Motor Vehicle Interior Structure Manufacturing with Positioning Stops
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for manufacturing motor vehicle interior equipment structures, such as soundproofing components, face challenges in achieving precise assembly and cost-effectiveness due to inaccuracies and increased cycle times, particularly when adding complementary heavy mass parts, which can lead to irregularities and performance deficits.
Innovation Solution
A method involving a kit with a mold having positioning stops and pre-cut complementary parts that are arranged laterally and fixed using hot compression or adhesives, allowing for precise positioning and assembly without structural modifications, ensuring accurate placement and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional heavy mass parts are deposited on the heavy mass layer before heating and softening, then the acoustic behavior is locally improved, but manufacturing precision deteriorates due to inaccuracy in positioning and irregular relief on hole peripheries
Solution Approach 1:
The patent applies preliminary action by pre-cutting the additional heavy mass parts to their final shape and size before assembly, and by pre-positioning them on the heavy mass layer before the heating and softening steps. This ensures that the parts are already accurately shaped and positioned, avoiding subsequent irregularities and positioning inaccuracies that would occur if cutting and positioning were done after heating.
Solution Approach 2:
The patent segments the manufacturing process into distinct sequential steps: first pre-cutting the additional heavy mass parts, then positioning them on the base layer, and finally heating and softening the entire assembly. This segmentation allows each operation to be optimized independently, ensuring both acoustic performance and manufacturing precision.
2Reliability
If additional heavy mass parts are deposited on the heavy mass layer before heating, then local acoustic improvement is achieved, but manufacturing cycle time increases due to longer heating required for thicker zones
Solution Approach 1:
The patent applies preliminary action by pre-cutting the additional heavy mass parts to their final shape and size before assembly. This eliminates the need for prolonged heating to achieve the desired thickness variation, as the parts are already precisely formed. The heating cycle is thus reduced to only what is necessary for softening and bonding, not for thickening specific zones.
3Reliability
If fluid material is injected or sprayed on the heavy mass layer to form complementary parts, then the soundproofing component is improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent replaces the expensive fluid injection or spraying process with a simpler, cheaper method of pre-cutting additional heavy mass parts from solid material. These pre-cut parts are then positioned and bonded to the base layer. This approach uses inexpensive solid materials and simple positioning operations instead of costly fluid handling and injection equipment.
Solution Approach 2:
The patent extracts the expensive fluid injection/spraying process from the manufacturing method and replaces it with a simpler solid material handling approach. By removing the fluid material step and using only solid pre-cut parts, the manufacturing cost is significantly reduced while maintaining the quality of the soundproofing component.
4Manufacturing precision
If fixing points and openings are formed in layers to improve positioning, then assembly precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent uses simple, inexpensive positioning elements (abutments or stops) that are temporarily present during the forming process but do not require permanent structural modifications to the parts. These positioning features are integrated into the mold or formwork and are removed or abandoned after forming, avoiding the need for complex fixing points and openings in the final product structure.
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 production of high-quality motor vehicle interior equipment structures with improved acoustic insulation and precise positioning of parts, reducing inaccuracies and cycle times while maintaining cost-effectiveness and maintaining the structural integrity of the components.
Implementation Method 1
acoustic attenuation of a porous and elastic mass-spring system
Implementation Method 2
materials in the form of single or double sheets (prestressed sandwich) having a visco-elastic behavior
Data Source
Figure 1~5
Figure 2
Figure 4~6
AI summary
The method involves applying a base layer (14) and positioning a second face of the base layer against a first wall (42) of a mould (40). It involves fixing a precut complementary component (16A to 16D) to the second face, the complementary component (16A to 16D) having an extent that it is smaller than that of the second face. The method involves a step of setting the complementary component (16A to 16D) facing a positioning stop (52A to 52E) that projects from the first wall (42).