Composite Molded Article Weir Portion Thermal Insulation

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Solution Overview

Problem

Existing methods for manufacturing vehicle interior materials, such as door trims, face challenges in reducing weight and cost while maintaining decorativeness, as they often require labor-intensive assembly and can result in thermal damage to materials due to resin injection, leading to limited material choices and aesthetic issues.

Innovation Solution

A method involving the integration of a flat plate-like first member and a second molded portion formed by hardening molten resin within a molding mold, where the molten resin is injected around a weir portion to prevent thermal transfer and create a composite article with reduced resin usage and improved structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If insert molding is used to fill resin on the back surface of skin material, then structural integrity is improved, but the skin material is thermally damaged by heat of molten resin

Engineering Contradiction:

Improvestructural integrityVSAvoidthermal damage to skin material

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

A heat insulating layer is introduced as an intermediary between the molten resin and the skin material. This layer prevents direct thermal contact, allowing the resin to be injected for structural reinforcement without causing thermal damage to the decorative skin material surface.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The structure is segmented into multiple functional layers: the skin material layer for decoration, the heat insulating layer for thermal protection, and the resin-filled structural layer for strength. This segmentation allows each layer to perform its specific function without interfering negatively with others.

Inventive Principle:

Principle #1Segmentation

2Weight of moving object

If resin is provided on the back surface of skin material to prevent thermal damage, then weight reduction is achieved, but resin leaks out through nonwoven fabric causing deterioration in outer appearance

Engineering Contradiction:

Improveweight of interior materialVSAvoidouter appearance quality

Core Design Contradiction:

Weight of moving objectVSManufacturing precision

Solution Approach 1:

The nonwoven fabric is designed with differentiated local properties: a dense surface layer that prevents resin leakage and maintains appearance, and a porous internal structure that allows weight reduction and resin penetration where needed for structural reinforcement.

Inventive Principle:

Principle #3Local quality

3Shape

If multiple extension portions are inserted through insertion holes to mount skin material, then decorativeness is improved, but manufacturing time and cost are increased due to labor-intensive assembly

Engineering Contradiction:

ImprovedecorativenessVSAvoidmanufacturing efficiency

Core Design Contradiction:

ShapeVSProductivity

Solution Approach 1:

The mounting of skin material and the formation of structural reinforcement are merged into a single integral molding process. The resin is injected to simultaneously bond the skin material extension portions and create the structural framework, eliminating separate assembly operations and reducing manufacturing time.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The skin material extension portions are pre-formed with mounting holes and peripheral edges in a preliminary shaping step before the integral molding process, allowing them to be ready for automated insertion and bonding without requiring complex assembly operations during final manufacturing.

Inventive Principle:

Principle #10Preliminary action

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 method reduces manufacturing time and cost, enhances the decorative appearance, and results in a lightweight, high-strength composite article with reduced residual stress, effectively addressing the limitations of previous technologies.

Implementation Method 1

a first molded portion that is stereoscopically formed by a first member which is softened under heating

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

the weir portion is made to abut against a thin portion reduced in thickness and provided at a peripheral edge of the first molded portion

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS12257748B2Method for manufacturing composite molded article and composite molded article

Publication Date: 2025.03.25 VUTEQ CORP

AI summary

A composite molded article is manufactured in such a manner that a molding mold that forms a molding space by mold closing and has a weir portion projecting into the molding space is opened, a flat plate-like first member that is softened under heating is arranged in a part of a portion where the molding space is formed, the stereoscopic first molded portion is formed with mold closing, simultaneously an injected molten resin is filled in a remaining portion of the molding space around the first member outside the weir portion in a state that the weir portion is made to abut against a thin portion provided at a peripheral edge of the first molded portion, and the second molding portion joined to the first molding portion is formed by hardening molten resin after the resin is caused to contact the first molded portion.