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Article(id=1209856648504545851, tenantId=1146029695717560320, journalId=1189873562199433220, issueId=1209856645690159533, articleNumber=null, orderNo=null, doi=10.19710/J.cnki.1003-8817.20230278, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=research-article, receivedDate=null, receivedDateStr=null, revisedDate=null, revisedDateStr=null, acceptedDate=null, acceptedDateStr=null, onlineDate=1766381903052, onlineDateStr=2025-12-22, pubDate=1716134400000, pubDateStr=2024-05-20, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1766381903052, onlineIssueDateStr=2025-12-22, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1766381903052, creator=13701087609, updateTime=1766381903052, updator=13701087609, issue=Issue{id=1209856645690159533, tenantId=1146029695717560320, journalId=1189873562199433220, year='2024', volume='', issue='5', pageStart='1', pageEnd='72', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1766381902382, creator=13701087609, updateTime=1766381902382, updator=13701087609, preIssue=null, nextIssue=null, ext=null, issueFiles=null}, startPage=14, endPage=17, ext={EN=ArticleExt(id=1209856649855111748, articleId=1209856648504545851, tenantId=1146029695717560320, journalId=1189873562199433220, language=EN, title=Optimization & Application of IMGL Process Based on TPO Skin, columnId=null, journalTitle=Automobile Technology & Material, columnName=null, runingTitle=null, highlight=null, articleAbstract=

In order to solve the existing problems of too many processes in the In-Mold Graining Lamination (IMGL) process, the IMGL process based on Thermoplastic Olefin (TPO) skin was optimized and applied in practice. Compared with the existing problem of too long processes, this paper proposed the reduction of some processes and optimization of the forming equipment and mold, which were put in production. Compared with the existing IMGL process flow chart, the new flow reduced 6 processes, saved 35 m2 production site, shortened the IMGL forming cycle by 15 s, reduced glue usage, and improved the utilization rate of glue by 90%.

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为解决现有阴模真空覆合成形工序过多的问题，对热塑性聚烯烃弹性体（TPO）表皮的阴模真空覆合成形（IMGL）工艺流程进行了优化与应用，通过对比分析现有工序，提出了减少工序流程同时优化成形工艺设备及模具等新方案并实施应用。与现有的阴模真空覆合成形工艺流程相比，工序减少6道、生产场地节省35 m2，成形周期缩短15 s，胶水用量减少且胶水利用率提升至90%。

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胡学川（1972—），男，正高级工程师，硕士学位，研究方向为汽车内外饰新技术新工艺研发。

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胡学川（1972—），男，正高级工程师，硕士学位，研究方向为汽车内外饰新技术新工艺研发。

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胡学川（1972—），男，正高级工程师，硕士学位，研究方向为汽车内外饰新技术新工艺研发。

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工序 打孔 火焰处理 喷胶 烘烤 阴模成形 切边 二次喷胶 二次烘烤 包覆(含手工)
优化
前工艺		 √ √ √ √ √ √ √ √ √
优化前人员需求 1 1 0 1 1 1 6
优化后
工艺		 × × √ × √ × × × √
优化后
人员需求		 0 0 1 0 2 0 0 0 6
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优化前后工序人员对比 人

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工序 打孔 火焰处理 喷胶 烘烤 阴模成形 切边 二次喷胶 二次烘烤 包覆(含手工)
优化
前工艺		 √ √ √ √ √ √ √ √ √
优化前人员需求 1 1 0 1 1 1 6
优化后
工艺		 × × √ × √ × × × √
优化后
人员需求		 0 0 1 0 2 0 0 0 6
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检测项 阴模成形周期
传统IMGL设备 85
新双工位IMGL设备 70
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优化前后成形周期对比 s

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检测项 阴模成形周期
传统IMGL设备 85
新双工位IMGL设备 70
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传统水性胶
（喷胶）		 每件喷胶 每件二次喷胶 每件
总用胶量
理论用量/g 25 3 28
实际用量/g 50 5 55
利用率/% 50.91
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传统的水性胶喷胶工艺胶水利用率

