Composite Cargo Trim Panels with Wood Grain Finish
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Solution Overview
Problem
Current methods for achieving a wood grain finish in automotive parts, such as cargo trim panels, either use expensive genuine wood or less attractive simulated wood, with existing solutions being costly and requiring extensive maintenance or design limitations.
Innovation Solution
A cargo management system featuring a vehicle load floor and cargo trim panels with a cellulose-based core and a wood grain finish, achieved through a composite compression molding process, where the panels include a base layer of fiber-reinforced polymeric material and a coverstock sheet with a simulated or natural wood layer, providing a durable and aesthetically pleasing wood grain appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If genuine wood is used for wood grain finish, then aesthetic appearance is improved, but manufacturing cost increases
Solution Approach 1:
The patent uses a molded plastic surface that replicates the visual appearance of genuine wood grain through mold texturing, creating a convincing copy that eliminates the need for expensive real wood materials while maintaining aesthetic appeal
Solution Approach 2:
The patent employs composite plastic materials with wood grain patterns integrated into the molding process, combining the durability and cost-effectiveness of plastic with the aesthetic qualities of wood grain appearance
2Ease of manufacture
If simulated wood grain is used, then manufacturing cost is reduced, but aesthetic appearance deteriorates
Solution Approach 1:
The patent enhances the visual parameters of the plastic material by incorporating realistic wood grain textures and patterns into the mold design, changing the surface characteristics to closely resemble genuine wood and thereby improving aesthetic appearance while maintaining cost effectiveness
3Illumination intensity
If wood trim is applied after molding, then aesthetic appearance is improved, but device complexity increases
Solution Approach 1:
The patent merges the wood grain finish application into the molding process itself by texturing the mold surfaces, so that the aesthetic finish is created simultaneously with the part formation, eliminating separate post-molding operations and reducing overall manufacturing complexity
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
The solution offers a cost-effective, low-maintenance, and attractive wood grain finish for automotive parts, combining the benefits of composite materials with the appearance of genuine wood, while minimizing material waste and design constraints.
Implementation Method 1
compression molding process
Implementation Method 2
bonded to the base layer by press molding
Data Source
AI summary
A cargo management system including a vehicle load floor and a pair of opposing cargo trim panels supported above the load floor at opposite sides of the load floor within the interior of the vehicle is provided. The load floor has a wood grain finish. The load floor includes a first outer layer, a second outer layer and a core of cellulose-based material positioned between the outer layers and having a large number of cavities. The outer layers are bonded to the core by press molding. The trim panels are compression-molded, composite cargo trim panels supported above the vehicle load floor at opposite sides of the load floor. Each panel includes a base layer and a coverstock sheet bonded to the base layer by press molding. Each coverstock sheet provides its respective trim panel with a wood grain finish.