Method of manufacturing a component having at least one embedded feature

Abstract

The present disclosure provides a "method of manufacturing a component having at least one embedded feature". A method of manufacturing a component having at least one embedded feature, comprising the steps of: defining a boundary template for the component; reserving a functional area within the boundary template for the at least one embedded feature; consolidating and structurally optimizing the component to allow for more efficient material distribution; and manufacturing the component using an additive manufacturing technique. Also disclosed is a motor vehicle component, the motor vehicle component comprising a motor vehicle center console.

Description

TECHNICAL FIELD

[0001] This document relates generally to the field of additive manufacturing, and more particularly, to a method of manufacturing a part having at least one embedded feature and such a part for a motor vehicle. BACKGROUND

[0002] Many manufactured parts incorporate one or more embedded features and are not optimized for weight and production efficiency. For example, a motor vehicle center console can incorporate a plurality of embedded features, such as system routing features (i.e., (a) electrical wiring, (b) heating, ventilation, and air conditioning system plumbing, (c) electronic modules, (d) antennas). Such embedded features require additional parts and assembly. As a result, center consoles incorporating embedded features are often bulky and over-engineered. Such center consoles can contain excess mass.

[0003] This document relates to a new and improved method of manufacturing such a part. The method utilizes and leverages the unique capabilities of additive manufacturing to achieve a more efficient and lighter weight design with fewer parts and simpler assembly. SUMMARY

[0004] In accordance with the purposes and benefits described herein, a method for manufacturing a part having at least one embedded feature is provided. The method includes the steps of: (a) defining a boundary template for the part, (b) reserving a containment space or functional area within the boundary template for the at least one embedded feature, (c) consolidating and structurally optimizing the part to allow for more efficient material distribution during part manufacturing, and (d) manufacturing the part using an additive manufacturing technique.

[0005] The step of consolidating and structurally optimizing can include the step of performing a statistical analysis between all possible structural variations of the part by a computer device while considering all different non-design spaces for the most efficient path of the embedded system. Additionally, the step of consolidating and structurally optimizing can include the step of performing design modifications to achieve a final solution after the statistical analysis.

[0006] The method can also include the step of routing electrical wiring through the part. Further, the method can include the step of embedding the electrical wiring in the material of the part.

[0007] In some embodiments, the method can include the step of routing plumbing through the part. Additionally, the method can include the step of embedding the plumbing in the material of the part. In other embodiments, the method can include the step of manufacturing the plumbing within the part using an additive manufacturing technique.

[0008] In one or more of the many possible embodiments, the method can include reserving the functional area for an electronic module. Further, the method can include embedding the electronic module in the material of the part.

[0009] In other possible embodiments, the method can include the step of reserving the functional area for an antenna. Additionally, the method can include embedding the antenna in the material of the part.

[0010] In at least one of the many possible embodiments, the method can include using additive manufacturing techniques to manufacture the plumbing within the part.

[0011] In one or more of the many possible embodiments, the part can be an automotive vehicle part. Thus, the part can include a console. In other embodiments, the part can include an instrument panel. In other embodiments, the part can include a seat frame and trim. In other embodiments, the part can include a door trim panel. In other embodiments, the part can include a pillar trim. In other embodiments, the part can include an overhead console. In other possible embodiments, the part can include a rock panel. In other possible embodiments, the part can include a rear window deck. Additionally, the part can include a combination of any of these structures.

[0012] According to a further aspect, an automotive vehicle part is provided. The automotive vehicle part includes a body made by additive manufacturing and a system routing feature embedded in the body. In one or more of the many possible embodiments, the system routing feature can include air ducting. In one or more of the many possible embodiments, the system routing feature can include electrical wiring. In one or more embodiments, the system routing feature can also be made by additive manufacturing.

[0013] According to another aspect, an automotive vehicle center console is provided. The automotive vehicle center console includes a body and a system routing feature, both made by additive manufacturing. The system routing feature can include plumbing for a heating, ventilation, and air conditioning system of the automotive vehicle.

[0014] In the following description, a number of preferred embodiments of a method of manufacturing a part having at least one embedded feature and a part so manufactured are shown and described. It should be realized that the method and part are capable of other different embodiments and that many details thereof can be modified in various obvious respects, all without departing from the method and part set forth and described in the following claims. Thus, the drawings and description are to be regarded as illustrative in nature and not restrictive. BRIEF DESCRIPTION OF DRAWINGS

[0015] The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate several aspects of the methods and components, and together with the description, serve to explain certain principles thereof.

