3D Trim Part Structure With Integrated Functional Element Connection
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Solution Overview
Problem
Existing solutions for integrating functional elements within vehicle trim parts face challenges in connecting these elements to electrical sources without causing structural discontinuity, limiting design flexibility and requiring additional connection materials.
Innovation Solution
A multi-layered self-supporting 3D shaped trim part with a structural support layer and a covering layer, where the functional element has a local extension that crosses the support layer through a sealed slot, allowing connection at any convenient location without additional elements, maintaining mechanical integrity and design flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a separate connection part is used to extend through the support layer, then the functional element can be connected to electrical sources, but the support layer experiences structural and mechanical discontinuity
Solution Approach 1:
The connection means is merged with the functional surface element to form an integral unit. The local extension is directly formed as part of the functional element during the same manufacturing process, eliminating the need for separate connection parts and maintaining the continuity of the support layer.
Solution Approach 2:
The local extension serves multiple functions: it provides electrical connection capability while simultaneously maintaining the structural integrity of the support layer. The extension is designed to be both electrically conductive and mechanically integrated, combining connection and structural roles in a single element.
2Ease of operation
If connection sites are located on the rear face of the trim part, then connection to electrical sources is enabled, but additional cables and connection materials are required
Solution Approach 1:
The connection capability is extracted directly to the exposed face of the trim part through the local extension of the functional surface element. This eliminates the need for additional cables and connection materials by providing the connection interface at the location where it is most needed, without requiring separate connection components.
3Productivity
If functional elements are integrated close to the exposed surface for efficient interaction, then interaction efficiency with interior occupants is improved, but connection to electrical sources becomes more constrained
Solution Approach 1:
The functional surface element and its connection means are merged into a single integrated component. The local extension is formed as an integral part of the functional element, allowing the element to be positioned optimally near the exposed surface for efficient interaction while the extension provides the necessary electrical connection path without adding separate connection components.
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
Enables efficient integration of functional elements with easy operational steps, maintaining mechanical resistance and structural integrity, while allowing for multiple functional elements and flexible design without altering the manufacturing process.
Implementation Method 1
The support layer (2) consists of a thermo-compressed thermoplastic material layer reinforced with fibres
Implementation Method 2
which is sealed during thermocompression
Data Source
Figure 1A~1B
Figure 1C~2C
Figure 2A~2B
AI summary
The invention concerns a multi-layered self-supporting 3D shaped trim part (1) comprising a support layer (2), a covering layer (3) forming the exposed face (1') of the trim part (1) and at least one thin surface element (4) with at least one functional area (4'), located between the aforementioned support (2) and covering (3) layers and being associated with at least one connection means (4") extending through the support layer (2) and providing on the rear face (2') of said support layer (2), opposed to the exposed face (1'), a connecting site or area (4‴). Said trim part (1) is characterized in that the support layer (2) consists of a thermo-compressed thermoplastic material layer reinforced with fibres and in that the or each connection means consists of an integral local extension (4") of the functional surface element (4) which crosses the support layer (2) at a throughway (2") in the original uncompressed composite material blank (5) of said support layer (2), which is sealed during thermocompression.