Composite Automotive Trim Part Textured Skin Process
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Solution Overview
Problem
Current overmolding processes for producing composite automotive trim parts are costly, require oversized tools, and result in long cycle times and imperfect quality, particularly for large and aesthetic pieces.
Innovation Solution
A method involving the application of an aqueous thermoplastic dispersion derived from extrusion melt blending of thermoplastic polymer, dispersing agent, and water onto a rigid or foam substrate, followed by molding in a textured mold to create a composite part with a textured skin and substrate layer, using a compression molding machine or similar apparatus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional overmolding processes are used to produce composite automotive trim parts, then the parts can be manufactured with multiple materials, but the process requires numerous costly tools, has long cycle times, and produces imperfect quality pieces
Solution Approach 1:
The patent combines multiple operations (spray application, drying, molding) into a single integrated process using one mold with multiple cavities. The mold receives sprayed dispersion in one cavity, transfers to another cavity for molding, eliminating the need for numerous separate tools and machines while maintaining multi-material composite production
Solution Approach 2:
The single mold performs multiple functions: it serves as both the application surface for the sprayed dispersion and the molding tool for forming the final part. The mold's multiple cavities allow simultaneous production of different sections, making one tool replace numerous specialized tools
2Area of stationary object
If traditional overmolding processes use oversized tools to accommodate large pieces, then large aesthetic parts can be produced, but the tools become very costly and require oversized machines
Solution Approach 1:
The mold is divided into multiple cavities, each capable of receiving sprayed dispersion and forming different sections of the final part. This segmentation allows the production of large aesthetic parts by assembling multiple smallerformed sections within a single mold, avoiding the need for one oversized tool
3Adaptability or versatility
If movable blocks with hydraulic cylinders are used to achieve single-impression tooling, then both single-material and bi-material pieces can be obtained, but operating clearances are required and burrs appear on visible surfaces at high production rates
Solution Approach 1:
The patent removes the movable blocks and hydraulic cylinders from the process entirely. Instead, the mold is stationary with multiple fixed cavities that receive sprayed dispersion and are filled by transfer, eliminating the mechanical complexity and clearance issues while maintaining the ability to produce both single-material and bi-material pieces
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 high-quality, aesthetically pleasing multi-material composite parts with a textured skin and substrate layer at high production rates, reducing costs and tooling requirements while improving finish and appearance.
Implementation Method 1
The process comprises the steps of spraying or casting an aqueous thermoplastic dispersion onto a rigid or foam substrate
Implementation Method 2
C) heating the composite structure
Implementation Method 3
E) closing the mold halves and contacting the composite structure; F) forming a rigid or foam substrate composite part
Implementation Method 4
H) cooling the composite part
Implementation Method 5
the aqueous thermoplastic dispersion is derived from the extrusion melt blending of a) a thermoplastic composition in the presence of b) at least one dispersing agent, and c) water
Data Source
Figure 1
AI summary
The present invention relates to a method for producing a composite part comprising a textured skin and a rigid or foam substrate layer, in particular a composite automotive trim part. The method comprises the steps of spraying or casting an aqueous thermoplastic dispersion onto a rigid or foam substrate composite followed by forming the composite into a composite part comprising a textured skin and a rigid or foam substrate layer. Preferably, the dispersion is derived from the extrusion melt blending of thermoplastic polymer, a dispersing agent, and water.