Instrument Panel Reinforcement Suspension in Foam Trim
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Solution Overview
Problem
Instrument panels with wire reinforcement structures within foam layers often result in an unappealing aesthetic due to visible reinforcement profiles and increased scrap rates, as the wire reinforcement can be pushed against the outer skin during molding.
Innovation Solution
A reinforcement member, such as a tube with a hollow center, is suspended within the foam layer using holders like clips, ensuring it is spaced apart from the substrate and outer skin, allowing gas venting and preventing contact with the skin, thus maintaining an aesthetically pleasing appearance and reducing scrap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If wire reinforcement is positioned on the internal side of the outer skin after the outer skin is placed in a mold, then structural rigidity is improved, but the wire profile becomes visible through the external surface causing aesthetic deterioration and increased scrap
Solution Approach 1:
The patent introduces foam as an intermediary material between the wire reinforcement and the outer skin. The foam layer absorbs and distributes the pressure during molding, preventing the wire from pushing against the outer skin and becoming visible. This mediator resolves the conflict by allowing the wire to provide structural support while remaining hidden within the foam layer.
Solution Approach 2:
The patent positions the wire reinforcement within the thickness dimension of the foam layer, rather than directly against the outer skin surface. By embedding the wire at a specific depth within the foam (suspended in the foam), it creates a three-dimensional arrangement that prevents visibility while maintaining structural function.
2Strength
If wire reinforcement is positioned close to the outer skin to provide rigidity, then structural support is improved, but the wire pushes against the skin during foam introduction causing visibility and scrap increase
Solution Approach 1:
The foam acts as a pressure-distributing intermediary between the wire reinforcement and outer skin during the molding process. The foam's compressible nature allows it to absorb the force of expanding material without transmitting it to the wire, preventing the wire from shifting or pushing against the skin surface.
Solution Approach 2:
The patent positions the wire reinforcement within the foam layer before the molding process begins, creating a cushioning effect. The foam layer serves as pre-positioned protection that prevents direct contact between the wire and outer skin during subsequent foam introduction, eliminating the cause of visibility and scrap before it can occur.
3Strength
If reinforcement member is embedded directly in foam without suspension, then structural rigidity is achieved, but the reinforcement profile becomes visible through the outer skin
Solution Approach 1:
The outer skin serves as a visual intermediary that conceals the reinforcement member. By ensuring the reinforcement is suspended within the foam and not in direct contact with the outer skin, the skin layer acts as a hiding barrier that maintains aesthetic appearance while allowing the reinforcement to provide structural support underneath.
Solution Approach 2:
The patent creates a vertical separation between the reinforcement member and the outer skin surface by suspending the reinforcement within the foam's thickness. This dimensional arrangement places the reinforcement in a different spatial plane than the visible surface, eliminating profile visibility while maintaining structural function.
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 solution effectively eliminates reinforcement member visibility and scrap by suspending it within the foam, providing structural support while allowing gas venting to prevent foam voids, thereby enhancing the panel's appearance and production efficiency.
Implementation Method 1
the at least one tube includes a hollow center through which gas vents when the foam is applied to the substrate
Implementation Method 2
a foam that is applied to the substrate to form a least a portion of an interior trim part, and at least one reinforcement member supported by the at least one holder such that, when the foam is applied, the at least one reinforcement member is suspended within the foam
Data Source
AI summary
A method and apparatus includes a substrate, a foam that is applied to the substrate to form a least a portion of an interior trim part, at least one holder fixed to the substrate, and at least one reinforcement member supported by the at least one holder such that, when the foam is applied, the at least one reinforcement member is suspended within the foam.