Vehicle Trim Barrier Layer for Slip-Free Back-Foaming
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Solution Overview
Problem
The existing methods for producing multilayer moldings, particularly those involving leather and plastic, face challenges such as slipping during back-foaming, inadequate sealing, and dimensional instability under different climatic conditions, leading to high reject rates and damage to the cover material.
Innovation Solution
A method where the cover material is connected to a self-supporting barrier layer before introduction into the foaming tool, preventing slipping and ensuring reliable sealing, with the barrier layer being preformed to match the outer contour of the molded body and optionally self-adhesive or using a separate adhesive layer for fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive tape is applied to seal seams before back-foaming, then sealing is improved, but the seam still slips during back-foaming and sufficient sealing is not achieved
Solution Approach 1:
The patent applies adhesive tape to seal seams before the back-foaming process begins. This preliminary sealing action prevents foam leakage through seams during the subsequent foaming operation, directly addressing the sealing reliability issue while maintaining seam positioning through the pre-applied tape barrier
2Reliability
If polyurethane barrier layer is applied to the back of upholstery material, then sealing is improved, but the cover material properties change and slippage still occurs
Solution Approach 1:
The patent introduces a polyurethane barrier layer as an intermediary substance applied to the back of the upholstery material. This barrier layer serves as a mediator that provides sealing against foam leakage while the adhesive tape applied to the front surface provides the primary anchoring function, distributing the functional requirements across multiple layers to minimize property changes in the cover material itself
3Productivity
If conventional back-foaming process is used, then production speed is maintained, but reject rate increases due to slippage and damage
Solution Approach 1:
The patent applies adhesive tape to seal seams and positions covering material before the back-foaming process begins. This preliminary preparation prevents slippage and damage during foaming, reducing reject rates without requiring changes to the fundamental back-foaming process timeline, thus maintaining production speed while improving product quality reliability
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 allows for precise positioning and fixation of the cover material, preventing slipping and damage, while ensuring effective sealing and dimensional stability, thereby reducing reject rates and improving the quality of the multilayer moldings.
Implementation Method 1
at least one adhesive layer (13) is applied to the self-supporting barrier layer (11), by means of which the covering material (14-1, 14-2) is connected to the support element (18)
Implementation Method 2
a foamed plastic is applied to the back of a covering material
Data Source
Figure 1a~1e
Figure 2a~2e
Figure 3a~3c
AI summary
The present invention relates to a method for producing multilayer molded bodies, in particular interior trim parts for vehicles, in which a foamed plastic (25) is applied to the back side of a covering material (14-1, 14-2), wherein a self-supporting barrier layer (11) is first produced which is impermeable to the foamed plastic (25). By applying and fixing the covering material with at least a partial area of its back side to the self-supporting barrier layer (11), a pre-bond (17) is created between the barrier layer (11) and the covering material (14-1, 14-2) even before it is inserted into the foaming tool (20). This effectively prevents the covering material from slipping during the back-foaming process.