[0016] Figure 1 is a perspective view of a component in the form of a motor vehicle center console incorporating two different embedded features.

[0017] Figures 2 to 7 is a series of views schematically illustrating a method of manufacturing a component having at least one embedded feature. More specifically:

[0018] Figure 2 illustrates the step of defining or establishing a footprint for the component.

[0019] Figure 3 illustrates the step of defining or establishing a boundary template for the component and reserving functional areas within the boundary template for necessary features or other requirements.

[0020] Figure 4 illustrates the frozen areas for various embedded features and areas of the component to be solidified and structurally optimized to allow for more efficient material distribution during component manufacturing.

[0021] Figure 5 illustrates the first iteration results of structurally optimizing the component.

[0022] Figure 6a illustrates the optimization results taking into account Figure 5 a possible route for the embedded electrical wiring.

[0023] Figure 6b illustrates the optimization results taking into account Figure 5 a second possible route for the embedded electrical wiring.

[0024] Figure 6c illustrates the shortest route for the embedded electrical wiring without taking into account the optimization results illustrated in Figure 5

[0025] Figure 7 illustrates the step of manufacturing the component using additive manufacturing techniques.

[0026] Reference will now be made in detail to the preferred embodiments of the method of manufacturing a component having at least one embedded feature and the component itself, examples of which are illustrated in the accompanying drawings. DETAILED DESCRIPTION

[0027] Reference is now made to Figure 1 ​, showing a component 10 made using a new improved method of manufacturing the component with at least one embedded feature, generally indicated by reference numerals 12 and 14. More specifically, in the illustrated embodiment, the component 10 comprises a motor vehicle center console, the embedded feature 12 comprises plumbing for a heating, ventilation and air conditioning (HVAC) system of the motor vehicle, and the embedded feature 14 comprises electrical wiring.

[0028] The motor vehicle component 10 includes a body 16 made by additive manufacturing. The embedded features 12, 14 are system routing features embedded into the body 16. More specifically, the body 16 includes a grid engineering of side walls 17 and ribs 18. The embedded feature / plumbing 12 passes through at least some of the ribs 18 from a front end 20 of the component 10 to a rear end 22 of the component. In some embodiments of the component 10, the ribs 18 are made with openings to receive a subsequently installed section of the plumbing 12. In other possible embodiments, the embedded feature / plumbing 12 is also made by additive manufacturing at the same time that the body 16 is made.

[0029] The embedded feature / electrical wiring 14 of the illustrated component 10 is received in a slot or channel 24 formed in the side wall 17 of the component 10 and specifically dedicated for this purpose when the component is designed.

[0030] Reference is now made to Figures 2 to 5 , Figures 6a to 6c and Figure 7 which schematically illustrate a new improved method of manufacturing a component 10, such as the motor vehicle center console shown in Figure 1 . The method includes the step of defining a boundary template 26 for the component 10. See Figure 2 which shows the footprint F for the component 10 when viewed from above, and Figure 3 which shows the boundary template 26 when viewed from above. While Figure 2 and Figure 3 are two-dimensional representations of the component 10 and the boundary template 26, it should be understood that the component and the boundary template are three-dimensional in the case where the boundary template defines the outer design boundary of the component.

[0031] Next is the step of reserving containment spaces or functional areas 28a-28f within the boundary template 26 for each of the embedded features (not shown). Figure 4 A frozen area or reserved functional areas 28a-28f are shown, as well as a region 30 of the component 10 to be structurally optimized. Examples of the functional areas 28a-28f can include, but are not limited to, attachment locations, clearance areas, storage spaces, and customer-facing features.

[0032] Next, the method includes consolidating and structurally optimizing the part 10 to allow for more efficient distribution of materials during part manufacturing. Consolidating and structurally optimizing the part includes performing a statistical analysis between all possible structural variations of the part by the computing device. This results in a first iteration or design of the part 10 including a grid or rib structure S (as shown in Figure 5 FIG. 1) that stretches across the region 30 to be optimized while avoiding the frozen or functional regions 28a-28f.

