Fiber-Reinforced Cladding Components with Integrated Attachment Elements
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Solution Overview
Problem
Existing methods for producing fiber-reinforced interior trim components for motor vehicles often require multiple tool steps and high pressures/temperatures, leading to procedural inefficiencies and material distortions like warping or folding, especially when forming large add-on elements like reinforcing ribs.
Innovation Solution
A method involving a combined injection and pressing tool where add-on elements are first injected and partially solidified within a core, then a fiber mat is pressed over them using a second die at controlled temperatures, ensuring an optimal connection without material distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If back-injection is used to form add-on elements on fiber composite mats, then functional elements and reinforcements can be integrated, but high pressures and temperatures cause folds or warping of the material composite
Solution Approach 1:
The add-on elements are pre-formed in a separate injection molding step before the fiber composite mat is placed. This preliminary formation allows the elements to be ready for integration without exposing the fiber mat to high pressures and temperatures during element formation, thereby preventing folds and warping while achieving integration
Solution Approach 2:
The manufacturing process is segmented into two distinct steps: first forming the add-on elements via injection molding, then separately placing and pressing the fiber composite mat over them. This segmentation separates the high-pressure element formation from the fiber mat processing, protecting the material composite integrity while still achieving integration
2Adaptability or versatility
If add-on elements are pressed with the fiber composite mat during the pressing process, then integration is achieved, but two different tools are required causing procedural disadvantages
Solution Approach 1:
The invention merges the injection molding process and the fiber composite pressing process into a single integrated tool system. The tool includes both an injection molding unit for forming add-on elements and a pressing unit for forming the fiber composite mat, allowing both operations to be performed sequentially in one device rather than requiring two separate tools
3Length of moving object
If large areas or long add-on elements are back-injected, then functional requirements are met, but folds or warping occur due to high pressures and temperatures
Solution Approach 1:
Large or long add-on elements are pre-formed via injection molding at controlled conditions before the fiber mat is applied. This preliminary formation allows creation of large-scale elements without subjecting the fiber composite mat to high pressures and temperatures that would cause folding or warping
Solution Approach 2:
The process segments element formation from mat formation, allowing large add-on elements to be created first through injection molding, then the fiber mat is separately pressed over them at lower pressures. This segmentation enables production of large elements while maintaining material composite integrity
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 multiple tool steps and high-pressure/temperature processes, achieving a robust and distortion-free connection between fiber mats and add-on elements, enhancing the manufacturing efficiency and quality of interior trim components.
Implementation Method 1
the add-on elements are injected in a tool (1) comprising a core (2) and a first die (1) using a thermoplastic or duroplastic material
Implementation Method 2
the fiber mat is pressed together with the molded parts still in the core. This step is preferably carried out at temperatures between 100°C and 230°C
Data Source
Figure 1~2
Figure 3~5
AI summary
The method involves injection molding of the attachment elements (5) into a tool by applying a thermoplastic or thermosetting plastic, where the tool has a core (2) and a die-plate. The attachment elements injection molded with the die plate remain in the tool core and are overpressed with a fiber mat (7) by another die-plate (6). The injection molded attachment elements are partially cooled before overpressing with the fiber mat. An independent claim is included for a device for manufacturing fiber-reinforced inner lining components with attachment elements for a motor vehicle.