Molded Part Decorative Foil Edge Separation
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Solution Overview
Problem
Current methods for producing molded parts with multiple decorative areas for motor vehicle interiors require multiple processing steps and can result in irregular joint patterns and visual imperfections at the edge areas, making it difficult to achieve a clean and visually flawless design.
Innovation Solution
A method using a molding tool with a gripper and mold core that allows decorative foils to be placed with overlapping edges, which are then fixed into grooves in the mold core and separated by slides, enabling back-molding without additional edge processing, resulting in a molded part with adjacent decorative areas separated by a narrow groove for a clean visual finish.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate parts with different surface structures are prefabricated and connected, then different decorative areas can be achieved, but several processing steps and transport operations are required, increasing time and production engineering effort
Solution Approach 1:
The patent combines multiple decorative foils and their edge processing into a single integrated mold cavity. The mold core contains multiple cavities that can simultaneously receive different decorative foils, and the edge profile is formed in one operation during the molding process itself, eliminating the need for separate prefabrication and assembly steps.
Solution Approach 2:
The edge profile of the decorative foils is pre-formed during the molding process itself rather than requiring subsequent separate processing. The mold cavity and edge profile work together to automatically trim and shape the decorative foil edges as the molding is produced, performing the edge processing action in advance before the product leaves the mold.
2Adaptability or versatility
If decorative foils are inserted separately and fixed in the mold, then different decorative areas can be produced, but the loose insertion creates risk of displacement and irregular joint patterns affecting visual appearance
Solution Approach 1:
The mold core acts as an intermediary structure that provides grooves and retention features to securely hold the decorative foils in their precise intended positions. These grooves guide and fix the foils during insertion and prevent displacement, ensuring accurate alignment and clean joints between different decorative areas.
Solution Approach 2:
The molding process itself serves to automatically position and secure the decorative foils. As the thermoplastic material is injected and cooled, it naturally pushes against and secures the decorative foils in place, while the edge profile mechanism automatically trims excess material, eliminating the need for separate fixing operations and ensuring precise positioning.
3Manufacturing precision
If edge trimming is performed separately after molding, then decorative elements can be fitted perfectly, but additional processing steps and complexity are required
Solution Approach 1:
The edge trimming function is merged with the main molding operation. The mold cavity includes an integrated edge profile that performs both the shaping of the main molding and the trimming of decorative foil edges in a single simultaneous operation, eliminating the need for separate trimming equipment and processes.
Solution Approach 2:
The molding process itself performs the edge trimming function automatically. The edge profile of the mold cavity acts as a built-in trimming tool that cuts and shapes the decorative foil edges as the thermoplastic material is injected and cooled, with the material itself pushing against the profile to achieve the trim, requiring no additional processing steps.
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 approach eliminates the need for separate edge processing and ensures a clean, joint-accurate, and optically perfect transition between decorative areas, achieving a visually appealing and precise edge separation without additional trimming or gluing of components.
Implementation Method 1
a section is punched out of the semi-finished product produced in this way. In a second step, a second fabric or a second decorative film is then inserted in place of the removed part of the semi-finished product and the semi-finished product is then also back-formed in the area of the second fabric or the second film
Implementation Method 2
at least one decorative film is inserted with the aid of a gripper into the cavity of an open mold comprising a die and a core and is fixed with the help of slides integrated in the core
Data Source
Figure 1~3
Figure 4~5
Figure 6~7
AI summary
The present invention relates to a method and to a device for producing a molded part having a plurality of different decorative regions that abut on each other, wherein the different decorative films (9, 10) are inserted into a molding tool (1) by a gripper (4). There they are fixed by means of sliders (8) and are then back-molded with a thermoplastic material (15).