Stretch-Bent Plastic Trim for Cost-Effective Transport
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Solution Overview
Problem
The challenge is to reduce transport costs of high-quality, dimensionally accurate plastic parts like roof trim strips for vehicles without compromising their quality, as their length and curvature require complex and costly handling and packaging to prevent deformation during shipping.
Innovation Solution
A method involving extruding a plastic base body, painting it in sections, and then stretch-bending it into shape after transport, allowing for denser packaging and simpler shipping without the need for complex support devices, enabling higher local content and cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If plastic parts are transported in their finished curved shape, then dimensional accuracy and surface quality are maintained, but transport costs increase due to complex handling and packaging requirements
Solution Approach 1:
The patent applies preliminary action by performing the curvature formation (stretch-bending) after transport rather than before. The base body is transported in its straight, unpainted, or partially painted state where it requires minimal support, and only after arrival at the destination is it curved into its final shape. This reverses the conventional sequence and eliminates the need for complex curved-support transport devices.
2Manufacturing precision
If plastic parts are painted before transport, then surface quality is improved, but transport costs increase due to increased risk of damage and deformation
Solution Approach 1:
The patent applies preliminary action by performing the painting operation before transport, but specifically notes that the base body can be painted in sections or entirely while in its stable straight state. The painting is done on the base body before it undergoes stretch-bending, ensuring the painted surface is established before the part assumes its final curved configuration. This sequencing allows quality control during painting while avoiding damage risks associated with painting already-curved parts.
3Manufacturing precision
If complex support devices are used during transport, then dimensional accuracy is maintained, but packing density decreases leading to higher transport costs
Solution Approach 1:
The patent applies preliminary action by transporting the base body in its straight, uncurved state where it occupies minimal space and requires no complex support structures. The curvature is formed after transport using stretch-bending technology at the destination. This allows base bodies to be packed densely in standard containers without specialized curved supports, dramatically increasing packing density while maintaining final dimensional accuracy through the post-transport forming process.
4Adaptability or versatility
If painting is performed at all production locations, then local content is increased, but infrastructure requirements and costs increase
Solution Approach 1:
The patent applies the extraction principle by separating the painting operation from the final product completion. Instead of requiring full painting capabilities at all production locations, the system extracts the painting function to be performed centrally on base bodies before distribution. The curved finished parts are then produced at various locations using only stretch-bending equipment, not full painting facilities. This reduces infrastructure requirements at distributed locations while still enabling local value addition through the forming operation.
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 method significantly reduces transport costs by allowing for higher packing densities and easier handling, maintaining quality and surface finish, and enabling the same high-quality parts to be produced across different locations without requiring local painting facilities.
Implementation Method 1
the plastic material is extruded to produce the base body
Implementation Method 2
the base body is stretch-bent to form the at least partially painted plastic part
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
Producing at least sectionally coated plastic part exhibiting a plastic material containing base body (4), preferably for an automobile, comprises (i) extruding the plastic material for producing the base body, (ii) at least sectionally coating the base body, and (iii) packaging the coated base body such that the coated base body is transported or dispatched without damage, or (iv) stretch bending the sectionally coated base body to form the sectionally coated plastic part. Independent claims are also included for: (1) at least sectionally coated plastic part produced by the above method; and (2) a stretch-bendable base body for producing the sectionally coated plastic part, comprising a plastic material that is molded by extrusion, where the stretch-bendable base body is at least sectionally coated.