Composite Part Holding Profile for Soft Haptics and Seam Positioning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing composite parts for automotive applications, such as instrument panels and vehicle seats, face challenges in achieving a balance between simple seam positioning and soft haptics, as traditional methods result in firm haptics due to the use of holding profiles, which can compromise positioning reliability.
Innovation Solution
A composite part design featuring a sub-material with a compression hardness of up to 50 kPa, a holding profile with a groove and wings, and a foam layer, allowing for soft haptics while maintaining positioning reliability, achieved through the use of a sub-material with low density and an adhesive layer for secure skin retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a holding profile is used to position skins on a substrate, then seam positioning is simplified, but haptics become firm
Solution Approach 1:
The holding profile is segmented into a base portion (integrally formed with the substrate) and a separate wing portion that can be adjusted or removed. This segmentation allows the base to provide structural support for positioning while the wing can be optimized for softer contact with the skins, thus simplifying seam positioning without compromising haptics.
Solution Approach 2:
Different regions of the holding profile are given different properties: the base portion has higher stiffness for reliable positioning, while the wing portion has lower stiffness to maintain soft haptics when contacting the skins. This local differentiation resolves the contradiction between positioning reliability and tactile comfort.
2Object-affected harmful factors
If a soft sub-material is used to achieve soft haptics, then haptics improve, but positioning reliability of the holding profile may be reduced
Solution Approach 1:
The holding profile is designed as a composite structure combining a rigid base portion (integrally formed with the substrate) and a more compliant wing portion. This composite design allows the base to ensure positioning reliability while the wing adapts to the soft sub-material, maintaining both positioning accuracy and soft haptics.
Solution Approach 2:
The stiffness parameter of the holding profile is varied across different regions: the base has high stiffness for reliable positioning, while the wing has reduced stiffness to accommodate soft sub-materials. This parameter differentiation allows the system to achieve both soft haptics and positioning reliability simultaneously.
3Strength
If wings with large thickness are used in the holding profile, then structural strength is improved, but the profile cannot be properly received in the groove
Solution Approach 1:
The wing thickness is made variable along its length, with the thickness decreasing toward the distal end. This dynamic thickness profile allows the wing to provide sufficient structural strength at the base while becoming thin enough to be properly received in the groove, resolving the contradiction between strength and fit precision.
Solution Approach 2:
The thickness parameter of the wings is optimized to vary along their length, providing maximum strength where needed (near the base) while minimizing thickness for proper groove engagement (at the distal end). This parameter optimization simultaneously satisfies both structural strength and manufacturing precision requirements.
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 design enables soft haptics in composite parts like vehicle seats and arm rests with high positioning reliability, reducing material usage and production costs, and allowing for complex seam courses with reduced bending stiffness in the holding profile.
Implementation Method 1
The sub-material (19) has a compression hardness of 50 kPa at the most with a compression of 40%. This means that at the most, a pressure of 50 kPa is necessary in order to compress the sub-material (19) by 40%.
Data Source
AI summary
A composite part includes a sub-material having a compression hardness of up to 50 kPa with a compression of 40% and a recess formed in the sub-material. A first skin and a second skin are connected at a seam that is disposed within the recess. A holding profile that includes a groove having side walls and a base and at least one wing is introduced into the recess.