Foamed Decorated Carrier Structure for Vehicle
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Solution Overview
Problem
Existing methods for producing foamed, decorated support parts for motor vehicles are inefficient, requiring complex processes and special surface activation, leading to increased costs, contamination, and resource requirements.
Innovation Solution
A method involving a thin film with integrated laminating adhesive, where the film is back-injected or foamed using an injection molding intergalactic process, allowing for the removal of a protective layer to activate the adhesive for lamination without the need for special surface activation, reducing contamination and resource usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If existing methods for producing foamed, decorated support parts are used, then decorative paneling elements can be produced, but the process becomes complex and requires special surface activation
Solution Approach 1:
The patent combines the adhesive layer and protective layer into a single integrated film structure that is applied during the foam injection molding process. This merging eliminates the need for separate surface activation steps and subsequent adhesive application, directly resolving the technical contradiction by simplifying the manufacturing process while reducing overall complexity.
Solution Approach 2:
The adhesive layer is pre-applied to the foam carrier structure during the injection molding process before the final decoration lamination step. This preliminary action eliminates the need for separate surface activation and adhesive application steps, directly addressing the contradiction between ease of manufacture and process complexity.
2Reliability
If special surface activation is performed, then adhesive bonding can be achieved, but contamination and resource requirements increase
Solution Approach 1:
The foam carrier structure itself provides the adhesive bonding function through the integrated adhesive layer that is part of the film structure. This self-service approach eliminates the need for separate surface activation treatments, thereby preventing contamination while maintaining reliable adhesive bonding quality.
3Adaptability or versatility
If multiple separate processes are used for foam creation and decoration, then functional requirements can be met, but production time and costs increase
Solution Approach 1:
The patent merges the foam injection molding process with the film application process into a single integrated operation. The film with adhesive and protective layers is applied during the foam creation process itself, eliminating sequential steps and directly improving production efficiency while maintaining all functional requirements.
Solution Approach 2:
The patent uses a composite film structure comprising an adhesive layer and a protective layer that are integrated during the foam injection molding process. This composite material approach allows multiple functions (adhesion, protection, decoration) to be achieved in a single process step, thereby increasing productivity while meeting all adaptability requirements.
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 simplifies the production process, reduces contamination, and lowers costs by eliminating the need for special surface activation, while enabling efficient creation of foamed, decorated support parts for motor vehicles.
Implementation Method 1
A plastic is injected together with a propellant into a molding space of a mold. After injection, the mold is opened by one foaming stroke to allow foaming of the not yet solidified plastic
Implementation Method 2
the mold is opened by one foaming stroke to allow foaming of the not yet solidified plastic inside the carrier part
Implementation Method 3
the film is heated, if necessary, by means of a heating device in order to enable plastic deformation of the film
Implementation Method 4
the film is vacuum-assisted thermoformed on the mold part of the mold
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Method for producing a foamed decorable support part (100) for a motor vehicle, wherein a sheet (102) is laminated with a base layer, an adhesive layer and a protective layer in an injection-moulding process, sheet (100) for use in such a method, wherein the sheet (102) has a base layer, an adhesive layer and a protective layer, and foamed decorable support part (100) for a motor vehicle, wherein the support part (100) is produced by such a method.