Thermoplastic Composite Panel Welding With an Integrated Interface Layer
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Solution Overview
Problem
The challenge lies in manufacturing composite parts, such as vehicle dashboards with integrated air cushion devices, where thermoplastic materials used for the deployment channel and panel are not sufficiently compatible, leading to a weak weld connection that may not withstand deployment stresses without damage or debris projection, and existing solutions complicate the production process with additional operational phases and materials.
Innovation Solution
A method involving the use of different thermoplastic materials for the main and secondary bodies, with an interfacing layer compatible with the secondary body being integrated during thermoforming or thermocompression, and welding parameters optimized for temperature, pressure, and duration to achieve a strong bond between the interfacing layer and the secondary body, ensuring a robust connection without additional operational phases or complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is performed between deployment channel and panel using incompatible thermoplastic materials, then manufacturing process remains simple, but weld connection strength is insufficient and may fail under deployment stresses
Solution Approach 1:
An intermediate layer made of thermoplastic material compatible with both the deployment channel and panel is introduced between the two incompatible materials. This intermediate layer acts as a mediator that enables welding connections to both components, solving the incompatibility issue without requiring complex manufacturing processes or additional assembly steps.
Solution Approach 2:
The solution uses a composite structure consisting of the deployment channel, intermediate layer, and panel assembled together. The intermediate layer is made of a composite or blended thermoplastic material that is compatible with both the deployment channel material (e.g., PP/SEBS or PP/EPDM) and the panel material (e.g., thermoformed mixed nonwoven), creating a multi-material composite assembly that achieves strong weld connections.
2Reliability
If an intermediate layer is added to ensure compatible welding, then weld connection strength is improved, but production process becomes more complex with additional operational phases
Solution Approach 1:
The intermediate layer is integrated with either the deployment channel or panel during their respective manufacturing processes (injection molding or thermoforming) using merging techniques. This combining approach incorporates the intermediate layer into the existing production workflow without requiring separate assembly operations, thereby maintaining production efficiency while ensuring deployment integrity through compatible material bonding.
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 enables the production of a robust and mechanically resistant composite part with a simplified manufacturing process, maintaining the integrity of the dashboard assembly without disturbing the current production cycle, ensuring the connection between the dashboard panel and deployment channel is strong enough to resist deployment stresses.
Implementation Method 1
heated between two plates (figure 2B: for example for 60 s, at 200-210° C, under 5 bars in a contact heating oven)
Implementation Method 2
assembling the two bodies together by welding without filler material, in particular by vibration, at the level of respective assembly zones brought into mutual contact under pressure
Implementation Method 3
compressed in the preheated state in a thermoforming mold, for example under 10 bars at 20° C (figures 2C And 2D)
Data Source
Figure 1
Figure 2A~2C
Figure 2D~3B
AI summary
The present invention relates to a method for manufacturing a composite part comprising a main body (2) in the form of a panel and a secondary body (3) attached to one (2') of the faces of said panel (2), said method consisting of manufacturing the main body (2) by thermoforming a piece of material, then assembling the two bodies (2 and 3) together by welding at the level of respective assembly areas (5, 5') brought into mutual contact under pressure.The method is characterized in that it consists of placing, at each assembly zone (5) of the material panel, an interface layer (6) based on a material compatible with that of the secondary body (3), in that it consists of bonding each interface layer (6) with the main body (3) during a pre-assembly phase during the thermoforming operation of the material panel, and in that the welding operation makes it possible to achieve a material bond after plasticization between each interface layer (6) and the assembly zone (5') concerned of the secondary body (3) in contact with it.