Knitted Trim Lamination With Heat-Setting for Stable Interior Parts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing trim parts in vehicle interiors are limited in application potential due to the materials and production methods used, restricting design and functional possibilities.
Innovation Solution
A method involving the generation of knitted semi-finished products on a flat-bed knitting machine, followed by washing, heat-setting, and laminating onto a carrier part, allowing for customizable and versatile trim parts with improved tactile and visual characteristics, including multi-colored designs and functional finishes like water-repellency, using 2D or 3D knitting techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional laminating methods with films or skins are used, then adhesive bonding is achieved, but application potential and design versatility are restricted
Solution Approach 1:
The patent changes the fundamental parameter of the surface covering material from traditional films/skins to knitted fabrics. This material parameter change enables new production methods (knitting machine production) and opens up diverse application potentials while maintaining ease of manufacture through standardized textile production processes.
Solution Approach 2:
The patent creates a composite structure by laminating knitted fabric onto a carrier part. This composite material approach combines the flexibility and design versatility of knitted textiles with the structural support of the carrier, achieving both adaptability and ease of manufacture.
2Adaptability or versatility
If knitted semi-finished products are used as surface covering, then design versatility and application potential are enhanced, but production process complexity increases
Solution Approach 1:
The patent applies preliminary actions by pre-processing the knitted semi-finished product through washing and heat-setting before lamination. These preliminary steps stabilize the fabric dimensions and properties, ensuring consistent lamination results and reducing production complexity during the actual bonding process.
Solution Approach 2:
The heat-setting process changes the physical parameters of the knitted fabric by fixing the loop structures and stabilizing dimensions. This parameter change simplifies subsequent production steps by eliminating the need for continuous dimensional adjustment during lamination.
3Stability of the object's composition
If heat-setting is applied to knitted semi-finished product, then dimensional stability is achieved, but energy consumption increases
Solution Approach 1:
The heat-setting process utilizes phase transition principles by heating the knitted fabric to a temperature where the polymer fibers undergo structural changes and then cooling them to lock in the desired dimensions. This controlled phase transition achieves dimensional stability through the material's inherent thermal properties rather than continuous energy input.
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 enables the creation of trim parts with enhanced resilience, abrasion resistance, and customizable designs, offering increased application potential beyond vehicle interiors to other transport means and furniture, while minimizing waste and optimizing adhesive bonding.
Implementation Method 1
The knitted semi-finished product during heat-setting is set on both sides and run through a conveyor oven. The knitted semi-finished product is set in the oven, wherein the knitted semi-finished product as a result of the input energy shrinks to the desired nominal dimensions.
Implementation Method 2
The heat for activating the adhesive is introduced through the skin into the adhesive joint by a warm press die of the press-laminating tool by way of contact heat
Implementation Method 3
The heat for activating the adhesive is introduced through the skin into the adhesive joint by a warm press die of the press-laminating tool by way of contact heat or by means of IR radiation.
Data Source
AI summary
A method for producing a trim part includes the following steps: generating a surface covering, wherein a knitted semi-finished product is generated on a flat knitting machine; the knitted semi-finished product is washed; the washed knitted semi-finished product is heat set; and laminating, in particular press-laminating or compression-laminating, the generated surface covering onto a carrier part.