection molding / In-mold decoration to improve the material utilization, physical properties and surface quality of the auto interior and exterior decoration. Through theoretical study, experimental test and finite element simulation, microscopic analysis, the change mechanism of gas – polymer blend melt flow properties and the evolvement rule of microspores histomorphology were uncovered under the intervention of decorative film, meanwhile, the develop rules of forming geometric accuracy and physical properties were also researched. The process theory and design method of microcellular injection molding / In-mold decoration was established. In this project, In-mold decoration was employed to optimize the microcellular injection molding of vehicle interior & exterior, from considering macro-molding forming to a comprehensive analysis of the macro-molding and micro-molding. This project has a great academic value and practical significance in proposing the automotive interior and exterior trim foam injection molding technology engineering theory, promoting high performance and light-weighting plastic parts in automotive applications.

汽车饰件是汽车不可或缺的零件之一，提高材料利用率和产品质量是汽车饰件应用发展亟待解决的关键技术问题。本项目拟采用微孔发泡/模内装饰注塑成型技术提高材料利用率、物理性能和表观质量。通过理论研究、实验测试和有限元模拟，宏微观分析相结合，揭示装饰薄膜介入后，气体-聚合物混合熔体流动性能变化机理、微孔组织形态演化规律和成型几何精度与物理性能形成规律，建立汽车饰件微孔发泡/模内装饰注塑成型成性工艺理论与设计方法。本项目将模内装饰引入到优化汽车饰件微孔发泡注塑成型工艺中，从考虑宏观成型推进到综合分析宏、微观成型相互作用，对于形成汽车内外饰微孔发泡注塑成型技术工程科学理论，促进高性能、轻量化塑料件在汽车中的应用具有重要的学术意义。

本项目提出的微孔发泡/模内装饰复合注塑成型技术是一种节能减排效果显著的先进注塑成型技术，将其应用与汽车饰件的制造，有利于提高汽车饰件的材料利用率、物理性能和表观质量。通过理论研究、实验测试和有限元模拟，宏微观分析相结合，针对汽车饰件微孔发泡/模内装饰注塑成型过程中的传质传热规律开展了深入系统的研究。建立了微孔发泡/模内装饰一体化注塑成型系统，并通过设备联合调试，满足微孔发泡/模内装饰一体化注塑成型试验的要求，建立了微孔发泡/模内装饰成型过程的有限元分析模型，实现了工艺全流程的有限元仿真分析，揭示了微孔发泡/模内装饰注塑成型工艺特点。建立了非对称热传递与自然降温耦合状态下的传热数学模型，揭示了微孔发泡/模内装饰一体化注塑成型过程中的传热机制，并研究了传热特性对微孔发泡/模内装饰成型制件性能的影响机理。针对气体-聚合物混合熔体与预制薄膜的材料特性，根据材料学、流体力学和传热学理论，通过理论研究、数值分析和实验测试相结合的方法，揭示了伴随着非对称热传递和自然降温注塑成型过程中泡孔形态、力学性能和几何精度的形成规律；揭示了材料、气体、模具和工艺参数影响微孔发泡/模内装饰一体化注塑成型性能的内在物理机制；研究了异质界面与泡孔形态协同控制机制，形成了汽车饰件微孔发泡/模内装饰一体化注塑成型工艺理论与设计方法。本项目将模内装饰引入到优化汽车饰件微孔发泡注塑成型工艺中，从考虑宏观成型推进到综合分析宏、微观成型相互作用，对于形成汽车内外饰微孔发泡注塑成型技术工程科学理论，促进高性能、轻量化塑料件在汽车中的应用具有重要的学术意义。