Vehicle Trim Element Two-Step Lamination Process
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Solution Overview
Problem
Current methods for manufacturing trim elements with multiple layers are inefficient in terms of resource usage and energy consumption, as they require full adhesion and curing in initial lamination steps, which can lead to incomplete bonding and damage to materials like precious wood veneer during injection molding.
Innovation Solution
A two-step lamination process where the first layer is bonded to a lamination under pressure and heat in the first step, with incomplete crosslinking, and the second layer is bonded to another lamination in the second step, allowing heat from the second step to enhance adhesion between the first lamination and the first layer, resulting in improved bonding without full energy expenditure in the initial step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If full adhesion and curing are achieved in the initial lamination step, then bonding strength is improved, but energy consumption increases and material damage risk increases
Solution Approach 1:
The lamination is applied in advance to the decorative layer before injection molding, but the adhesive is not fully cured at this stage. This preliminary lamination provides initial bonding while allowing the material to remain slightly flexible during the injection molding process, preventing damage to the decorative layer while reducing the energy required compared to full curing
Solution Approach 2:
The patent controls the curing degree of the adhesive as a variable parameter, keeping it incomplete (around 60-80% cured) during the injection molding process. This parameter change allows the lamination to provide sufficient bonding strength while maintaining material flexibility and reducing energy consumption, with full curing occurring after the injection molding is complete
2Reliability
If full curing of lamination is achieved in the first step, then adhesion quality is improved, but material damage to veneer occurs during injection molding
Solution Approach 1:
The lamination is applied in advance to the decorative layer before injection molding, but the adhesive is not fully cured at this stage. This preliminary lamination provides initial bonding while allowing the material to remain slightly flexible during the injection molding process, preventing damage to the decorative layer
Solution Approach 2:
Instead of achieving complete curing (100%) in the first lamination step, the patent intentionally leaves the adhesive partially cured (around 60-80%). This partial action provides sufficient adhesion quality for handling and positioning, while the remaining uncured adhesive acts as a buffer that prevents stress concentration and material damage during the injection molding process
3Use of energy by moving object
If incomplete crosslinking is used in the first lamination step, then energy consumption is reduced, but adhesion quality may be insufficient
Solution Approach 1:
The lamination is applied in advance to the decorative layer before injection molding, but the adhesive is not fully cured at this stage. This preliminary lamination provides initial bonding while allowing the material to remain slightly flexible during the injection molding process
Solution Approach 2:
The adhesion process is continued across multiple stages: initial lamination with partial curing, injection molding with continued heating and pressing, and final curing after demolding. This continuous useful action ensures that adhesion quality is progressively improved without requiring complete curing in the energy-intensive first step, distributing the energy requirement across the entire manufacturing process
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 reduces energy consumption and resource usage while achieving better adhesion quality between layers, preventing damage to materials like veneer during back injection molding and ensuring a cost-effective, resource-saving production process.
Implementation Method 1
The lamination can be formed by combining a nonwoven material with adhesive. The film of adhesive can be formed on the basis of phenol, melamine, acrylic, polyurethane or their combinations. Such laminations are known and common, in particular, in the furniture industry. The film of adhesive is crosslinked by applying pressure and temperature. It bonds accordingly with the layer.
Implementation Method 2
When the multi-layer structure is created, only the lamination provided on the upper side is then activated, but not the lamination disposed on the underside. However, the conditions are set such that even the lamination provided on the upper side does not fully cure.
Implementation Method 3
The lamination and the layer are bonded to each other subject to the application of pressure and temperature by a die driven against the table.
Implementation Method 4
The heat introduced in the second lamination step also acts in the first lamination. The effect of the heat introduced in the second lamination step into the first lamination is such that improved adhesive bonding between the first lamination and the first layer is obtained.
Implementation Method 5
The film of adhesive is crosslinked by applying pressure and temperature. It bonds accordingly with the layer.
Data Source
AI summary
A cost-effective and resource-saving method for manufacturing a trim element, in particular a trim element which is used as a vehicle interior lining element. The trim element has a rear side reinforcement layer and a decorative surface. In the method according to the invention, a first layer is bonded in a first lamination step under pressure and heat to a first lamination and a second layer is bonded in a second lamination step under pressure and heat to a second lamination. The heat introduced in the second lamination step also acts in the first lamination and increases its bonding strength to the first layer.