Vehicle Interior Material Pressing Mold with Elastic Clamping
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Solution Overview
Problem
Conventional methods for manufacturing vehicle interior materials with real stitches are complicated and costly due to positional deviations during the pressing process, leading to wrinkles and increased manufacturing time, as they require tilting the mold and separate equipment for temporary adhering and pressing.
Innovation Solution
An apparatus and method that utilize a first and second mold unit with elastic members to clamp the skin without tilting the mold, applying elastic forces to prevent wrinkles and simplify the manufacturing process by pressing the core and skin together without tilting the mold, using an air control unit to manage air between the core and skin for precise contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the upper mold is lifted and tilted at a predetermined angle to mount the core or skin, then the core or skin can be mounted on the lower surface of the upper mold, but the manufacturing process becomes complicated and the time required increases
Solution Approach 1:
Instead of tilting the upper mold to mount the core or skin on its lower surface, the invention inverts the approach by mounting the core on the lower mold's upper surface and the skin on the upper mold's lower surface, then pressing them together in a vertical orientation. This eliminates the need for tilting operations while achieving the same mounting objective.
Solution Approach 2:
The invention combines the mounting and pressing operations into a single integrated process. By designing the mold units with fixing parts that can both mount and press the core and skin simultaneously in a vertical orientation, it merges multiple steps (mounting, tilting, pressing) into one straightforward operation.
2Reliability
If the skin and core are pressed together after temporary adhering, then they can be bonded, but equipment for temporary adhering and pressing is required, increasing manufacturing cost
Solution Approach 1:
The invention merges the temporary adhering and pressing functions into a single mold unit assembly. The fixing parts on both mold units serve dual purposes: temporarily holding the core and skin in position during mounting, and then pressing them together for bonding. This eliminates the need for separate temporary adhering equipment.
Solution Approach 2:
The fixing parts of the mold units are designed with multi-functionality, serving both as mounting fixtures and pressing elements. This universal design allows the same components to perform multiple functions (mounting, temporary adhering, and pressing), reducing the overall equipment requirements and manufacturing cost.
3Reliability
If the skin and core are pressed together after temporary adhering, then bonding can be achieved, but positional deviation during pressing causes wrinkles in the skin
Solution Approach 1:
Instead of pressing the skin and core horizontally after temporary adhering (which causes positional deviation and wrinkles), the invention inverts the process orientation by pressing them vertically between the two mold units. This vertical pressing approach maintains better positional alignment and prevents skin wrinkles while achieving reliable bonding.
Solution Approach 2:
The fixing parts of the mold units preliminarily position and clamp the skin and core in precise alignment before the pressing operation begins. This preliminary positioning action ensures that when pressing occurs, there is no positional deviation, thereby preventing wrinkles and ensuring high manufacturing precision.
4Productivity
If conventional pressing operation is used, then the core and skin can be pressed together, but positional deviation between mold and skin causes wrinkles
Solution Approach 1:
The fixing parts of the mold units perform preliminary positioning and clamping of the skin and core before the pressing operation. This preliminary action ensures precise alignment and eliminates positional deviation during pressing, maintaining both high productivity and manufacturing precision.
Solution Approach 2:
The invention inverts the conventional pressing approach by using vertical pressing between two mold units instead of horizontal pressing. This inverted orientation, combined with the fixing parts, provides better positional control and prevents wrinkles while maintaining efficient pressing 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 approach simplifies the manufacturing process, reduces defects, and lowers costs by preventing wrinkles and improving surface quality, while eliminating the need for tilting the mold and separate adhering and pressing equipment.
Implementation Method 1
a first support part including a first elastic member configured to apply a first elastic force to the first fixing part; and a second support part including a second elastic member configured to apply a second elastic force to the second fixing part
Data Source
AI summary
Proposed are an apparatus and a method for manufacturing an interior material for a vehicle, in which a core and a skin can be integrated by a pressing operation. The apparatus includes a first mold unit having a first molding surface, and a second mold unit having a second molding surface corresponding to the first molding surface. The core is mounted on the second molding surface. The first mold unit includes a first fixing part, and the second mold unit includes a second fixing part. The first fixing part and the second fixing part are configured to fix an outer peripheral portion of a skin placed between the first mold unit and the second mold unit.