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传统水性胶
（喷胶）		 每件喷胶 每件二次喷胶 每件
总用胶量
理论用量/g 25 3 28
实际用量/g 50 5 55
利用率/% 50.91
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热熔胶(刮胶） 每件卷材喷胶面积 每件二次喷胶面积 每件总用胶量面积
理论用量/m2 0.333 0 0 0.333 0
实际用量/m2 0.367 5 0 0.367 5
利用率/% 90.61
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热熔胶刮胶工艺胶水利用率

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热熔胶(刮胶） 每件卷材喷胶面积 每件二次喷胶面积 每件总用胶量面积
理论用量/m2 0.333 0 0 0.333 0
实际用量/m2 0.367 5 0 0.367 5
利用率/% 90.61
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基于TPO表皮的IMGL工艺流程优化与应用
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胡学川 1 , 李又兵 2 , 张继祥 3 , 杨瑶 1
汽车工艺与材料 | 生产现场 2024,(5): 14-17
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汽车工艺与材料 | 生产现场 2024, (5): 14-17
基于TPO表皮的IMGL工艺流程优化与应用
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胡学川1, 李又兵2, 张继祥3, 杨瑶1
作者信息
  • 1 重庆平伟汽车零部件有限公司， 重庆 401133
  • 2 重庆理工大学材料科学与工程学院， 重庆 400054
  • 3 重庆交通大学机电与汽车工程学院， 重庆 400074

    • 胡学川（1972—），男，正高级工程师，硕士学位，研究方向为汽车内外饰新技术新工艺研发。

Optimization & Application of IMGL Process Based on TPO Skin
Xuechuan Hu1, Youbing Li2, Jixiang Zhang3, Yao Yang1
Affiliations
  • 1 Chongqing Pingwei Auto Parts Co., Ltd., Chongqing 401133
  • 2 College of Materials Science and Engineer, Chongqing University of Technology, Chongqing 400054
  • 3 College of Mechanic & Electronic Automobile Chongqing Jiaotong University, Chongqing 400074
出版时间: 2024-05-20 doi: 10.19710/J.cnki.1003-8817.20230278
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摘要
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为解决现有阴模真空覆合成形工序过多的问题，对热塑性聚烯烃弹性体（TPO）表皮的阴模真空覆合成形（IMGL）工艺流程进行了优化与应用，通过对比分析现有工序，提出了减少工序流程同时优化成形工艺设备及模具等新方案并实施应用。与现有的阴模真空覆合成形工艺流程相比，工序减少6道、生产场地节省35 m2，成形周期缩短15 s，胶水用量减少且胶水利用率提升至90%。

TPO表皮  /  阴模真空覆合成形  /  工艺流程  /  优化方案  /  实施应用

In order to solve the existing problems of too many processes in the In-Mold Graining Lamination (IMGL) process, the IMGL process based on Thermoplastic Olefin (TPO) skin was optimized and applied in practice. Compared with the existing problem of too long processes, this paper proposed the reduction of some processes and optimization of the forming equipment and mold, which were put in production. Compared with the existing IMGL process flow chart, the new flow reduced 6 processes, saved 35 m2 production site, shortened the IMGL forming cycle by 15 s, reduced glue usage, and improved the utilization rate of glue by 90%.

