Vehicle Interior Panel with Integrated Cushioning and Non-Uniform Hardness
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Solution Overview
Problem
Existing vehicle interior panels lack an aesthetically pleasing upholstering method that incorporates natural fibers effectively, requiring a soft foam layer and decorative skin layer, which is not addressed by previous methods like U.S. Patent Application Publication No. 2015/0197069.
Innovation Solution
A method involving pressing a fiber mat with natural and thermoplastic fibers between heated and cooled tool portions to form a compression-formed panel with non-uniform hardness, allowing for a decorative layer to be adhered and stitched, and optionally overmolded with a rib structure, eliminating the need for a distinct cushioning layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If natural fibers are used as reinforcing component in polymer composites, then carbon footprint is reduced, but structural integrity and hardness are insufficient
Solution Approach 1:
The patent combines natural fibers with thermoplastic polymers to create a composite material that maintains structural integrity while reducing carbon footprint. The thermoplastic matrix provides the necessary strength and rigidity, while the natural fibers contribute to mechanical properties and sustainability.
Solution Approach 2:
The patent creates regions of different fiber concentration and distribution within the panel, with higher fiber density in areas requiring greater strength and stiffness, while maintaining lower fiber content in areas where flexibility is needed. This local variation in material properties optimizes both structural integrity and environmental performance.
2Strength
If conventional injection molded polymer composites are used with thickness of 2.5 mm to 3.0 mm, then structural integrity is maintained, but upholstering aesthetic appeal is compromised
Solution Approach 1:
The patent divides the panel into distinct functional zones: a structural core layer providing strength and stiffness, and a separate upholstery layer providing aesthetic appeal and comfort. This segmentation allows each layer to be optimized independently for its specific function.
Solution Approach 2:
The patent modifies the thickness parameter of the panel to be less than 1.0 mm while compensating for structural integrity through optimized fiber reinforcement patterns and thermoplastic matrix selection, enabling both thin profile and adequate strength for upholstering applications.
3Ease of manufacture
If fiber mat is compressed uniformly to form panel, then manufacturing simplicity is maintained, but non-uniform hardness required for aesthetic upholstering is not achieved
Solution Approach 1:
The patent implements a dynamic compression process where the pressing force and duration are varied across different regions of the fiber mat during manufacturing. This allows creation of non-uniform hardness profiles with softer areas for comfort and harder areas for structure, while maintaining a single-step manufacturing process.
Solution Approach 2:
The patent pre-positions fibers and thermoplastic materials in specific patterns and concentrations within the fiber mat before compression, creating zones with different mechanical properties that will manifest as varying hardness after forming, thereby achieving the desired hardness profile through material distribution rather than complex post-processing.
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 creates a vehicle interior panel with integrated cushioning and aesthetic features, reducing material components and enhancing carbon-neutral manufacturing, while providing structural integrity and preventing microbial or water ingress.
Implementation Method 1
pressing a fiber mat between heated first and second tool portions to form a hot mat
Implementation Method 2
The thermoplastic fibers are heated above a melting point of the thermoplastic fibers
Implementation Method 3
pressing the hot mat between cooled first and second tool portions to form a compression-formed panel
Implementation Method 4
pressing the hot mat between cooled first and second tool portions to form a compression-formed panel
Implementation Method 5
The thermoplastic fibers of the fiber mat and the thermoplastic fibers of the decorative layer each comprise polyolefin fibers
Data Source
Figure 1~2
Figure 3A~3E
Figure 4A~4E
AI summary
A vehicle interior panel includes a substrate with non-uniform hardness, providing cushioned portions of the panel without the need for a distinct cushioning layer. The substrate is made from a mat of natural and synthetic fibers that is heated and pressed so that the pressed mat has thick and thin portions. The thin portions are rigid and structural, and the thick portions are soft. Application of a decorative layer can be incorporated into the process, as can back-injection molding (BIM) for additional structure.