Cold Lamination with Radiation for Automotive Interiors

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Solution Overview

Problem

The existing press lamination process for producing motor vehicle interior structural elements is hindered by poor heat conductivity of the material layer, leading to longer process times and higher energy input due to inefficient heat transfer, which can also damage the decorative surface and cause adhesion defects.

Innovation Solution

The process employs electromagnetic radiation, such as microwave or high-frequency radiation, to activate the adhesive directly through the use of graphene-like materials applied to the tool halves or the material layer, avoiding direct heat input and enabling uniform temperature distribution and reduced energy consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If heat from the laminating tool is transferred through the structural element to activate the adhesive, then the adhesive develops bonding properties, but the process time increases and energy consumption increases due to poor heat conductivity of the material layer

Engineering Contradiction:

Improveadhesive bondingVSAvoidprocess time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces the thermal conduction mechanism (heat transfer through the material layer) with electromagnetic radiation (microwave or high-frequency radiation) that can directly penetrate and activate the adhesive without relying on heat conduction through the poor conductor material layer

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces graphene-like materials as an intermediary that absorbs electromagnetic radiation and converts it to heat locally at the adhesive interface, enabling selective and efficient adhesive activation without heating the entire structural element

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If heat from the laminating tool is transferred through the structural element to activate the adhesive, then the adhesive develops bonding properties, but the energy input increases due to poor heat conductivity of the material layer

Engineering Contradiction:

Improveadhesive bondingVSAvoidenergy input

Core Design Contradiction:

ReliabilityVSUse of energy by stationary object

Solution Approach 1:

The patent replaces the thermal conduction mechanism with electromagnetic radiation that directly activates the adhesive, eliminating energy losses associated with heating the entire structural element through poor conductors

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent applies energy locally at the adhesive interface through electromagnetic radiation and graphene-like materials, rather than heating the entire structural element, thereby reducing overall energy consumption

Inventive Principle:

Principle #3Local quality

3Reliability

If heat from the laminating tool is transferred through the structural element, then the adhesive is activated, but the decorative surface may be damaged and adhesion defects may occur

Engineering Contradiction:

Improveadhesive activationVSAvoidsurface damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces graphene-like materials as an intermediary that selectively absorbs electromagnetic radiation and converts it to heat only at the adhesive interface, preventing excessive heat exposure to the decorative surface

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent enables localized heating at the adhesive interface through electromagnetic radiation and graphene-like materials, activating the adhesive without subjecting the decorative surface to harmful thermal exposure

Inventive Principle:

Principle #3Local quality

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 significantly shortens cycle times, prevents surface damage, and reduces energy consumption while ensuring uniform adhesion, thereby improving the quality and efficiency of the laminating process.

Implementation Method 1

Methodology Applied

Scientific EffectElectromagnetic radiation heating: Dielectric Heating

Implementation Method 2

heat from the laminating tool is transferred from the tool to the components and, from there, into the adhesive between the components

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

The heat activates and crosslinks the adhesive so that it develops its adhesive and bonding properties

Methodology Applied

Scientific EffectCrosslinking: Chemical Bonding

Data Source

PatentUS10059088B2Cold lamination with radiation

Publication Date: 2018.08.28 LISA DRAXLMAIER GMBH

AI summary

A process for laminating a material layer to a support including: providing the support, applying the material layer to the support, a heat-activatable adhesive being applied to s side of the material layer facing the dimensionally stable support and/or to the side of the dimensionally stable support facing the material layer, pressing the flexible material layer and the dimensionally stable support together by means of a lower dimensionally stable mold half and an upper dimensionally stable mold half, irradiating the mold halves, the support and the material layer with electromagnetic radiation, in particular with microwave radiation, high-frequency radiation or induction radiation, whereby the adhesive is activated directly or indirectly.