Laminated Molded Part Manufacturing with Differential Tool Heating
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Solution Overview
Problem
The automotive industry faces challenges in producing lightweight, multi-layer components for motor vehicles that require reduced layer thickness while maintaining structural strength, sound insulation, and heat insulation, with existing methods often resulting in inadequate bonding and increased cycle times due to low adhesion between layers.
Innovation Solution
A method involving a mold with a temperature difference of at least 50°C between the upper and lower tools, where the carrier layer, typically fiber-reinforced thermoplastic, is heated more extensively than the additional layer, allowing for quick deformation and strong bonding, and using lightweight foam with a density of up to 40 kg/m³ to reduce vehicle weight while maintaining insulation properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the carrier layer and cover layer are bonded using conventional hot pressing methods, then the layers can be connected, but the adhesion is insufficient and requires additional adhesive layers
Solution Approach 1:
The patent applies a temperature difference of at least 50°C between the upper and lower tools during hot pressing. The carrier layer is heated to a higher temperature than the cover layer, which changes the thermal parameters of the bonding process. This temperature differential enables the carrier layer to achieve sufficient adhesion to the cover layer without requiring additional adhesive layers, thereby improving bond strength while reducing process complexity.
Solution Approach 2:
The carrier layer is pre-heated to a higher temperature before bonding with the cover layer. This preliminary heating action prepares the carrier layer to achieve optimal adhesion properties during the bonding process, enabling strong bonding without additional adhesives and eliminating the need for separate adhesive application steps.
2Weight of moving object
If the layer thickness is reduced to achieve lightweight components, then the weight decreases, but the structural strength and insulation properties deteriorate
Solution Approach 1:
The patent uses a composite structure consisting of a carrier layer made from fiber-reinforced thermoplastic material and a cover layer. This composite material approach allows the carrier layer to maintain high structural strength even at reduced thickness, while the overall multi-layer construction provides both weight reduction and preserved mechanical properties.
Solution Approach 2:
By applying differential heating with the carrier layer at higher temperature, the patent enhances the bonding strength at the interface between layers. This allows for thinner overall construction while maintaining structural integrity, as the improved adhesion compensates for reduced material thickness.
3Productivity
If the carrier layer is heated to high temperature for quick deformation, then the forming time decreases, but the adhesion to the cover layer may be compromised
Solution Approach 1:
The patent applies different temperatures to different parts of the system: the carrier layer is heated to a higher temperature for quick deformation, while the cover layer is maintained at a lower temperature. This local quality approach ensures that each layer receives the appropriate thermal treatment - the carrier layer achieves rapid forming while the cover layer maintains optimal bonding conditions.
Solution Approach 2:
The patent changes the thermal parameters by implementing a temperature difference of at least 50°C between the upper and lower tools. The carrier layer is heated more extensively, enabling quick deformation and high productivity, while the controlled temperature differential ensures that bonding quality is maintained or improved due to the enhanced adhesion properties of the heated carrier layer.
4Weight of moving object
If lightweight foam material is used to reduce vehicle weight, then the weight decreases, but the structural support capability deteriorates
Solution Approach 1:
The patent employs a composite structure where the carrier layer is made from fiber-reinforced thermoplastic material, providing high structural strength, while the cover layer can be lightweight foam material. This composite approach allows the use of lightweight materials without compromising structural support capability, as the fiber-reinforced carrier layer compensates for the lower strength of the foam cover layer.
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 production of lightweight, multi-layer components with improved structural strength, sound insulation, and heat insulation, reducing cycle times and eliminating the need for additional adhesive layers, thus addressing the cost and weight reduction pressures in the automotive industry.
Implementation Method 1
the lower tool (3) has a higher temperature than the upper tool (2)... the carrier layer can be deformed very quickly, with good bonding of the at least one further layer despite the short forming time
Implementation Method 2
the carrier layer can be deformed very quickly... due to the carrier layer being hotter by at least this temperature value
Implementation Method 3
the two layer materials being connected to one another in a mold at a temperature above room temperature
Data Source
Figure 1~2
Figure 3~4
AI summary
The method involves utilizing a supporting layer (7) made of layer material. A layer (8) is made of another layer material, where the layer materials are connected with each other in a form of a molding tool (1) at a temperature above room temperature. The molding tool is provided with an upper tool (2) and a lower tool (3). A surface of a molded part (6) is applied with different temperatures at another surface lying opposite to the former surface along cross section of the molded part. A fiber-reinforced thermoplastic material is utilized as the layer material for the supporting layer. An independent claim is also included for a molding tool for manufacturing a laminated molded part.