Integrated Pressure Moulding and Lamination for Automotive Interiors
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Solution Overview
Problem
The existing two-stage production process for laminated moulded parts in motor vehicle interiors is time-consuming and complex, with the decorative element often damaged during pressure moulding due to high injection pressure, and requires separate equipment for lamination, which increases space and equipment requirements.
Innovation Solution
A method and device that integrate pressure moulding and lamination in the same moulding cavity, allowing the moulded part to remain in the pressure moulding tool for bonding with a laminating element, eliminating the need for a separate lamination facility and utilizing residual heat for efficient lamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the decorative element is introduced together with the blank for the moulded part into the pressure tool, then the pressure moulding and lamination processes are combined in one step, but the decorative element is often damaged due to high injection pressure
Solution Approach 1:
The process is divided into two sequential stages: first pressure moulding the blank to form the moulded part, then introducing and bonding the decorative element. This segmentation avoids subjecting the decorative element to high injection pressure while maintaining production efficiency through integration in the same tooling.
Solution Approach 2:
The blank is pressure moulded first to create the moulded part, and only after this preliminary action is completed is the decorative element introduced into the moulding cavity. This preliminary action ensures the decorative element is not exposed to harmful high pressure during the moulding process.
2Productivity
If the decorative element is introduced together with the blank for the moulded part into the pressure tool, then the pressure moulding and lamination processes are combined in one step, but the stiffening ribs are injected over the decorative element making them visible
Solution Approach 1:
The process is segmented into two stages: first forming the moulded part with stiffening ribs, then introducing the decorative element. This ensures stiffening ribs are injected before the decorative element is placed, preventing them from becoming visible through the decorative element.
Solution Approach 2:
The moulded part including stiffening ribs is formed first as a preliminary action, and only after this is the decorative element introduced. This preliminary formation of the base structure ensures subsequent decorative elements are not compromised by injected ribs.
3Manufacturing precision
If a separate lamination facility is used after pressure moulding, then high-quality laminated moulded parts are produced, but the production process is time-consuming and complex
Solution Approach 1:
The pressure moulding tool is designed to perform both pressure moulding and lamination functions. The moulding cavity is configured to receive both the blank and the decorative element, and the tooling mechanism provides both pressure moulding and bonding capabilities, merging two previously separate processes into one integrated system.
Solution Approach 2:
The pressure moulding tool is designed with multi-functionality to perform both pressure moulding of the blank and subsequent lamination of the decorative element. The tooling system includes universal features such as adjustable moulding cavities and heating mechanisms that serve dual purposes for both processes.
4Manufacturing precision
If a separate lamination facility is used after pressure moulding, then high-quality laminated moulded parts are produced, but the equipment and space requirements increase
Solution Approach 1:
The pressure moulding tool and lamination facility are merged into a single integrated tooling system. The moulding cavity serves dual purposes for both pressure moulding and lamination, eliminating the need for separate equipment and reducing overall space requirements.
Solution Approach 2:
The pressure moulding tool is designed with multi-functionality to perform both pressure moulding and lamination operations. This universal tooling system reduces equipment complexity by consolidating multiple functions into a single device.
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 reduces production time and equipment needs, enhances processing speed, and minimizes damage to decorative elements by integrating lamination into the pressure moulding process, while utilizing residual heat for energy efficiency.
Implementation Method 1
the residual heat in the pressure moulding tool can be used for the subsequent lamination process
Data Source
AI summary
A method for producing a laminated moulded part comprises a pressure moulding of a blank to form a moulded part in a moulding cavity between a first moulding tool unit and a second moulding tool unit, introducing of a laminating element into the moulding cavity after the pressure moulding of the blank, and a bonding of the moulded part with the laminating element in the moulding cavity.