Vehicle Interior Board Edge Oxidation Prevention
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Solution Overview
Problem
Existing vehicle interior boards face issues with deterioration, peeling, and oxidation at the metal plate edges, along with challenges in demolding and ensuring surface quality, due to exposed cutting surfaces and inefficient vacuum suction systems, which affect reliability, durability, and productivity.
Innovation Solution
A vehicle interior board design featuring a foamed polyurethane layer that covers the peripheral edges of metal plates, formed flush with the outer surfaces, and a manufacturing method that includes epoxy resin-based coating, larger setting surfaces in molds, and vacuum-sealed positioning to prevent oxidation and peeling, while allowing for accurate positioning and reduced need for additional mounting steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the recesses and setting surfaces in the molds have a planar shape conforming to the steel plate, then the molding process is simple, but the end portion of the steel plate is exposed and deteriorates by oxidation
Solution Approach 1:
The patent applies preliminary action by forming a protrusion on the setting surface before the molding process begins. This protrusion extends beyond the peripheral end of the steel plate, creating an overhang that prevents oxidation exposure from the outset. The protrusion is formed as part of the mold structure, so no additional steps are needed during molding - the protection is built-in beforehand.
Solution Approach 2:
The protrusion acts as an intermediary element between the steel plate and the oxidizing environment. By extending beyond the plate edge, it creates a physical barrier that shields the vulnerable end portion from direct exposure to air and moisture, preventing oxidation without requiring changes to the steel plate itself or complex post-processing.
2Measurement precision
If vacuum suction is used to hold the steel plate, then positioning is achieved, but foamable raw materials leak into the vacuum hole and cause clogging
Solution Approach 1:
The patent extracts the harmful function of the vacuum hole by covering it with a seal member during the foamable raw material injection process. The seal member is temporarily placed over the vacuum hole opening, removing its ability to suck in materials. After injection completes, the seal is removed and vacuum function is restored for the next cycle, thus eliminating clogging while preserving positioning capability.
Solution Approach 2:
The seal member functions as a disposable or temporary protective element. It is placed over the vacuum hole only during the critical injection phase to prevent clogging, then removed afterward. This temporary measure protects the expensive vacuum system from damage by inexpensive, easily replaceable sealing elements.
3Strength
If the steel plate is held by electromagnet or vacuum suction, then the steel plate is fixed in position, but demolding becomes difficult and peeling occurs at the end portion
Solution Approach 1:
The protrusion is formed on the setting surface before molding begins, creating a predetermined positioning structure. This protrusion fits into a corresponding recess in the steel plate, establishing precise positioning and strong fixation during molding. The same protrusion structure also facilitates easy demolding by providing a clear separation plane between the mold and the finished product.
Solution Approach 2:
The patent introduces rounded corners at the peripheral end of the steel plate in the molded product. This curvature prevents sharp edges that would catch on the mold during demolding. The rounded geometry allows the plate to be easily released from the mold cavity without peeling or damage, while still maintaining strong fixation during the molding process through the protrusion-recess engagement.
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 solution enhances the bonding between metal plates and foamed polyurethane, prevents peeling and oxidation, facilitates easy demolding, and improves the quality and productivity of the vehicle interior board by ensuring a flush and rounded edge, thus increasing the board's strength and reducing weight.
Implementation Method 1
the metal plate set in the upper mold is held by an electromagnetic force of an electromagnet or a vacuum action of a vacuum suction section provided in the upper mold
Implementation Method 2
the liquid foamable raw materials containing polyol and isocyanate are supplied to the molding space formed between the pair of metal plates. Thereafter, the foamable raw materials are heated to a predetermined temperature. This causes a chemical reaction. At this time, foaming also occurs.
Implementation Method 3
the foamable raw materials are heated to a predetermined temperature. This causes a chemical reaction. At this time, foaming also occurs. Then, the rigid foamed polyurethane layer having a planar shape conforming to the planar shape of the steel plate is formed between the pair of steel plates.
Data Source
AI summary
A vehicle interior board which has less deterioration and peeling near an end portion of a metal plate, has high quality, is thin, lightweight, and has high strength and excellent productivity. The vehicle interior board includes a pair of metal plates and a foamed polyurethane layer formed between the pair of metal plates. At the peripheral edge portion of the vehicle interior board, the foamed polyurethane layer covers peripheral end portions of the metal plates and is formed flush with outer surfaces of the metal plates. This makes it possible to suppress oxidation of the peripheral end portions which are cutting surfaces of the metal plates. Further, bonding is good between the metal plates and the foamed polyurethane layer. Further, it is possible to prevent peeling of the metal plates, chipping of the foamed polyurethane layer, and the like. Furthermore, it is easy to demold a vehicle interior board.