Skin-Integrated Automotive Interior Molding With Edge Sealing
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Solution Overview
Problem
The manufacturing process of automotive interior materials is complicated by skin wrinkles, requires excessive trimming, generates environmental pollutants, and risks skin damage due to high temperature and pressure.
Innovation Solution
An apparatus and method using a mold unit configuration with a sealing block and mold drive module to integrate skins with base materials, minimizing wrinkles and environmental pollutants while preventing skin damage through controlled pressure and temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional wrapping process is used to attach skin to base material, then skin can be adhered to base material, but the process becomes complicated and requires excessive trimming
Solution Approach 1:
The patent merges the skin attachment process with the base material molding process into a single integrated operation. The skin is placed on the mold before injection molding, allowing both the base material formation and skin wrapping to occur simultaneously during injection, eliminating separate wrapping and trimming steps
Solution Approach 2:
The skin is pre-positioned on the mold surface before the injection molding process begins. This preliminary placement ensures the skin is already in the correct position and orientation before material injection, preventing wrinkles and eliminating the need for post-processing trimming
2Manufacturing precision
If high temperature and pressure are applied to mold the base material, then the base material can be formed, but the skin may be damaged and become hard
Solution Approach 1:
The patent introduces a release film or protective layer as an intermediary between the skin and the hot mold surface. This intermediary layer allows the skin to be positioned on the mold during setup while protecting it from direct contact with high temperatures and pressures during the injection molding process
Solution Approach 2:
The skin is pre-positioned on the mold surface before injection molding begins, and the molding process parameters (temperature, pressure, injection rate) are carefully controlled and optimized to form the base material without exposing the skin to damaging conditions
3Strength
If skin is attached to base material using adhesives, then skin can be adhered to base material, but environmental pollutants such as VOCs are generated
Solution Approach 1:
The patent replaces the chemical adhesion method (using adhesives that generate VOCs) with a mechanical integration method. The base material itself is molded to wrap around and mechanically interlock with the skin edges, creating a strong bond without requiring additional adhesive materials or generating harmful emissions
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 process simplifies manufacturing, reduces costs, and enhances productivity by eliminating excess skin trimming and minimizing skin damage, achieving eco-friendly production of integrated automotive interior materials.
Implementation Method 1
a pressurizing tip that presses the edge portion to bring the edge of the skin into full contact with the first molding surface
Implementation Method 2
a gate that injects molten resin to shape a base material and integrate the base material with the skin
Implementation Method 3
a wrapping molding surface that closes the opening to form an enclosed molding space and guides the skin to wrap a peripheral portion of the base material
Data Source
AI summary
Proposed is an apparatus and method for manufacturing automotive interior materials. The apparatus includes a first mold unit provided with a first molding surface and a gate disposed on the first molding surface, wherein a skin is set on the first molding surface. The apparatus further includes a second mold unit provided with a second molding surface facing the first molding surface, and configured to provide an opening exposing an edge of an edge portion of the set skin along a periphery between the first molding surface and the second molding surface when the second mold unit is combined with the first mold unit, and a sealing block provided with a tip portion disposed along the opening when the first mold unit and the second mold unit are combined.