Absorptive Lining Production via Steam Vacuum Forming
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Solution Overview
Problem
Existing methods for producing absorptive linings in motor vehicles require complex systems and processes, leading to unnecessary material usage and inefficiencies, as they often involve preforming absorbers or insulations as circuit boards, which result in overweight components and inefficient material distribution.
Innovation Solution
A method where absorber material is formed into flakes and molded with defined cavity distributions, allowing for direct connection with an outer fabric in a steam/vacuum tool, enabling defined rigidity, strength, and acoustic properties without prior absorber production, and allowing for material savings by only using what is necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If absorber material is pressed to form stiffening fleece or carrier as circuit boards, then mechanical strength and rigidity are improved, but component weight increases and material distribution becomes inefficient
Solution Approach 1:
The patent applies local quality by distributing absorber material non-uniformly according to local requirements. The steam/vacuum forming process enables material accumulations in specific areas where strength is needed, while leaving other areas thinner, thus achieving weight reduction without compromising mechanical strength where required.
Solution Approach 2:
The patent changes the physical state and distribution parameters of absorber material through steam/vacuum forming. The material is transformed from a uniform preformed state to a locally varied thickness distribution, optimizing both weight and strength characteristics by adjusting material parameters locally.
2Stability of the object's composition
If preformed absorbers are laminated or back-injected with carriers, then structural stability is improved, but production complexity and system requirements increase
Solution Approach 1:
The patent merges multiple production steps into a single integrated process. The absorber material is formed, shaped, and connected to the outer fabric in one continuous steam/vacuum forming operation, eliminating the need for separate lamination or back-injection steps and reducing production complexity while maintaining structural stability.
Solution Approach 2:
The steam/vacuum tool serves multiple functions simultaneously: it forms the absorber material to desired thickness, provides structural stability through controlled deformation, and connects the outer fabric to the absorber. This multi-functional approach reduces the number of required systems and production steps.
3Ease of manufacture
If absorber material is distributed uniformly, then manufacturing simplicity is maintained, but material waste increases and acoustic properties are suboptimal
Solution Approach 1:
The patent implements local quality by enabling non-uniform distribution of absorber material through steam/vacuum forming. Material is concentrated in areas requiring higher acoustic absorption or mechanical strength, while minimizing material usage in areas where less is needed, thus reducing overall material waste while maintaining manufacturing simplicity.
4Strength
If outer fabric and absorber are connected through complex shaping processes, then mechanical properties in deformed areas are improved, but production time and process steps increase
Solution Approach 1:
The patent combines shaping and connection operations into a single steam/vacuum forming step. The outer fabric is connected to the absorber material while simultaneously shaping it to the final contour, eliminating separate shaping and trimming steps, thus reducing production time while maintaining mechanical properties in deformed areas.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces material waste by over 10% and allows for customized material distribution, achieving up to 20% weight savings and enabling varied thicknesses and properties through fiber flock technology, resulting in optimized mechanical and acoustic performance.
Implementation Method 1
the upper fabric is deformed by applying steam from the underside of the absorber material, the binder in the absorber material is activated and the upper fabric and absorber material are connected to one another
Implementation Method 2
the vapor pressure is reduced by lower pressure on the upper side compared to the pressure on the underside of the absorber material
Data Source
AI summary
The invention relates to a method for producing at least two-layer components and correspondingly produced components per se as absorptive lining in the interior and/or boot or for floor coverings of motor vehicles, comprising a top material and an absorber.