TPO Skin  /  IMGL  /  Process flow  /  Optimization plan  /  Implementation and application
胡学川, 李又兵, 张继祥, 杨瑶. 基于TPO表皮的IMGL工艺流程优化与应用. 汽车工艺与材料, 2024 , (5) : 14 -17 . DOI: 10.19710/J.cnki.1003-8817.20230278
Xuechuan Hu, Youbing Li, Jixiang Zhang, Yao Yang. Optimization & Application of IMGL Process Based on TPO Skin[J]. Automobile Technology & Material, 2024 , (5) : 14 -17 . DOI: 10.19710/J.cnki.1003-8817.20230278
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1 前言
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随着汽车行业对外观设计和品质要求的不断提高，阴模真空覆合成形（In-Mold Graining Lamination，IMGL）工艺技术作为一种先进的汽车内饰生产工艺，关注度越来越高。IMGL通过在成形工序中镍壳模真空吸附实现表面纹理和热塑性聚烯烃弹性体（Thermoplastic Olefin，TPO）表皮背面胶水激活与骨架覆合，可以使汽车内饰更具质感。由于TPO表皮为环保型材料，具有耐候性、耐化学品、抗冲击性、柔韧性、防水性和环保性的特性，已成为汽车门板或仪表板等部位的理想用料。
目前，国内研究者就TPO表皮的IMGL工艺在汽车内门板和仪表板等应用，围绕材料、成形参数、产品应用等方面开展了一系列研究。王志兵等[1]着重研究了IMGL真空包覆仪表板高温起泡的原因，并说明了改善方向和改善后的效果，为起泡问题的解决提供了思路；潘琦等[2]提出了采用IMG工艺的仪表板出现的缺陷以及解决措施；徐钧等[3]着重分析了IMGL工艺在成形过程中皮纹失真、厚度不均问题，通过仿真和试验，结合六西格玛方法提出了合理的表皮参数并进行了可行性验证。国外对IMGL的研究主要集中在IMGL的镍壳模成形技术、IMGL设备和粘接工艺等方面。目前在材料选择、成形参数、产品应用等方面的研究较为完善，但在IMGL工艺流程上的研究较少。在实际生产中，传统的IMGL工艺流程存在生产工序长、占地面积大、成形周期长、胶水用量大的问题，限制了IMGL技术的发展和推广。为此，急需寻求一种高效的基于TPO表皮IMGL的制造工艺路线。
2 现有工艺流程及其存在的问题
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通常情况下，汽车内门板上装骨架、嵌饰件或仪表板上的装饰件等包覆件大多采用阴模真空吸附覆合成形，一般采用玻纤增强改性聚丙烯（Glass Fiber reinforced Polypropylene，PP-GF）骨架材料、TPO表皮及水性胶覆合，现有的阴模真空覆合成形工艺流程如图1所示。
由图1可知，现有的阴模真空覆合成形工艺流程存在工序流程长、占地场地大、成形周期长、胶水用量大、效率低的问题。
3 工艺流程方案设计优化
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为解决以上问题，对现有阴模真空覆合成形的工艺流程进行优化，形成一种高效的上装骨架或嵌饰板阴模真空覆合成形的制造工艺。
3.1 工艺流程设计优化
以某车型上装骨架为例，材料由玻纤增强改性聚丙烯PP-GF改为丙烯腈-丁二烯-苯乙烯共聚物（Acrylonitrile-Butadiene-Styrene copolymer，ABS），TPO光表皮材料为0.6 mm厚的TPO表皮带背泡2.5 mm厚的聚丙烯泡沫（PP Foam），胶水由水性胶改为聚氨酯（Polyurethane，PUR）热溶胶，优化后的真空吸附覆合成形工艺流程如图2所示。
与现有的阴模真空覆合成形工艺流程（图1）相比，优化后的工艺流程优点如下：
a. TPO表皮卷材无需裁剪，直接在TPO表皮背面刮胶完成后收卷，送到阴模成形入口处；
b. 取消了打孔工序，该产品上的真空孔通过模具机构实现；
c. 取消了火焰处理，因产品骨架本身采用ABS极性材料，满足达因值要求；
d. 由2次烘烤改为1次烘烤，2条烘烤线改为1条烘烤线；
e. 阴模成形后不再需要单独的切边工序将表皮裁剪成所需的形状，而是直接在阴模成形后滑动上刀模到成形工位，上下合模裁剪成后续包覆所需的形状；
