Fiber-Laminated Vehicle Trim With Adhesive-Free Resin Anchoring
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Solution Overview
Problem
The existing methods for attaching synthetic resin members to fiber molded bodies in vehicle interiors and exteriors require adhesives, leading to increased costs, weight, and complexity, as well as potential deformation and sink marks due to molding shrinkage.
Innovation Solution
A method where molten synthetic resin, potentially containing gas bubbles formed by a foaming agent, is injected into a fiber laminated body to solidify and anchor the synthetic resin member directly to the fiber molded body, eliminating the need for adhesives and reducing weight and sink marks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesives such as hot-melt adhesive are used to attach synthetic resin members to fiber molded body, then the synthetic resin members can be fixed to the fiber molded body, but the weight increases and assembly time increases
Solution Approach 1:
The patent merges the attachment function with the synthetic resin member itself by causing molten resin to seep into the fiber layer during injection molding. This creates an integrated structure where the synthetic resin member and fiber molded body are bonded together without requiring separate adhesives, thereby eliminating the weight penalty of additional bonding materials.
Solution Approach 2:
The synthetic resin member performs its own attachment function by utilizing its material properties. The molten resin naturally seeps into the fiber layer during the molding process and bonds to the fiber molded body upon solidification. This self-attachment mechanism eliminates the need for external adhesives and reduces assembly steps.
2Reliability
If adhesives such as hot-melt adhesive are used to attach synthetic resin members, then the synthetic resin members can be fixed to the fiber molded body, but the number of man-hours for assembly increases
Solution Approach 1:
The patent combines the attachment process with the molding process itself. The molten synthetic resin is injected into the mold cavity containing the fiber molded body, seeps into the fiber layer, and solidifies to create a bonded structure. This integrated process eliminates separate attachment steps and reduces assembly time.
Solution Approach 2:
The attachment action occurs continuously during the injection molding process. As the molten resin is injected and seeps into the fiber layer, bonding occurs simultaneously with the molding action. This continuous process eliminates idle time between molding and attachment operations.
3Reliability
If adhesives are used to attach synthetic resin members, then the synthetic resin members can be fixed to the fiber molded body, but temperature management becomes complicated and deformation may occur
Solution Approach 1:
The synthetic resin member utilizes its own thermal properties for attachment. The molten resin is injected at elevated temperature, naturally seeps into the fiber layer, and solidifies upon cooling to create a bonded structure. This self-bonding process eliminates the need for external heat sources and complex temperature management systems.
Solution Approach 2:
The attachment process exploits the phase transition of the synthetic resin from molten state to solid state. The resin is injected in molten form, penetrates the fiber layer, and solidifies upon cooling to create a permanent bond. This phase change-driven bonding eliminates the need for continuous heating and complex temperature control.
4Weight of moving object
If synthetic resin members are attached by injection molding into fiber laminated body, then adhesives are eliminated and weight is reduced, but this method is difficult to apply to fiber molded bodies with low rigidity
Solution Approach 1:
The patent modifies the physical parameters of the fiber molded body by temporarily heating it above the softening point of the thermoplastic resin. This parameter change increases the deformability of the fiber molded body, allowing it to accommodate the injection molding process. After cooling, the fiber molded body regains its rigidity while maintaining the integrated structure.
Solution Approach 2:
The fiber molded body is pre-heated to a temperature above the softening point of its thermoplastic resin before the injection molding process. This preliminary heating action prepares the fiber molded body to accept the molten synthetic resin by increasing its deformability. After the injection molding completes and the assembly cools, the fiber molded body regains its structural rigidity.
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 method provides a strong, lightweight, and aesthetically improved vehicle interior and exterior member with reduced assembly time and costs, while preventing sink marks and deformation, by integrating the synthetic resin member directly into the fiber molded body through a combined press molding and injection molding process.
Implementation Method 1
molten synthetic resin as seeped into the fiber layer of the fiber laminated body
Implementation Method 2
gas bubbles formed by a foaming agent
Data Source
AI summary
A vehicle interior and exterior member comprises a fiber molded body and a synthetic resin member fixed to a surface of the fiber molded body. The fiber molded body has a fiber layer including thermoplastic synthetic resin as a base material layer. The base material layer has fiber layer surfaces on its both surfaces or, the base material layer has another fiber layer including the other type of thermoplastic synthetic resin on one of the fiber layer surface to form a fiber laminated body. The fiber molded body is formed by molding the fiber laminated body into a three-dimensional face shape. The synthetic resin member has a fixed portion which is fixed to the fiber molded body by solidifying it in a state that molten synthetic resin has seeped into the fiber layer of the fiber laminated body.