Two-Dimensional Composite Component Narrow-Side Injection Moulding
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Solution Overview
Problem
In existing methods for producing composite components, the injection moulded component covers at least one region of the basic component's base side, limiting its sound absorption capabilities.
Innovation Solution
The method involves injecting moulding material directly onto the narrow side of the basic component, ensuring both sides remain acoustically effective by preventing material penetration into the inner regions, and using a moulding tool with projections to control material distribution and maintain acoustic characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the injection moulded component covers at least one region of the basic component's base side to ensure rigid joining, then the joining strength is improved, but the sound absorption capability of the basic component is reduced
Solution Approach 1:
The patent transitions from covering the base side (two-dimensional surface contact) to joining exclusively at the narrow side (one-dimensional edge contact). This dimensional change allows the basic component to remain fully exposed on both base sides, preserving sound absorption capability while achieving rigid joining through the narrow side contact and microscopic positive locking in the pores.
2Stability of the object's composition
If the injection moulding material penetrates into the pores of the basic component to create microscopic positive engagement, then the joining rigidity is improved, but the acoustic effectiveness of the basic component is reduced
Solution Approach 1:
The patent applies local quality by concentrating the material penetration and microscopic positive engagement exclusively in the joining region at the narrow side, while preventing penetration into the inner regions of the basic component. This localized approach ensures rigid joining at the contact interface while preserving the acoustic effectiveness of the bulk basic component material.
3Manufacturing precision
If the basic component is compressed along a predetermined contour to control material penetration, then the material distribution is improved, but the production complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-forming the basic component with a predetermined contour that defines the compression zone before injection. This pre-prepared geometry allows the compression step during injection to control material distribution precisely without requiring complex real-time control systems, thus managing production complexity while achieving precise material placement.
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 produces a rigidly joined composite component with enhanced sound absorption, suitable for motor vehicle applications, while minimizing material consumption and maintaining structural integrity.
Implementation Method 1
the injection moulding material also penetrates at least into the pores of the basic component in a joining region of said basic component which adjoins a contact surface between basic component and injection moulded component
Data Source
AI summary
The present invention relates to a method for producing a two-dimensional composite component (150) having a porous basic component (152) and an injection molded component (154) rigidly joined to the basic component (152), said method comprising the following steps: introduction of the mat-like or panel-like basic component (152), comprising two mutually spaced-apart base sides (152b1, 152b2) and a circumferential narrow side (152s) joining the base sides (152b1, 152b2), into a basic component cavity (114) of a molding tool (112), which further comprises an injection molding cavity (116), closure of the molding tool (112), so that at least a portion (152s) of the basic component (152) forms a portion of a wall of the injection molding cavity (116), and injection of injection molding material (156) into the injection molding cavity (116), and formation thereby of the injection molding component (154) and joining of the injection molding component (154) to the basic component (152), wherein upon closure of the molding tool (112) before the injection molding material (156) is injected, the entire region (152s), formed by the basic component (152), of the wall of the injection molding cavity (116) is formed by the narrow side (152s) of the basic component (152).