Common Carrier for Decorative Layer Application
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Solution Overview
Problem
Current methods for producing decorative parts in the automotive sector require multiple steps and tools, leading to increased costs due to the need for separate carriers for high-quality decorative layers, which is inefficient and costly.
Innovation Solution
A production device with a common carrier for both the base and additional decorative layers, utilizing a vacuum device and contour generator to apply and shape the layers in a single step, eliminating the need for separate carriers and reducing tool requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate carriers are used for high-quality decorative layers, then the quality and appearance of the decorative part is improved, but the production cost and device complexity increase
Solution Approach 1:
The patent merges the function of multiple separate carriers into a single common carrier that supports both the basic decorative layer and the additional high-quality decorative layer. This single carrier integrates the support functions previously distributed across multiple carriers, reducing device complexity while maintaining the ability to produce high-quality decorative surfaces through the additional decorative layer.
Solution Approach 2:
The common carrier is designed to perform multiple functions simultaneously: it supports both the basic decorative layer and the additional decorative layer, provides structural stability for the entire assembly, and enables the production of multi-quality decorative surfaces. This multi-functional design eliminates the need for separate carriers for different decorative layers.
2Reliability
If multiple steps and tools are used to produce decorative parts, then each decorative layer can be properly applied and secured, but the production time and manufacturing cost increase
Solution Approach 1:
The patent combines multiple production steps into a single integrated process. Both the basic decorative layer and the additional decorative layer are applied and secured to the common carrier in one simultaneous operation, rather than through separate sequential steps. This merging of steps reduces production time while maintaining application quality through the unified design of the common carrier and application process.
Solution Approach 2:
The common carrier is pre-configured with appropriate adhesive surfaces and structural features that enable both decorative layers to be applied correctly in a single step. The carrier's design includes pre-prepared areas for receiving the basic decorative layer and the additional decorative layer, ensuring proper application and secure attachment without requiring multiple separate operations.
3Ease of manufacture
If separate carriers are used for different decorative layers, then each layer can be independently managed and applied, but the material cost and waste increase
Solution Approach 1:
The patent combines the material resources into a single common carrier structure that supports both decorative layers, eliminating the need for multiple separate carrier materials. This reduces material consumption and waste associated with producing and disposing of multiple carriers, while the carrier's design ensures both decorative layers can be independently positioned and applied.
Solution Approach 2:
The common carrier is designed to be reusable across multiple production cycles. After the decorative layers are applied and the decorative part is assembled, the common carrier can be recovered, cleaned, and reused for producing additional decorative parts, reducing material waste compared to single-use separate carriers.
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
Enables the production of decorative parts with different surface qualities and materials in a single step, reducing production time and costs by integrating the application and shaping of both decorative layers on a common carrier, resulting in a cost-effective and efficient process.
Implementation Method 1
a vacuum device (50) arranged in the upper tool device (40), which is designed in such a way that a vacuum can be generated between the second surface section (30) and an additional decorative layer (130) that is received and/or between the first surface section (20) and a basic decorative layer (120) that is received
Data Source
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AI summary
The manufacturing device comprises a support (110), where a base decorative layer (120) is associated at a side surface of the support. An additional decorative layer (130) is associated at the similar side surface of the support. A contour surface is formed with a surface portion (20) for receiving the base decorative layer. A contour generator (60) is arranged along the edge of another surface portion (30). Independent claims are also included for the following: (1) a method for manufacturing a decorative part; and (2) a decorative part with a foam layer.