[0033] Consolidating and structurally optimizing the part 10 also includes the step of performing design modifications to achieve a final solution after the statistical analysis. Thus, as shown in Figure 6a and Figure 6b the method can include routing wiring through the part 10 between the wiring inlets / outlets 28b and 28e. As shown in Figure 6a and Figure 6b two potential wiring routes are indicated by dashed lines LI and L2. In contrast, Figure 6c a shortest route L3 for any embedded wiring through the part 10 between the inlets / outlets 28b, 28e is shown without regard to the structure of the first iteration.

[0034] After performing the statistical analysis between all possible variations, the method can include performing design modifications to achieve a final solution after the statistical analysis. Thus, as shown in Figure 7 the grid or rib structure S between the functional regions 28b and 28e is modified to accommodate embedded wiring through the part 10 between the inlets / outlets 28b, 28e according to the shortest route. To achieve this result, the method also includes embedding the wiring 32 in the ribs 34 extending between the inputs / outputs 28b, 28e.

[0035] Figures 2 to 7 a part 10 is shown in which the embedded feature is wiring 32. It should be understood herein that the embedded feature can take many other forms, including but not necessarily limited to plumbing, electronic modules, and / or antennas. In the case where the embedded feature is plumbing, the method can include the steps of reserving functional regions for the plumbing, routing the plumbing through the part 10, and finally embedding the plumbing in the material of the part.

[0036] In some embodiments, the method can include the step of using additive manufacturing techniques to actually manufacture the plumbing within the part 10. Thus, the plumbing can be formed during the process of manufacturing the optimized structure of the part.

[0037] In the case where the embedded feature is an electronic module, the method can include the steps of reserving functional regions for the electronic module, and embedding the electronic module in the material of the part.

[0038] In the case where the embedded feature is an antenna, the method can include the steps of reserving a functional area for the antenna, and embedding the antenna in the material of the part. In the case where the antenna includes a cable connection, the method can also include the steps of routing the cable through the part 10, and embedding the cable in the material of the part.

[0039] As described above, the part 10 can be a motor vehicle part. The motor vehicle part can be selected from the group of parts including a console, an instrument panel, a seat frame and trim, a door trim panel, a pillar trim, an overhead console, a scuff plate, a rear window shelf, and combinations thereof. Additionally, it should be noted that this list of parts is presented for illustrative purposes and should not be considered limiting in scope.

[0040] The foregoing has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the embodiments to the precise form disclosed. Obvious modifications and variations are possible in light of the above teachings. The embodiments were chosen and described in order to best explain the principles of the application and its best mode of operation to others skilled in the art.

[0041] According to the present application, there is provided a motor vehicle part having a body made by additive manufacturing; and a system routing feature embedded in the body.

[0042] According to embodiments, the system routing feature is selected from the group including an air duct, an electrical wiring, and combinations thereof.

[0043] According to the present application, there is provided a motor vehicle center console having a body made by additive manufacturing and a system routing feature.

[0044] According to embodiments, the part is selected from the group of parts including a console, an instrument panel, a seat frame and trim, a door trim panel, a pillar trim, an overhead console, a scuff plate, a rear window shelf, and combinations thereof.

[0045] According to embodiments, the system routing feature is also made by additive manufacturing.

[0046] According to embodiments, the system routing feature is a ductwork for a heating, ventilation and air conditioning system of a motor vehicle.

Claims

1. A method for manufacturing a component having at least one embedded feature, comprising: A boundary template defined for the component; The functional area within the boundary template is reserved for the at least one embedded feature. Consolidating and structurally optimizing the component to allow for more efficient material distribution during the manufacturing of the component, wherein the consolidation and structural optimization includes a statistical analysis performed by a computing device among multiple possible structural variations of the component to be manufactured to generate a first iterative design of the component, and performing design modifications on the first iterative design to achieve a final solution after the statistical analysis, thereby enabling more efficient material distribution and accommodating the at least one embedded feature during manufacturing; as well as The component is manufactured using additive manufacturing technology.

2. The method of claim 1, wherein electrical wiring is laid through the component.

3. The method of claim 2, further comprising embedding the electrical wiring into the material of the component.

4. The method of claim 1, wherein the method includes laying a pipeline through the component.

5. The method of claim 4, further comprising embedding the piping in the material of the component.

6. The method of claim 1, wherein the functional area is reserved for the electronic module.

7. The method of claim 6, further comprising embedding the electronic module in the material of the component.

8. The method of claim 1, wherein the functional region is reserved for the antenna.

9. The method of claim 8, further comprising embedding the antenna in the material of the component.

10. The method of claim 4, further comprising using additive manufacturing technology to manufacture piping within the component.

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