Back-Molded Decorative Element With Foil Positioning

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Solution Overview

Problem

Existing methods for producing components with two-dimensionally extending decorative elements, such as those in automobile construction, are complex and often result in island-shaped parts not being precisely flush with the surface due to the need for struts or elaborate vacuum positioning, which can be aesthetically undesirable and prone to displacement during molding.

Innovation Solution

A method where a translucent plastic foil is applied to the backside of the decorative element, filling through-holes and engaging with island-shaped parts to ensure precise positioning and protection from external influences, allowing for simpler production and avoidance of sharp edges, with the foil being molded into the component to create a stable composite.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If struts or vacuum positioning are used to position island-shaped parts in the injection-molding tool, then the island-shaped parts can be positioned, but the production process becomes complex and the parts are not precisely flush with the surface

Engineering Contradiction:

Improvepositioning precision of island-shaped partsVSAvoidcomplexity of injection-molding tool

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

A foil is introduced as an intermediary element between the island-shaped parts and the injection-molding tool. The foil is applied to the backside of the decorative element and engages into the through-holes, serving as a mediator that positions the island-shaped parts without requiring complex struts or vacuum systems in the molding tool itself

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The foil is applied to the decorative element before the injection-molding process. This preliminary action pre-positions the island-shaped parts and prepares the structure for molding, eliminating the need for complex positioning mechanisms during the actual injection process

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If the decorative element is directly back-molded, then the production process is simple, but the injection point cannot be freely selected and island-shaped parts may be displaced by molding pressure

Engineering Contradiction:

Improvesimplicity of production processVSAvoidpositioning stability of island-shaped parts

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The foil is applied to the backside of the decorative element before injection-molding. This preliminary action creates a protective structure that allows the island-shaped parts to be securely positioned and prevents their displacement during the molding process, while still maintaining production simplicity

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A thin foil is used to create a flexible yet effective positioning structure. The foil engages into the through-holes and provides sufficient support to prevent displacement of island-shaped parts during molding, while allowing for flexible design and easy application

Inventive Principle:

Principle #30Flexible shells and thin films

3Ease of manufacture

If through-holes are left empty or filled with transparent plastic, then the decorative element can be produced, but sharp edges remain and intermediate spaces may be contaminated during prolonged use

Engineering Contradiction:

Improveease of producing decorative elementVSAvoidcontamination of intermediate spaces

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The foil acts as a flexible shell that fills the through-holes and eliminates sharp edges. By engaging into the through-holes, the foil creates a smooth, continuous surface that prevents contamination in intermediate spaces while maintaining the decorative appearance and not requiring additional filling materials

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The through-holes, which could potentially cause contamination problems, are converted into beneficial engagement points for the foil. The foil uses these through-holes to anchor itself and eliminate the harmful sharp edges and intermediate spaces, turning a potential problem into a solution

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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

The method simplifies the production of components with flush island-shaped parts, enhances aesthetic appeal by eliminating sharp edges, and ensures precise positioning, while allowing for flexible design and uniform illumination, suitable for various applications including motor vehicles and furniture.

Implementation Method 1

the at least one layer is molded on the foil

Methodology Applied

Scientific EffectMolding:

Data Source

PatentUS10449911B2Component having a two-dimensionally extending decorative element

Publication Date: 2019.10.22 WEIDPLAS

AI summary

Before back molding, the planar decorative element is provided with through-holes. At least in the area of the through-holes, a film is applied to the rear of the planar decorative element. When a plastic melt is introduced, for example by way of injection molding or extruding, the pressure of the plastic melt presses the film into said through-holes. The component is used, in particular, to produce an illuminable field, for example, of a door sill protector of a motor vehicle.