Interior Trim Multi-Cavity Molding for Fixed Decorative Layer Positioning

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Solution Overview

Problem

Existing methods for producing interior trim parts in vehicles are inefficient and costly, particularly in achieving reliable and rapid production of interconnected components with decorative, light-permeable, and opaque structural parts.

Innovation Solution

A method involving plastic injection molding to produce interconnected components of an interior trim part, where a translucent decorative layer and a light-permeable body are integrated with an opaque structural part as a multi-component structural part, without requiring the mold part carrying the decorative layer to be moved, thus ensuring reliable positioning and rapid processing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the mold part carrying the decorative layer is moved during production, then the production process can be completed, but the positioning reliability deteriorates and processing time increases

Engineering Contradiction:

Improveproduction speedVSAvoidpositioning reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The mold is divided into multiple cavities (first cavity and second cavity) within a single mold structure. The decorative layer remains fixed in the first cavity while the opaque structural part is transferred to the second cavity, allowing sequential operations without moving the decorative layer carrier.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A transfer mechanism acts as an intermediary to move the opaque structural part from the first cavity to the second cavity without requiring movement of the decorative layer carrier. This mediator enables the transfer operation while preserving the fixed position of the decorative layer.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If traditional multi-step production methods are used, then interconnected components can be produced, but production costs increase and process complexity increases

Engineering Contradiction:

Improveproduction costVSAvoidprocess complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

Multiple production operations (injection molding of opaque structural part, transfer operation, injection molding of light-permeable body) are merged into a single automated cycle within one mold system. This integration reduces the number of separate production steps and lowers overall process complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single mold system performs multiple functions: it serves as both the first cavity for producing the opaque structural part and the second cavity for producing the light-permeable body, and includes the transfer mechanism. This multi-functional design eliminates the need for separate dedicated equipment for each operation.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Loss of time

If the decorative layer is repositioned for each work operation, then the production process can continue, but time is lost and reliability decreases

Engineering Contradiction:

Improveprocessing timeVSAvoidpositioning reliability

Core Design Contradiction:

Loss of timeVSReliability

Solution Approach 1:

The decorative layer is preliminarily positioned in the first cavity at the start of the production cycle and remains fixed throughout. The mold system is pre-configured with multiple cavities and transfer mechanisms that automatically handle subsequent operations without requiring repositioning of the decorative layer.

Inventive Principle:

Principle #10Preliminary action

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 method enables cost-effective production of interconnected components suitable for series or mass production, ensuring reliable positioning of the decorative layer and rapid processing, thereby enhancing process reliability and reducing production costs.

Implementation Method 1

The interconnected components (10, 12) are produced as a multi-component structural part in a plastic injection molding process

Methodology Applied

Scientific EffectInjection molding:

Implementation Method 2

After hardening, interconnected components of an interior trim part result

Methodology Applied

Scientific EffectCooling and hardening: Cooling

Data Source

PatentUS20250033259A1Method for producing interconnected components of an interior-trim part, and interconnected components of an interior-trim part

Publication Date: 2025.01.30 VOLKSWAGEN AG

AI summary

A method for producing interconnected components of an interior trim part. At least one decorative layer is translucent at least in areas. At least one body is light-permeable at least in sections. The body that is light-permeable at least in sections and an opaque structural part are produced as a multi-component structural part in a plastic injection molding process. The opaque structural part is produced in a first cavity of a mold in the plastic injection molding process and transferred into at least one part of a second cavity of a mold. A carrier film that carries the translucent decorative layer is positioned in another part of the second cavity. The body is produced, which is light-permeable at least in sections, in a space by a plastic injection molding process. A composite part that has the decorative layer, the body, and the opaque structural is removed from the mold.