Ligneous Trim Coating via Precut Positioning

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Solution Overview

Problem

Existing methods for coating a surface with ligneous material to form trim elements, such as those for motor vehicles, face challenges in correctly positioning the material due to its three-dimensional shape, leading to defects like incorrect orientation and cracks, resulting in excess production costs and unsatisfactory aesthetic appearance.

Innovation Solution

The method involves precutting the ligneous material to create areas that can be securely fastened to a forming tool, ensuring correct positioning and adherence to the supporting element, allowing the material to adopt complex shapes while maintaining flexibility and preventing defects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If the layer of ligneous material is positioned on a mold part to adopt a three-dimensional shape, then the coating can cover complex surfaces, but the positioning becomes difficult and incorrect positioning occurs

Engineering Contradiction:

Improvethree-dimensional shape of coating layerVSAvoidpositioning accuracy of coating layer

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by pre-cutting the ligneous material layer before positioning it on the mold. The pre-cut areas create openings that allow fastening means to penetrate and secure the layer in the correct position beforehand, ensuring accurate positioning is achieved before the actual coating process begins.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent introduces fastening means as an intermediary element between the ligneous material layer and the mold. These fastening means (such as hooks or clips) act as mediators that connect the layer to the mold structure, enabling secure and accurate positioning without requiring direct adhesion between the layer and mold surfaces.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Stability of the object's composition

If the layer of ligneous material is fastened to the mold, then positioning is secured, but cracks may occur near the fastening points

Engineering Contradiction:

Improvepositioning stability of coating layerVSAvoidcracks in coating layer

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The patent segments the ligneous material layer by creating multiple pre-cut areas distributed across the layer's surface. This segmentation allows fastening means to be positioned at multiple locations, distributing the mechanical stress and preventing crack propagation that would occur if a single large fastening area was used.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies local quality by creating pre-cut areas with specific geometric characteristics (openings) that are locally optimized for fastening. These pre-cut areas provide controlled access points for fastening means while maintaining the integrity of the surrounding material, preventing stress concentration and crack formation at the fastening locations.

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If incorrect positioning of the layer occurs, then aesthetic defects are produced, but the production costs increase due to rework

Engineering Contradiction:

Improveorientation accuracy of coating layerVSAvoidproduction efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent employs preliminary action by pre-cutting the ligneous material layer before positioning it on the mold. The pre-cut areas create openings that allow fastening means to penetrate and secure the layer in the correct position beforehand, ensuring accurate positioning is achieved before the actual coating process begins.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Inventive Principle:

Principle #24Intermediary (Mediator)

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 ensures accurate and cost-effective positioning of the ligneous material, improving adhesion and aesthetic quality by preventing defects and ensuring a homogeneous, high-quality trim element.

Implementation Method 1

the layer of ligneous material is flexible and suitable for adopting the three-dimensional shape of the surface of the supporting element to be coated

Methodology Applied

Scientific EffectFlexibility: Elasticity

Implementation Method 2

the layer of ligneous material is fastened to the surface of the supporting element by compression or thermocompression

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 3

the layer of ligneous material is fastened to the surface of the supporting element by compression or thermocompression

Methodology Applied

Scientific EffectThermocompression:

Data Source

PatentUS9757931B2Method for coating an element with a coating layer

Publication Date: 2017.09.12 FAURECIA INTERIEUR IND

AI summary

A method for coating a surface of a supporting element with a layer of ligneous material in order to form a motor vehicle trim element. The method includes the following consecutive steps: precutting the coating layer so as to form at least one precut area in the layer of ligneous material; positioning the layer of ligneous material relative to the supporting element by means of the precut area; and attaching the layer of ligneous material to the surface of the supporting element.