Journal of the Korea Academia-Industrial cooperation Society (한국산학기술학회논문지)

The Korea Academia-Industrial cooperation Society (한국산학기술학회)
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Development of Two-Shot Injection-Compression Soft Instrument Panel

2샷 사출 압축 소프트 인스트루먼트 패널 개발

  • Kong, Byung-Seok (Interior Research Lab, Hyundai Motor Company) ;
  • Park, Dong-Kyou (Department of Electromechnical Convergence Engineering, Korea University of Technology and Education)
  • 공병석 (현대자동차 인테리어리서치랩) ;
  • 박동규 (한국기술교육대학교 기전융합공학과)
  • Received : 2018.11.13
  • Accepted : 2019.02.01
  • Published : 2019.02.28
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Abstract

In order to reduce the cost and weight of the soft-foamed instrument-panel (IP), it was developed the new IP which is made by the two kinds of injection methods. One is the compression-injection with back-foamed foil inserted, and the other is two-shot injection with the passenger airbag door. We named it 'IMX-IP' which means that all components ('X') of the IP with different resins are made in a mold. The development procedure of this technology was introduced (1) Design of the new injection mold through TRIZ method, (2) Optimization of the injection conditions and back foamed-foil for minimizing the foam loss and thickness deviation, (3) Development of CAE for two-shot injection compression, (4) Reliability performance test and application to the mass production. The reduction of the processes through the two-shot injection with back foamed-foil inserted made it possible to enhance soft feeling on IP and reduce the cost and weight simultaneously.

자동차 소프트 인스트루먼트 패널의 비용과 중량을 줄이기 위하여 두 가지 사출을 동시에 수행하는 방법을 이용한 새로운 인스투르먼트 패널이 개발되었다. 첫 번째 사출은 뒷면 발포체 포일을 삽입하는 압축 사출을 하는 방법이고, 다른 하나는 동승석 에어백에 도어와 동시에 2샷 사출하는 방법이다. 우리는 그것을 'IMX-IP'라고 부르며, 이것은 인스트루먼트 패널의 모든 부품들이 종류가 다른 수지와 하나의 금형 안에서 만들어지는 방법인 것이다. 본 기술의 개발 과정은 (1) TRIZ 기법을 이용한 새로운 사출 금형 설계, (2) 사출 조건의 최적화와 폼의 손실과 두께 편차를 최소화하기 위한 뒷면 발포체 포일의 최적화, (3) 2샷 사출 압축에 대한 CAE 해석 검증, (4) 신뢰성 검증 시험과 양산에의 적용 순서로 이루어져 있다. 뒷면 발포체 포일 삽입을 이용한 2샷 사출을 통한 공정 감소는 개발비와 중량 절감과 함께 소프트 인스투루먼트 패널의 부드러운 느낌을 향상시키는 것을 가능하게 하였다.

Keywords

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Fig. 1. IMX technology application area and back foamed foil technology comparison

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Fig. 2. IP surface value analysis

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Fig. 3. Mold design concept using TRIZ method

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Fig. 4. System diagram and objective function of the IMX technology

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Fig. 5. The higher sensitivity of 4 control factors for recovery and the thickness variation

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Fig. 6. 1st optimum levels of each factors selected by experiments

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Fig. 7. Multi-layer foam for thermal and pressure blocking mechanism (Final optimization)

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Fig. 8. The boundary of the different resins (inside/outside); Analysis result and sample

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Fig. 9. Heat transfer from resin to foam with time

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Fig. 10. Prediction of deformation after injection

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Fig. 11. Analysis and testing of the airbag deployment and head impact

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Fig. 12. IMX IP of HYUNDAI-i20

References

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