Polyurethane Edge Strip Molding for Automotive Fabric
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Solution Overview
Problem
Current methods for producing foldable and windable automobile functional elements, such as wind deflectors and roller blind panels, are cost-intensive and lack precision due to manual sewing or high tool costs associated with injection molding, compromising both cost-effectiveness and appearance.
Innovation Solution
A method involving molding polyurethane edge strips onto fabric under atmospheric pressure using a dispensing head, eliminating visible seams and enabling high-accuracy, machine-based production without manual sewing or high tool costs, suitable for both industrial-scale and small-volume series.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual sewing is used to attach beadings or reinforcement strips to the fabric, then the fabric can be connected to deployment components, but the process is cost-intensive and produces visible seams that compromise appearance
Solution Approach 1:
The patent replaces the mechanical sewing process with a chemical bonding process using polyurethane adhesive applied via dispensing head. The adhesive is applied under atmospheric pressure and bonds the edge strip to the fabric through curing, eliminating the need for needles, threads, and sewing machines while achieving precise dimensional control and invisible bonding.
Solution Approach 2:
The patent changes the bonding method from mechanical (sewing) to chemical (adhesive bonding), and controls the adhesive application parameters (viscosity, application rate, curing conditions) to achieve precise dimensional accuracy. The polyurethane material's properties are adjusted to ensure proper bonding strength and flexibility matching the fabric.
2Productivity
If injection molding is used to produce beadings, then automated production is achieved, but tool costs are high and adjusting the tool for fabric dimension changes is complicated
Solution Approach 1:
The patent replaces the injection molding process with a direct adhesive dispensing process. Instead of using complex injection molding tools that require high pressure and precise cavity alignment, the system uses a dispensing head that applies polyurethane adhesive directly to the fabric edge, significantly simplifying the tooling while maintaining automated production capability.
Solution Approach 2:
The patent separates the edge strip production from the main fabric production, allowing the edge strip to be applied as a distinct component using adhesive bonding. This segmentation enables independent optimization of the edge strip application process and simplifies the overall manufacturing system compared to integrated injection molding.
3Ease of manufacture
If manual sewing is used to attach edge strips, then connection to deployment components is achieved, but the process is time-consuming and reduces productivity
Solution Approach 1:
The patent replaces manual sewing operations with automated adhesive dispensing and curing. The dispensing head can apply adhesive continuously along the fabric edge at controlled rates, and the curing process (thermal or ambient) bonds the edge strip without requiring manual dexterity, significantly increasing production speed while maintaining simplicity.
Solution Approach 2:
The patent enables continuous application of the edge strip through continuous adhesive dispensing along the fabric edge. The process can run continuously as the fabric moves through the application and curing zones, eliminating the start-stop nature of manual sewing operations and achieving sustained high productivity.
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
The method produces functional elements with high dimensional accuracy and no visible seams, reducing production costs and enhancing appearance, while allowing for efficient industrial-scale production of wind deflectors and roller blind panels with integrated edge reinforcement.
Implementation Method 1
molding at least one edge strip made of a polyurethane material to an edge of the fabric under atmospheric pressure
Data Source
AI summary
A method for producing a functional element of an automobile that can be folded and/or wound up, having the steps of providing a fabric that can be folded and/or wound up, arranging the fabric on an application table or in a casting tool in a level arrangement and molding at least one edge strip made of a polyurethane material to the fabric under atmospheric pressure. Furthermore, a wind deflector element of an automobile is provided to a roller blind panel of an automobile, each comprising a fabric that can be folded and/or wound up and that is provided with an edge strip made of a polyurethane material and forming an edge reinforcement.