Hollow Article Covering with Partial Wrap and Recessed Face
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Solution Overview
Problem
Conventional methods for attaching a carpet to blow-molded hollow articles, such as load floors, result in material inefficiencies, labor-intensive processes, and poor appearance due to plastic bleed-through and sharp edges, while adhesive-based methods incur additional costs and alignment challenges.
Innovation Solution
A hollow article design featuring a covering that partially wraps around the article, with a recessed face on the second wall to accommodate the covering and a molded edge with interlocking features that secure the covering in place, reducing material consumption and labor requirements while maintaining a flush surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional blow molding process with carpet in mold is used, then hollow article with bonded carpet is formed, but carpet is thinned at corners and edges leading to plastic bleed through or poor carpet appearance
Solution Approach 1:
The patent introduces a third dimension by allowing the covering to wrap around the hollow article from the first wall to the second wall, creating a multi-dimensional coverage system. This wrapping configuration ensures that the covering maintains consistent thickness across all surfaces including corners and edges, preventing plastic bleed-through while eliminating the thinning problem associated with conventional single-surface bonding methods
Solution Approach 2:
The covering is pre-formed with sufficient material allowance and wrapping capability before attachment to the hollow article. This preliminary preparation ensures that when the covering is bonded to the first wall and wraps around to the second wall, it maintains adequate thickness at corners and edges throughout the bonding process, preventing the thinning and plastic bleed-through issues that occur with conventional methods
2Loss of substance
If conventional blow molding process is used, then hollow article is produced, but surplus carpet and plastic flash must be trimmed along parting line resulting in sharp edges
Solution Approach 1:
The covering is pre-formed with exact dimensions and wrapping configuration before attachment, eliminating the need for post-molding trimming operations. This preliminary precision ensures that the covering fits perfectly around the hollow article without creating sharp edges or requiring material removal, thereby reducing waste and improving edge appearance
Solution Approach 2:
By transitioning from a flat, single-surface covering to a three-dimensional wrapping configuration that follows the contours of the hollow article, the patent eliminates the need for trimming along parting lines. The wrapping approach allows the covering to conform naturally to the article's shape, preventing sharp edges and reducing material waste
3Ease of manufacture
If adhesive method is used to attach carpet to plastic component, then carpet can be affixed in secondary operation, but significant additional material cost and bonding time are incurred
Solution Approach 1:
The patent combines the covering attachment process with the primary blow molding operation by bonding the covering to the first wall during or immediately after molding. This merging of operations eliminates the need for separate secondary adhesive bonding operations, thereby reducing both material costs (by eliminating or minimizing adhesive use) and manufacturing cycle time, while maintaining attachment flexibility
Solution Approach 2:
The covering is prepared and positioned on the hollow article before final molding completion or immediately thereafter, allowing for integrated bonding without requiring separate secondary operations. This preliminary positioning enables the covering to be attached in the primary manufacturing process rather than requiring additional adhesive bonding steps, improving productivity while maintaining ease of manufacture
4Ease of manufacture
If adhesive method is used, then carpet can be bonded to plastic, but alignment and placement of carpet is difficult and not exact
Solution Approach 1:
The covering is pre-formed with precise dimensions, shape, and wrapping configuration that match the hollow article's geometry before attachment. This preliminary precision ensures that when the covering is bonded to the first wall and wrapped around, it achieves exact alignment and placement without requiring complex adhesive application or adjustment operations, thereby improving manufacturing precision while maintaining ease of manufacture
Solution Approach 2:
The transition from flat covering to three-dimensional wrapping configuration provides inherent alignment features that guide proper placement on the hollow article. The wrapping approach creates natural registration points and conformal contact surfaces that ensure exact alignment during bonding, eliminating the alignment difficulties associated with flat adhesive bonding methods
Data Source
AI summary
A hollow article is provided having a first wall, a second wall and a plurality of edge walls interconnecting the first wall and second wall. A covering is bonded to the hollow article, wherein the covering is bonded to the first wall, and is dimensioned to partially wrap around the hollow article.