Vehicle Door Trim Assembly Co-Molding and Coextrusion
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Solution Overview
Problem
Conventional methods for manufacturing decorative trim for vehicles are inefficient in terms of time and cost, as they involve expensive materials and labor-intensive processes for bonding thin metal sheets and applying decorative films to multiple sealing elements.
Innovation Solution
A door assembly for vehicles featuring a molded trim portion with a polymeric base and a decorative member, co-molded and bonded simultaneously, and an extruded trim portion with a coextruded decorative member, where coupling members are formed and bonded during the manufacturing process, allowing for efficient and cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional methods are used to manufacture decorative trim with multiple sealing elements, then each sealing element can be manufactured separately with decorative film applied individually, but the production time and cost increase significantly
Solution Approach 1:
The patent combines multiple sealing elements into a single integrated trim piece with a continuous base structure. The decorative film is applied once to the entire base before bonding, eliminating the need to manufacture and decorate each sealing element separately. This merging of previously separate components into one unified structure resolves the contradiction by maintaining manufacturing simplicity while dramatically improving productivity.
2Ease of manufacture
If thin metal sheets are used for decorative trim, then material costs and processing costs for bonding increase, but if decorative films are used with multiple sealing elements, then the complexity of applying and bonding each film separately increases
Solution Approach 1:
The patent uses a single continuous base structure for the trim piece, allowing one decorative film to be applied and bonded across the entire structure in a single operation. This eliminates the complexity of applying and bonding multiple separate films to individual sealing elements, while still achieving the desired decorative effect across all sealing surfaces.
3Reliability
If decorative film is applied to each sealing element separately using heat bonding, then bonding quality can be maintained, but the production time and labor costs increase
Solution Approach 1:
The patent applies the decorative film to the entire base structure in a single heat bonding operation rather than bonding separate films to each sealing element individually. This maintains reliable bonding quality across all sealing surfaces while reducing production time and labor costs by performing the bonding operation once instead of multiple times.
4Adaptability or versatility
If conventional methods are used to manufacture trim with multiple sealing elements, then each element can be customized independently, but the overall manufacturing cost and time increase
Solution Approach 1:
The patent integrates multiple sealing elements into a single trim piece with a continuous base, allowing the entire assembly to be manufactured and decorated as one unit. This maintains the ability to customize the overall trim design while improving productivity by eliminating the need to manufacture and assemble multiple separate elements independently.
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 enables the rapid and cost-effective manufacturing of trim strip assemblies using inexpensive materials, reducing production time and costs, enabling the trim to be sold at a lower price compared to competitors.
Implementation Method 1
The polymeric base is formed of a polymeric material co-molded to the first decorative member
Implementation Method 2
The extruded base and the second decorative member are coextruded and mounted to the door frame
Implementation Method 3
The first coupling member is bonded to the second coupling member to interconnect the first trim portion with the second trim portion
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A trim strip assembly for a vehicle and method of making the same is provided. The trim strip assembly includes a first trim portion. The first trim portion has a polymeric base and a first decorative member bonded to the polymeric base. The polymeric base is formed of polymeric material molded to the first decorative member. The polymeric base includes a first coupling member. A second trim portion has an extruded base and a second decorative member bonded to the extruded base. The extruded base and the second decorative member are coextruded. The extruded base includes a second coupling member. The first coupling member is bonded to the second coupling member to interconnect the first trim portion and the second trim portion.