Adjustable Trim Part Forming Mold for Variable Thickness
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Solution Overview
Problem
Car manufacturers face high investment costs due to the need for separate forming molds to produce trim parts with different thicknesses, specifically regular and premium trim parts with and without compressible layers, which complicates integration in vehicle interiors without visible gaps.
Innovation Solution
A method and assembly that allow the same mold to be used for manufacturing trim parts with different thicknesses by adjusting the front and back inserts' final positions, accounting for the expansion of compressible layers, enabling the production of trim parts with and without foam layers in the same mold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate forming molds are used for trim parts with different thicknesses, then manufacturing precision is improved, but device complexity and investment cost increase
Solution Approach 1:
The mold incorporates adjustable inserts that can be dynamically repositioned along the molding direction to accommodate different trim part thicknesses. The inserts are mounted on adjustable supports allowing position modification without changing the mold structure, enabling the same mold to adapt to varying production requirements while maintaining manufacturing precision.
Solution Approach 2:
The invention changes the geometric parameters of the mold by adjusting the position of inserts and supports rather than using different molds. By modifying the distance between inserts and the mold walls, the mold can produce trim parts with different thicknesses, effectively changing the forming parameters to match different product specifications.
2Device complexity
If the same mold is used for different trim part thicknesses, then device complexity is reduced, but manufacturing precision deteriorates
Solution Approach 1:
The mold is segmented into modular components including adjustable inserts and supports that can be independently positioned. This segmentation allows precise control over the forming cavity dimensions for each trim part type while using the same mold base, maintaining manufacturing precision through modular adjustability rather than requiring entirely different molds.
3Adaptability or versatility
If inserts are repositioned for different trim parts, then adaptability is improved, but ease of manufacture deteriorates
Solution Approach 1:
The mold is designed with universal adjustable components that can serve multiple functions for different trim part configurations. The same adjustable inserts and supports system handles various trim part thicknesses and geometries, making the mold multi-functional and adaptable while maintaining relatively simple manufacturing through standardized adjustable 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 the production of trim parts with different thicknesses using a single mold, ensuring proper fit and integration in vehicle interiors without visible gaps, reducing production costs and simplifying the manufacturing process.
Implementation Method 1
accounting for the expansion of compressible layers, enabling the production of trim parts with and without foam layers in the same mold
Data Source
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AI summary
A method for manufacturing first and second trim parts (3, 21) of a vehicle, the first trim part (3) having a first thickness and the second trim part (21) having a second thickness different from the first thickness, the method comprising : - introducing the first trim part (3) and the second trim part (21) between a front and a back tool (29, 31) of the forming mould (27), the front tool (29) having a front fixed part (37) and a front movable insert (39) movable with respect to the front fixed part (37) along a main direction, the back tool (31) having a back fixed part (41) and a back movable insert (43) movable with respect to the back fixed part along the main direction; - adjusting settings of the forming mould (27) to different values for the first and second trim parts; - when the forming mould (27) is closed, the front insert (39) has a front final position along the main direction with respect to the front fixed part (37) function of the settings, and the back insert (43) has a back final position along the main direction with respect to the back fixed part (41) function of the settings.