Segmented Roller Shutter Strips for Flexible Car Doors
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Solution Overview
Problem
Traditional car roller shutter doors made from hard and soft rubber face challenges such as poor flexibility, difficulty in texturing, high manufacturing costs, and short service life due to the use of long film sheets that are prone to cracking and costly injection molds.
Innovation Solution
A method involving the injection molding of single film pieces, followed by vacuum forming and integration with molten rubber to create independent roller shutter strips, which are then laminated onto a flexible substrate, allowing for easier maintenance, design flexibility, and reduced manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If a long strip of whole film sheet is used in the injection mold, then the car roller shutter door can be manufactured, but the flexibility is poor and the film sheet is easy to crack resulting in short service life
Solution Approach 1:
The patent divides the continuous film sheet into multiple independent film pieces, each forming a separate roller shutter strip. This segmentation allows each strip to move independently, improving flexibility while preventing crack propagation across the entire structure, thereby extending service life.
2Ease of manufacture
If a long strip of whole film sheet is used, then the car roller shutter door can be manufactured, but the volume of the injection mold is large and the manufacturing cost is high
Solution Approach 1:
The injection mold is designed to produce multiple small film pieces simultaneously rather than one large continuous film. This reduces the overall mold volume, simplifies manufacturing complexity, and lowers tooling costs while maintaining production efficiency.
3Ease of manufacture
If the surface of soft rubber is used, then the material is easy to work with, but it is difficult to texture and the surface does not achieve high-gloss effect
Solution Approach 1:
The patent uses a composite structure combining a film piece (for texturing and gloss) with rubber material (for flexibility and sealing). The film piece can be easily textured and achieves high-gloss effect, while the rubber provides the necessary mechanical properties, resolving the contradiction between ease of texturing and surface appearance.
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 enhances the flexibility and service life of car roller shutter doors, reduces production costs, and simplifies maintenance by enabling targeted replacement of damaged strips, while achieving a high-gloss effect and improved durability.
Implementation Method 1
the softened film piece is subjected to a vacuum forming and molding processing through a vacuum forming method to mold the film piece into a desired shape
Implementation Method 2
the injection molding machine drives the second injection mold to clamp mold and injects molten rubber into the second injection mold, so that the molten rubber and the film piece are integrally formed in the second injection mold
Data Source
AI summary
The invention relates to a technical field of car roller shutter door production, in particular to a method for manufacturing a car roller shutter door. A single film piece is firstly vacuum formed into a desired shape, and then rubber is injected into the film piece after vacuum forming, so that the rubber and the film piece are integrally formed to form a single roller shutter strip, and then a required number of single roller shutter strips are placed and laminated on a flexible substrate in an integrated and orderly manner to form a car roller shutter door. Each of roller shutter strips is independent of each other and does not interfere or affect each other, which improves flexibility of the car roller shutter door. Compared with long strips of whole film sheet on the car roller shutter door in the prior art, each of film pieces of the present invention is independent of each other and does not have defect of easy fracture of the whole film sheet, which makes service life long. In addition, production of the single film piece is less expensive and more efficient, and pattern design is flexible. When one of the roller shutter strips is damaged, only the damaged roller shutter strip needs to be replaced in a targeted manner, avoiding the waste of resources and reducing maintenance costs.