Coated Vehicle Interior Frame for Primer-Free Glass Bonding
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Solution Overview
Problem
The existing methods for forming curved glass substrates for vehicle interiors require chemical primers, which are subject to environmental regulations, increasing manufacturing costs and disrupting the manufacturing process due to their short shelf-life and the need for on-site application.
Innovation Solution
A vehicle interior component is developed with a coated frame where the adhesive is directly bonded to a paint or electrodeposition coating, eliminating the need for chemical primers and allowing for off-site preparation and shipping, using coatings like polyurethane, acrylic, or epoxy that provide sufficient surface chemistry for bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If chemical primer is used to prepare glass substrate for adhesive bonding, then bonding strength is improved, but manufacturing cost increases and environmental compliance becomes difficult
Solution Approach 1:
The patent removes the chemical primer step from the bonding process by using a coated frame instead. The coating on the frame provides the necessary surface properties for adhesive bonding without requiring a separate chemical primer application, thereby eliminating the associated environmental compliance issues and manufacturing complexity
Solution Approach 2:
The coating on the frame acts as an intermediary between the frame surface and the adhesive. This coating layer provides the necessary surface chemistry for strong adhesive bonding without requiring the use of chemical primers on the glass substrate, thus resolving the contradiction between bonding strength and manufacturing ease
2Reliability
If chemical primer is applied on-site, then bonding reliability is improved, but manufacturing process is disrupted and productivity decreases
Solution Approach 1:
The frame is pre-coated with the appropriate coating material before assembly. This preliminary action ensures that the surface is ready for adhesive bonding without requiring on-site chemical primer application, thereby maintaining bonding reliability while improving manufacturing efficiency and avoiding process disruptions
Solution Approach 2:
The patent extracts the primer application step from the on-site manufacturing process by using a pre-coated frame. This eliminates the need for on-site chemical primer application, maintaining bonding reliability while significantly improving productivity and eliminating process disruptions
3Strength
If chemical primer with short shelf-life is used, then adhesive bonding performance is improved, but loss of time increases due to on-site application requirement
Solution Approach 1:
The frame coating is applied in advance during frame manufacturing, allowing for proper curing and shelf-life extension. This preliminary action eliminates the need for on-site chemical primer application, maintaining adhesive bonding performance while reducing manufacturing time losses
Solution Approach 2:
The patent replaces the short-lived chemical primer with a durable coating that can be applied once during frame manufacturing. This coating maintains its bonding performance over extended periods, eliminating the time loss associated with on-site primer application and the need for frequent reapplication
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 solution reduces manufacturing costs, improves efficiency by allowing single-facility production, and avoids environmental compliance issues while maintaining strong adhesive bonds, as demonstrated by the overlap shear and tensile strength tests.
Implementation Method 1
an adhesive joining the second major surface of the glass article to support surface of the frame. In one or more embodiments, the adhesive is bonded directly to the coating.
Data Source
AI summary
Disclosed are embodiments of a vehicle interior component. The vehicle interior component includes a glass article having a first major surface and a second major surface in which the second major surface is opposite to the first major surface. The vehicle interior component also includes a frame comprising a support surface and a coating disposed on the support surface of the frame. The vehicle interior component further includes an adhesive joining the second major surface of the glass article to support surface of the frame. The adhesive is bonded directly to the coating.