f. 由热熔胶刮胶工艺取代水性胶喷胶工艺，由2次喷水性胶（第1次为骨架喷胶，第2次为阴模成形及切边后表皮周边背面喷水性胶，以便包覆）改为1次刮涂热熔胶（即热熔胶刮涂在TPO表皮背面）。
3.2 优化后的成形工艺设备及模具
以上述某车型上装骨架为例，工艺设计优化后的阴模真空覆合成形工艺设备如下：
3.2.1 热溶胶刮涂设备
对TPO表皮卷材涂覆热熔胶，采用热熔胶刮涂设备，工艺如图3所示，工艺流程为卷材放卷、储布箱、牵引、喷胶、冷却、储布箱、收卷。
传统的水性胶采用机器人喷胶设备喷洒，浪费较大。而热熔胶工艺采用刮涂设备，将热熔胶加热熔化后通过一定压力送入刮涂设备，热熔胶直接从两片刮刀中间的间隙流出，刮涂到TPO表皮背面，故热熔胶利用率更高。
3.2.2 阴模成形设备
阴模成形采用带转台的双工位IMGL设备（图4）,将涂覆后的TPO表皮铺放在IMGL设备入口，通过传输链带动表皮进入设备加热区，加热后的表皮再传输到成形区阴模成形。
将产品骨架放置在双工位转台IMGL阴模下模，旋转到成形区位置即IMGL阴模上模位置，与TPO加热表皮一起，通过IMGL镍壳模上下模闭合形成密闭空间，通过阴模真空覆合成形，将镍壳模上模的纹理复制在TPO光表皮上，同时将产品骨架和TPO表皮粘接在一起，镍壳模上模和切表皮的刀模整体输送至成形工位，再上下合模切断表皮，形成所需要的表皮尺寸，以便后工序包覆成形。
3.2.3 阴模真空成形结构
阴模真空成形结构原理如图5所示。
阴模上模即镍壳模，用于TPO光表皮的纹理成形，阴模上模自带皮纹和真空孔，真空孔肉眼不易观察，孔径ϕ为(0.15±0.05) mm，间距为10~15 mm，阴模如图6所示。
3.2.4 模具结构
优化的IMGL工况2套模具，安装在同一台阴模成形设备上，分别为IMGL阴模成形模具和IMGL刀模切边模具。
a. IMGL阴模成形模具主要结构如图7所示。
b. IMGL切边模具主要结构如图8所示。
3.3 改进后的效果
以上述车型上装骨架为例，采用上述设计优化后的新工艺改进效果如下：
a. 通过对比新工艺与现有的工艺，新工艺工序缩短、操作人员减少、节省场地，如表1所示。由表1可知，优化后比优化前减少6道工序，节省场地35 m2，同时减少2名操作人员。
b. 骨架放置在带双工位转台的IMGL设备上，放置骨架和取件的同时进行成形及冲切表皮，节省了取放件时间，缩短了阴模成形周期，提升了生产效率，如表2所示。
由表2可知，采用带双工位转台的IMGL新设备每模周期缩短约15 s。
c. IMG上装表皮与ABS骨架采用PUR热熔胶工艺，与传统的水性胶喷胶工艺相比，热熔胶刮胶工艺的胶水利用率更高。传统的水性胶工艺胶水利用率如表3所示，热熔胶刮胶工艺的胶水利用率如表4所示。
由表3可知，传统的水性胶喷胶工艺胶水利用率约为50%。
由表4可知，采用热熔胶刮胶工艺的胶水利用率约为90%。
4 结束语
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基于本文对IMGL工艺流程的改进优化结果，得出如下结论：
a.设计优化后的IMGL成形工艺流程，工序减少6道，场地面积节省35 m2，操作人员减少2名；
b.基于以上的工艺设计理念，阴模成形周期缩短约15 s。
c.相比水性胶喷胶工艺，热熔胶刮胶工艺减少了胶水的用量，胶水利用率提升至90%。
文献
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参考文献 引证文献
排序方式：
[1]
王志兵, 陈典汉. 关于IMG-L真空包覆仪表板高温起泡的解决方案[J]. 汽车工艺与材料, 2023(3): 39-42.
[2]
潘琦, 李亚喆, 江诚. 浅析IMG阴模真空成形仪表板的外观缺陷及改善措施[J]. 汽车工艺与材料, 2018(10): 68-72.
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徐钧, 刘兵, 郭庆. 表皮真空成形性能研究[J]. 机械, 2018, 45(4): 15-17+23.
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doi: 10.19710/J.cnki.1003-8817.20230278
  • 首发时间：2025-12-22
  • 出版时间：2024-05-20
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    1 重庆平伟汽车零部件有限公司， 重庆 401133
    2 重庆理工大学材料科学与工程学院， 重庆 400054
    3 重庆交通大学机电与汽车工程学院， 重庆 400074
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