Co-Injected Thermoformed Interior Panels With Hidden Fasteners
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Solution Overview
Problem
The complexity and potential for part failure in producing and assembling various separately formed components for automotive interior trim panels compromise the aesthetic integrity and quality of vehicle interiors, especially as the industry shifts towards autonomous vehicles where interior refinement is crucial.
Innovation Solution
A thermoformed article with a self-supporting structural base layer and co-injected secondary features on one side, integrated during the same molding operation, allowing for a unified and aesthetically pleasing interior panel with hidden fasteners and reinforcement, reducing visible fasteners and enhancing assembly consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If separately formed components are used for interior trim panels, then manufacturing flexibility is maintained, but assembly complexity increases and aesthetic integrity deteriorates
Solution Approach 1:
The patent merges multiple separately formed components (structural base layer, coverings, fasteners, reinforcement features) into a single integrated thermoformed article. The co-injected secondary features including fasteners and reinforcement are formed directly on the base layer during the same molding operation, eliminating the need for separate assembly steps and reducing overall part complexity while maintaining manufacturing adaptability through modular tooling design.
2Reliability
If multiple separately formed components are assembled, then functional requirements are met, but aesthetic integrity is compromised due to visible fasteners and assembly joints
Solution Approach 1:
The patent combines structural and aesthetic functions into a single integrated component. The covering is thermoformed directly over the base layer with co-injected fasteners and reinforcement features, creating a seamless appearance without visible assembly joints or exposed fasteners, thereby improving aesthetic integrity while simplifying the manufacturing process.
Solution Approach 2:
The covering acts as an intermediary layer that conceals the co-injected secondary features (fasteners and reinforcement) while maintaining structural functionality. This intermediary layer provides a continuous aesthetic surface that hides the functional elements from view, resolving the conflict between visible fasteners and visual appeal.
3Productivity
If separately formed components are produced and assembled, then production volume can be increased, but potential for part failure increases and quality consistency decreases
Solution Approach 1:
The patent integrates multiple components into a single thermoforming process, reducing the number of separate parts that could potentially fail. The co-injected secondary features are formed as an integral part of the base layer, eliminating interface failures between separately assembled components and improving overall part reliability while maintaining high production volume through efficient one-step manufacturing.
4Strength
If traditional multi-component assembly is used, then functional requirements are satisfied, but structural integrity is reduced due to assembly joints and interfaces
Solution Approach 1:
The patent merges structural base layer, coverings, fasteners, and reinforcement features into a single integrated thermoformed article. The co-injected secondary features create a unified structure without weak interfaces or assembly joints, significantly improving structural integrity while reducing the total number of discrete components from multiple separate parts to a single multi-functional element.
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 assembly process, enhances aesthetic appeal by hiding fasteners, and ensures consistent production of high-quality interior panels with improved structural integrity and reduced complexity, aligning with the evolving automotive industry's focus on interior refinement.
Implementation Method 1
a thermoplastic material is heated to a forming temperature and molded into a base layer
Implementation Method 2
the thermoplastic material is cooled to form the base layer
Data Source
AI summary
A thermoformed article is disclosed that includes a self-supporting structural base layer, a covering applied to a first side of the base layer, and one or more secondary features co-injected upon a second side of the base layer. The covering and the secondary features of the thermoformed article are applied to the base layer during the same molding operation. Also disclosed is a process for forming a thermoformed article that includes placing a covering in a mold tool as a first layer, placing a self-supporting structural base layer in the mold tooling as a second layer, closing the mold tooling with the covering and base layer, and co-injecting upon a side of the base layer opposite to the covering one or more secondary features.