Composite Touch Zone for Automotive Panels
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Solution Overview
Problem
Existing methods for manufacturing automotive interior components, such as instrument panels and doors, require corner sewing, edge wrap, and trimming to achieve a soft-touch feel and visual appeal, which can be time-consuming and costly, and do not allow for features to be molded directly into the premium-touch material.
Innovation Solution
A method involving a mold apparatus with a substrate and two layers, where a soft-touch material and a fabric layer are bonded to a self-skinning foam layer, eliminating the need for sewing and wrapping, and enabling features to be molded into the surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional manufacturing methods are used with separate attachment of soft-touch materials, then the premium touch feel and visual appeal are achieved, but the production time and costs increase due to corner sewing, edge wrap, and trimming
Solution Approach 1:
The patent combines the substrate, soft-touch material, and foam layer into a single integrated molding process. The mold apparatus simultaneously forms all three layers together, eliminating the need for separate attachment operations like corner sewing, edge wrap, and trimming. This merging of previously separate manufacturing steps into one unified process directly reduces production time and simplifies manufacturing.
Solution Approach 2:
The soft-touch material and foam layer are pre-positioned and bonded to the substrate within the mold apparatus before the final component is completed. The vacuum bonding process preliminarily secures these layers in their final positions during the molding process itself, preventing the need for subsequent trimming and wrapping operations that would otherwise be required to achieve proper fit and finish.
2Manufacturing precision
If traditional manufacturing methods with corner sewing and edge wrap are used, then premium touch materials can be applied, but the process is time-consuming and costly
Solution Approach 1:
The patent merges the substrate, soft-touch material, and foam layer into a single integrated molding process. The mold apparatus simultaneously forms all three layers together, eliminating the need for separate attachment operations like corner sewing, edge wrap, and trimming. This merging of previously separate manufacturing steps into one unified process directly reduces production time and simplifies manufacturing.
3Adaptability or versatility
If traditional methods are used, then soft-touch materials can be applied, but features cannot be molded directly into the premium-touch material surface
Solution Approach 1:
The mold apparatus is configured with molding surfaces that directly form features into the soft-touch material during the initial molding process. Styling features, logos, or other design elements can be pre-formed in the mold cavities, allowing them to be integrated into the premium-touch material surface as it is being formed, rather than requiring separate post-processing steps to add these features.
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 allows for the production of high-quality automotive interior components with a premium-touch feel and visual appeal without the need for corner sewing or edge wrap, reducing production time and costs while enabling molded features, resulting in a zero gap fit appearance.
Implementation Method 1
The mold apparatus comprises a vacuum apparatus in fluid connection with the opening of the substrate and the method further comprises: applying a vacuum through the opening of the substrate; and bonding the first layer of the first material to the substrate.
Data Source
AI summary
A method of manufacturing an automotive interior component includes the steps of: providing a mold apparatus comprising a first mold component and a second mold component; providing a substrate; applying a first layer of a soft-touch material to the substrate; applying a second layer of a fabric to one of the first mold component and the second mold component of the mold apparatus; forming a self-skinning foam layer, wherein a first surface of the self-skinning foam layer is configured for bonding to the first layer and a second surface of the self-skinning foam layer is configured for bonding to the second layer; and fastening the substrate, the first layer, the second layer together. Additional methods of manufacturing automotive interior components and automotive interior components are also provided.