Single-Device Pressure Moulding for Composite Coating Coupling
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Solution Overview
Problem
The existing processes for manufacturing motor-vehicle interior components with composite materials require two distinct moulding devices, increasing complexity, time, and cost, and necessitate a custom-made second moulding device for coupling the coating sheet to the substrate.
Innovation Solution
A single pressure moulding device is used to form the substrate and coating sheet, couple them, and inject polymeric material to create functional structures, with conformation surfaces maintained at a temperature below 120°C to ensure the coating sheet's stiffness and hardness, allowing the process to be completed in a single device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two distinct moulding devices are used for substrate forming/injection and coating sheet coupling, then the functional structures can be created with proper support surfaces, but the process complexity and device cost increase significantly
Solution Approach 1:
The patent combines the functions of two separate moulding devices into a single device. The first moulding device performs both substrate forming with injection of functional structures and coating sheet coupling, eliminating the need for a second dedicated moulding device. This integration reduces device complexity and process steps while maintaining the quality of functional structures through proper support surface design.
2Reliability
If a second moulding device is used for coating sheet coupling downstream of injection, then the coating sheet can be properly coupled to the substrate, but the process time and manufacturing cost increase
Solution Approach 1:
The patent merges the coating sheet coupling operation with the substrate forming and injection process into a single simultaneous operation. The moulding device is designed to couple the coating sheet to the substrate while the functional structures are being formed, eliminating sequential processing steps and reducing overall manufacturing time and cost.
Solution Approach 2:
The coating sheet is positioned and prepared for coupling in advance within the moulding device before the injection process completes. This preliminary positioning allows the coupling to occur simultaneously with the injection and cooling process, rather than requiring a separate downstream operation.
3Reliability
If the coating sheet is present during polymeric material injection, then the functional structures can be formed against the substrate, but the coating sheet may be damaged by injection pressure and temperature
Solution Approach 1:
The patent carefully controls and adjusts process parameters including injection pressure, material temperature, and timing to prevent damage to the coating sheet. The polymeric material is injected at controlled temperatures and pressures that are sufficient to form functional structures against the substrate but remain below thresholds that would damage the coating sheet.
Solution Approach 2:
The coating sheet is positioned between the substrate and the injection cavity in advance, creating a protective arrangement where the substrate absorbs injection pressure and protects the coating sheet from direct exposure to high-pressure molten material. This spatial arrangement cushions the coating sheet from harmful effects.
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 reduces process complexity and cost while maintaining mechanical and aesthetic quality, avoiding damage to the coating sheet during polymeric material injection and enabling efficient formation of functional structures.
Implementation Method 1
a first compression step, in which the first and second half-moulds are thrusted against each other, and the substrate and the coating sheet are compressed under pressure between the first and the second conformation surface for firmly fixing to each other the substrate and the coating sheet
Implementation Method 2
during said first compression step (and preferably also during said second compression step), a temperature of said first and second conformation surface is less than 120°C
Implementation Method 3
The second polymeric material is injected in the molten/softened state into suitable injection cavities
Implementation Method 4
a second compression step, in which the substrate and the coating sheet are compressed between the first and the second conformation surface to a generally greater extent with respect to the first compression step, and in which the second polymeric material is injected (through the injection unit) into the injection cavity
Data Source
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AI summary
Pressure moulding process, and related device (100), for manufacturing an article, the process comprising: - providing a substrate (70) made of a composite material comprising a first polymeric material and fibres impregnated with said first polymeric material; - providing a coating sheet (71); - heating said substrate (70) to a temperature of the substrate (70) greater than 160°C; - subsequently, during a first compression step, compressing under pressure the substrate (70) and the coating sheet (71) between a first conformation surface (1) and a second conformation surface (2) for conforming the substrate (70) and the coating sheet (71) and for firmly fixing the substrate (70) and the coating sheet (71) to each other; - during a second compression step subsequent to the first compression step, compressing under pressure the substrate (70) and the coating sheet (71) between the first (1) and second conformation surface (2) and injecting a second polymeric material in an injection cavity (3) having an outlet mouth (4) onto the first conformation surface (1), wherein a first face of the substrate (70) opposite to the coating sheet (71) is in contact with the first conformation surface (1); - cooling the second polymeric material for firmly fixing the second polymeric material to the first face of the substrate (70), wherein, during the first compression step, a temperature of the first (1) and second conformation surface (2) is less than 120°C.