Coated Product Corner Bending with Pre-heating and Half-fold
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Solution Overview
Problem
Conventional methods for manufacturing coated products with decorative materials often result in sagging or cracking at outer corner curved surfaces, especially when the radius of curvature is small, due to uneven heating and improper bending of the decorative material's bending margin.
Innovation Solution
A method and device that involve heating the bending margin using a heater and bending it with a first bending member, followed by further bending with a second bending member in a non-heated state, utilizing an abutment base to restrict the tip and adjust the height, ensuring uniform heating and precise bonding to the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the bending margin is heated without external force during the heating step, then the decorative material becomes pliable for bonding, but the bending margin extends and undulates due to heat causing non-uniform heating
Solution Approach 1:
The patent applies preliminary action by bending the bending margin in a half-folded state toward the side surface of the substrate during the heating step, before the actual bonding occurs. This pre-bending action restrains the bending margin from extending and undulating due to heat, ensuring uniform heating while maintaining shape stability. The bending is performed while the decorative material is still pliable from heat, and then the bent state is maintained during subsequent cooling and bonding steps.
2Manufacturing precision
If the bending margin is bent at a stretch in a non-heated state during bonding, then the decorative material can be bonded to the side surface, but the bending margin cannot be smoothly bent causing improper bonding position
Solution Approach 1:
The patent performs the bending action in advance during the heating step rather than during bonding. The bending margin is bent in a half-folded state while the decorative material is still pliable from heat, making the bending smooth and easy to perform. This preliminary bending ensures the bending margin can be smoothly formed without stretching or damage, and the bent state is then maintained during cooling and bonding, achieving precise bonding position.
Solution Approach 2:
The patent utilizes parameter changes by performing bending when the decorative material is in a heated, pliable state rather than in a cold, rigid state. The heat softens the decorative material, changing its mechanical properties to allow smooth bending without stretching. After bending, the material cools and hardens, maintaining the bent shape precisely for accurate bonding positioning.
3Shape
If the outer corner curved surface part has an extremely small radius of curvature, then the design is more compact and modern, but sagging or cracking is more likely to occur
Solution Approach 1:
The patent applies preliminary action by bending the bending margin in a half-folded state during the heating step, before the decorative material fully cools and hardens. This timing allows the material to be more pliable and easier to bend into tight curves with small radii of curvature. The pre-bending in the heated state prevents stress concentration and cracking that would occur if bending were attempted after cooling, while also preventing sagging by establishing the correct shape before final hardening.
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 effectively suppresses sagging or cracking at outer corner curved surfaces with small radii of curvature, ensuring a smooth and appropriate bonding of the decorative material, enhancing the design quality of coated products.
Implementation Method 1
a heating step of heating a bending margin (3a) of the decorative material (3) projecting outward from a side surface (2b) of the substrate (2) during transport of the laminate (5)
Implementation Method 2
in the heating step, the bending margin (3a) being heated is bent by a first bending member (31) that is arranged so as to face the heater (30) in a half-folded state toward the side surface (2b) of the substrate (2)
Implementation Method 3
in the bonding step, the bending margin (3a) bent in the half-folded state in the heating step (31) is bent by a second bending member (42) that is arranged so as to be spaced apart from the heater (30) on a downstream side in a transport direction (D) of the laminate (5)
Data Source
Figure 1
Figure 2
Figure 3(a)~3(b)
AI summary
Provided is a method for manufacturing a coated product that can suppress the occurrence of sagging or cracking at an outer corner curved surface part of a coated product. This manufacturing method includes a transport step of transporting a laminate (5) in which a decorative material (3) is bonded to a surface (2a) of the substrate; a heating step of heating a bending margin (3a) of the decorative material projecting outward from a side surface (2b) of the substrate during transport of the laminate; and a bonding step of bending the bending margin heated in the heating step during transport of the laminate in a non-heated state to bond the bending margin to the side surface of the substrate. In the heating step, the bending margin being heated is bent in a half-folded state toward the side surface of the substrate. In the bonding step, the bending margin bent in the half-folded state in the heating step is further bent to be bonded to the side surface of the substrate.