Vehicle Interior Molding With Adhesive-Free Skin-Base Bonding
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Solution Overview
Problem
Conventional methods for manufacturing vehicle interior materials are complex, environmentally unfriendly due to the use of harmful adhesives, and result in increased VOC emissions and odor generation, leading to reduced productivity and consumer dissatisfaction.
Innovation Solution
A single device integrates base press forming, cutting, bonding, and injection molding processes, utilizing latent heat for bonding without adhesives, and enables pattern formation on the surface during a single process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional separate processes are used for base press forming, cutting, bonding, and injection molding, then each process can be performed with dedicated equipment, but the manufacturing complexity increases and productivity decreases
Solution Approach 1:
The patent combines base press forming, cutting, bonding, and injection molding processes into a single integrated manufacturing step. The molding device simultaneously performs all these operations on the base material to create the final interior component, eliminating the need for multiple separate processing steps and dedicated equipment for each operation.
Solution Approach 2:
The molding device is designed with multi-functional capabilities to perform press forming, cutting, bonding, and injection molding within a single device. This universal equipment replaces multiple specialized machines, reducing manufacturing complexity while maintaining or improving productivity through integrated operations.
2Strength
If harmful adhesives are used for bonding base and skin, then bonding strength is achieved, but environmental friendliness deteriorates and VOC emissions increase
Solution Approach 1:
The patent removes harmful adhesives from the bonding process entirely. Instead of using chemical adhesives that emit VOCs and create odors, the invention employs a mechanical interlocking structure where the skin is physically integrated with the base through molded features, eliminating the need for harmful bonding agents while maintaining structural integrity.
Solution Approach 2:
The patent replaces chemical bonding (adhesive-based) with mechanical bonding through molded interlocking structures. The skin and base are mechanically integrated during the molding process, substituting chemical mechanisms with physical mechanical connections that achieve bonding strength without harmful substances.
3Manufacturing precision
If multiple separate processes are used for manufacturing, then each process can be optimized independently, but manufacturing time increases and productivity decreases
Solution Approach 1:
The patent merges multiple manufacturing processes into a single integrated molding operation. By performing press forming, cutting, bonding, and injection molding simultaneously in one device, the total manufacturing cycle time is dramatically reduced compared to sequential processing, while the integrated design ensures proper coordination of all operations.
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 integration simplifies the manufacturing process, enhances productivity, reduces labor costs, improves cost competitiveness, and contributes to fuel efficiency through weight reduction while eliminating VOC emissions and odors.
Implementation Method 1
bonding the base and the skin, and injection-molding plastic resin on the rear surface of the base were all carried out as separate processes... in bonding the base and the skin, an adhesive was applied to the bonding surfaces of the skin and the base, and the components were then bonded by heat-pressing... achieve bonding by utilizing the latent heat retained in the preheated base
Data Source
AI summary
A vehicle interior material manufacturing device and a method for manufacturing a vehicle interior material using the same are disclosed. The device includes a first mold on which a Skin is supported, and a second mold configured to be opened and closed with respect to the first mold and on which a Base is supported. The first mold comprises a forming recess recessed on one surface of a first body, and a cutting section provided on both sides of the forming recess on the first body, the cutting section being configured to cut an end portion of the Base supported by the second mold during a mold closing process between the first and second molds.