Sunvisor Production via Lamination and Injection Molding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing sunvisor production methods are inefficient due to high labor costs and excessive components, with imported weldable foam materials being costly and inefficient.
Innovation Solution
A sunvisor production method involving lamination of craft paper with cross-linked polyethylene foam, combined with a polyurethane filler layer, which reduces material diversity, labor costs, and weight, using localized materials and high-frequency welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional sunvisor production methods are used with multiple components and imported weldable foam, then the structural integrity is maintained, but the labor costs are high and production efficiency is low
Solution Approach 1:
The patent combines multiple separate components (craft paper, cross-linked polyethylene foam, and polyurethane filler) into a single integrated structure through lamination and injection molding. The craft paper is laminated to the foam, and the polyurethane filler is injected into the mold containing these layers, creating a unified sunvisor structure that reduces assembly steps and labor costs while maintaining structural integrity
Solution Approach 2:
The patent uses composite materials by laminating craft paper with cross-linked polyethylene foam and combining it with polyurethane filler. This composite structure provides the necessary rigidity, cushioning, and structural support while reducing the number of separate components needed in traditional designs
2Ease of manufacture
If traditional sunvisor production methods are used with imported weldable foam, then the material properties are sufficient, but the material costs are high
Solution Approach 1:
The patent changes the material parameters by using cross-linked polyethylene foam with specific density and rigidity characteristics, combined with craft paper lamination and polyurethane filler. This combination provides the necessary mechanical properties (rigidity, cushioning, structural support) while using locally available materials instead of expensive imported weldable foam, thereby reducing material costs without compromising performance
Solution Approach 2:
The patent creates a composite material system where craft paper provides structural rigidity, cross-linked polyethylene foam provides cushioning and lightweight properties, and polyurethane filler provides additional structural support. This composite approach achieves the required material performance while using cost-effective local materials
3Weight of moving object
If traditional sunvisor production methods are used with multiple sub-materials, then the structural requirements are met, but the weight is excessive
Solution Approach 1:
The patent applies local quality by using different materials in specific locations within the sunvisor structure. The craft paper is laminated to the foam in areas requiring rigidity, while the polyurethane filler is injected into specific cavities to provide localized structural support. This targeted material distribution reduces overall weight while maintaining structural rigidity where needed
Solution Approach 2:
The patent uses a composite material structure where craft paper, cross-linked polyethylene foam, and polyurethane filler are combined in a specific arrangement. The foam provides lightweight cushioning, the paper adds rigidity, and the filler provides structural support, creating a weight-efficient structure that meets all structural requirements
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 significantly decreases material usage, labor costs, and weight, while increasing production capacity by utilizing localized materials and enabling efficient high-frequency welding, resulting in a lighter and cost-effective sunvisor.
Implementation Method 1
lamination of craft paper with cross-linked polyethylene foam
Implementation Method 2
The lamination device includes a head with 15 heating resistors... the head blowing hot air is approached to the connection point of the two materials and the lamination process starts
Implementation Method 3
injecting the filler layer (4) made of polyurethane material into said mould
Implementation Method 4
welding the outer layer (1) made of PVC material onto said filler layer (4) in the high frequency welding machine
Data Source
Figure 1
AI summary
The present invention relates to a production method for a sunvisor which is used in motor vehicles such as automobiles, buses (passenger car), trucks, construction equipments in automotive sector in order to get protected from sun rays, and the sunvisor produced by this method.