Vehicle Crash Pad Skin Layer Scoring Elimination
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Solution Overview
Problem
Conventional crash pads for vehicles require a skin scoring process for airbag deployment, which increases costs, cycle time, labor, and exposes seam lines, lacking technologies to eliminate scoring in structures composed of a skin layer, foam layer, and plastic core layer.
Innovation Solution
A crash pad design omitting the skin scoring process, featuring a skin layer with a tensile strength of 15 to 120 kgf/cm2 and elongation at break of 50 to 700%, bonded to a foam layer and core layer, using a composition of polyol compounds, alicyclic diisocyanate-based curing agents, and aromatic glycol-based chain extenders, formed through processes like powder slush molding or vacuum forming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If skin scoring process is applied for airbag deployment, then airbag can be deployed through the skin layer, but process costs increase, process cycle time increases, labor cost increases, and seam line is exposed on the surface
Solution Approach 1:
The invention extracts the scoring function from the skin layer and relocates it to the foam layer. The foam layer is designed with a scoring line that allows airbag deployment without requiring any scoring process on the skin layer, thus eliminating the harmful effects of skin scoring while maintaining airbag deployment capability
Solution Approach 2:
The foam layer acts as an intermediary element between the skin layer and the airbag module. It provides the scoring line function that enables airbag deployment while protecting the skin layer from direct scoring, thereby resolving the contradiction between deployment reliability and manufacturing complexity
2Reliability
If skin scoring process is applied, then airbag deployment is enabled, but bonding strength between skin layer and foam layer may be compromised and surface appearance deteriorates due to exposed seam line
Solution Approach 1:
The scoring function is extracted from the skin layer and placed in the foam layer. This prevents direct scoring of the skin layer, thereby preserving the bonding strength between the skin layer and foam layer while still enabling airbag deployment through the foam layer's scoring line
Solution Approach 2:
The foam layer is designed with localized scoring lines in specific regions where airbag deployment is needed, while the skin layer maintains its intact structure and excellent bonding properties in all areas
3Strength
If conventional skin layer with high tensile strength is used, then structural integrity is maintained, but airbag deployment becomes difficult without skin scoring
Solution Approach 1:
The foam layer serves as a mediator that enables airbag deployment without compromising the skin layer's structural integrity. The scoring line is created in the foam layer, allowing the airbag to deploy through the foam while the skin layer remains intact and maintains its high tensile strength
Solution Approach 2:
The foam layer provides localized deployment capability through scoring lines in specific areas, while the skin layer maintains uniform high strength properties across its entire surface
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
Enables rapid airbag deployment, excellent bonding strength, mechanical properties, and economic efficiency by simplifying the manufacturing process and reducing costs, while maintaining sensory and aesthetic qualities.
Implementation Method 1
excellent bonding strength between a skin layer and a foam layer
Data Source
AI summary
The present disclosure relates to a crash pad for a vehicle and a manufacturing method thereof. In an embodiment, the crash pad for a vehicle includes: a skin layer configured to form an outer surface of a crash pad including an airbag module; a core layer formed on a lower surface of the skin layer; and a foam layer formed between the core layer and the skin layer, wherein the skin layer has a tensile strength of 15 to 120 kgf/cm2 and an elongation at break of 50 to 700% measured in accordance with JIS K6301 standard, and a bonding strength of 0.25 kgf/cm or more as measured in accordance with ISO 813 standard.