Composite Surface Projections Formed Without Metal Preforming
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Solution Overview
Problem
Conventional methods for manufacturing composite decorative automotive components with surface projections require pre-forming of metal plates, which are time-consuming and costly, and involve complex tooling processes.
Innovation Solution
A method that eliminates pre-forming by using an injection mold with a negative image of the desired projection, deforming a stock material such as aluminum under high pressure to create the projection directly, bonded with a plastic layer using an adhesive.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pre-forming of metal plate is performed before composite plate manufacturing, then the design can be stamped into the metal plate, but the manufacturing process becomes time-consuming and costly
Solution Approach 1:
The patent combines the pre-forming operation and composite plate manufacturing into a single integrated injection molding process. The metal plate is placed in the mold before injection, and the plastic material is injected directly onto the metal plate in the same operation that forms the final composite structure, eliminating the need for separate pre-forming steps
Solution Approach 2:
The metal plate is prepared and positioned in the mold cavity before the plastic material is injected. This preliminary positioning of the metal plate allows the subsequent injection process to directly form the final composite structure without requiring separate pre-forming operations
2Shape
If pre-forming operations are performed on metal plate, then the decorative projection can be created, but complex tooling processes are required
Solution Approach 1:
The decorative projection design is directly copied into the injection mold cavity as a negative space. When the plastic material is injected, it fills this negative space and forms the positive decorative projection on the metal plate, eliminating the need for complex stamping tooling
Solution Approach 2:
The patent replaces complex mechanical stamping operations with a simpler injection molding process. Instead of using stamping machinery to press designs into metal plates, the design is formed by injecting plastic material into a mold cavity, substituting mechanical stamping with injection molding
3Strength
If solid metal plate is used for decorative automotive component, then durability is achieved, but the component becomes heavy and costly
Solution Approach 1:
The patent creates a composite component combining metal and plastic materials. The metal plate provides structural strength and durability, while the plastic material adds decorative projections and reduces overall weight. This composite structure achieves both durability and weight reduction compared to solid metal
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
Reduces manufacturing time and costs by eliminating pre-forming steps, allowing for efficient production of composite components with decorative projections without the need for stamping machinery and tooling.
Implementation Method 1
The injection mold may cause the mold material to deform the stock material such that the image projects from a second surface of the portion of stock material
Implementation Method 2
injecting the mold material at a pressure between about 10,000 PSI to about 25,000 PSI
Implementation Method 3
An adhesive may bond together the cooled mold material and the stock material to form the component
Data Source
AI summary
A method for manufacturing a composite component may include obtaining an image to be projected from an exterior surface of the component, forming an injection mold having a negative of the image formed on a portion of the mold surface, preparing a first surface of a portion of the stock material, placing the stock material into the injection mold, and injecting mold material into the injection mold. The injection mold may cause the mold material to deform the stock material such that the image projects from a second surface of the portion of stock material.