Interior Covering Part Forming with Dual-Press Texture Stabilization
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Solution Overview
Problem
Existing methods for producing interior vehicle covering parts fail to achieve a haptically and visually advantageous surface texture, as they either compromise on texture quality or suffer from instability during the forming process.
Innovation Solution
A method involving two press tools with cooling mechanisms to form a carrier component and decorative film using fibre moulding materials, where the first tool creates a textured surface and the second tool further forms the part while maintaining the texture through controlled cooling, ensuring the surface texture is stabilized and retained.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single press tool is used to form both the substrate and decorative layer, then the manufacturing process is simpler, but the surface texture quality and stability deteriorate
Solution Approach 1:
The manufacturing process is divided into two separate press tools: a first press tool for forming the substrate with decorative layer, and a second press tool for final forming. This segmentation allows each tool to be optimized for its specific function, with the first tool creating the base structure and the second tool applying the final surface texture without disturbing the decorative layer.
Solution Approach 2:
The first press tool performs preliminary forming of the substrate and decorative layer assembly before the second press tool applies the final forming. This preliminary action stabilizes the decorative layer and prevents it from being disturbed during subsequent forming operations, ensuring texture quality is maintained.
2Adaptability or versatility
If the decorative layer is formed at high temperature, then the material is more formable, but the surface texture becomes unstable and may be destroyed during further forming
Solution Approach 1:
The second press tool applies localized cooling to specific regions of the decorative layer during the forming process. This creates local temperature variations where the decorative layer is cooled and stabilized in areas where texture stability is critical, while other regions remain at forming temperature to maintain material formability.
Solution Approach 2:
The temperature parameter of the decorative layer is dynamically changed during the forming process by applying cooling. This allows the material to transition from a high-temperature formable state to a lower-temperature stable state, ensuring both formability during shaping and stability for texture preservation.
3Stability of the object's composition
If cooling is applied to the decorative layer, then the surface texture stability is improved, but the material becomes less formable
Solution Approach 1:
The decorative layer is pre-formed and stabilized in the first press tool before cooling is applied in the second press tool. This preliminary forming ensures the basic structure is established while the material is still formable, and subsequent cooling only affects the surface texture stability without compromising the already-established geometry.
Solution Approach 2:
Cooling is applied locally to the surface regions of the decorative layer where texture stability is most critical, rather than cooling the entire component uniformly. This localized approach maintains texture stability on the surface while preserving material formability in the bulk for final shaping operations.
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 produces interior covering parts with a stable surface texture and geometry, maintaining a desired roughness value and drapeability, enhancing both the visual and tactile experience while preventing texture destruction during further forming.
Implementation Method 1
cooling down of at least one thickness part region of the cross section of a decorative layer portion of the intermediate product by cooling down a first surface of the same by means of a cooling medium
Data Source
AI summary
A device and method for producing an interior covering part with a carrier component of a fiber molding material and a decorative film. The method may be carried out using the device and includes the steps of: in a first press tool with two tool halves, carrying out a first pressing together and forming of a semi-finished product provided for forming the substrate and of a semi-finished product provided for forming the decorative layer subject to forming a texture of a first surface of the decorative layer and because of this forming an intermediate product with a first forming state; cooling down a decorative layer portion of the intermediate product; and in a second press tool, forming a method end product with a second forming state.