Modular Mould Inserts for Flexible Plastic Skin Variants

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Solution Overview

Problem

Existing methods for manufacturing flexible moulded skins in the automotive industry are limited in producing variants with different shapes and visible surface features, as they require separate moulds for each design, and existing solutions struggle with creating skins with complex geometries and visible recesses without burs or the need for additional covers.

Innovation Solution

A modular mould arrangement using flexible mould inserts that can be applied to a base mould to alter its surface, allowing for the production of various skin shapes and textures without the need for additional mould slides, and enabling easy demoulding by stripping off the inserts after curing, which prevents plastic compound creep and bur formation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If separate moulds are used for each design variant, then manufacturing precision of specific shapes is improved, but device complexity and production time increase

Engineering Contradiction:

Improveshape accuracyVSAvoidmould variety

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The mould system is segmented into a base mould and interchangeable mould inserts. Each insert represents a separate design variant that can be independently manufactured and swapped. This allows the complex mould system to be broken down into manageable segments that can be produced with high precision individually, while the overall system complexity is reduced through modularity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A single base mould is designed to accommodate multiple different mould inserts, making it a universal platform that can produce various design variants. The base mould provides common functionality for all variants, while the interchangeable inserts provide variant-specific shaping capabilities. This multi-functionality eliminates the need for separate complete moulds for each design.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If mould inserts are used to alter mould surface, then adaptability of single mould is improved, but ease of manufacture deteriorates due to additional assembly steps

Engineering Contradiction:

Improvedesign variant capabilityVSAvoidmould assembly complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The mould system transitions from a static, fixed configuration to a dynamic, reconfigurable system. Mould inserts can be added, removed, or swapped on the base mould depending on the desired design variant. This dynamic capability allows a single mould to adapt to different production requirements without permanent modifications, enhancing versatility while keeping the base mould structure simple and easy to manufacture.

Inventive Principle:

Principle #15Dynamics

3Manufacturing precision

If rigid mould structures are used, then manufacturing precision is improved, but ease of operation deteriorates due to difficulty in demoulding complex geometries

Engineering Contradiction:

Improvesurface accuracyVSAvoiddemoulding difficulty

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The mould inserts are made from flexible materials such as silicone rubber or elastomers. These flexible materials allow the inserts to be easily removed from complex moulded skin geometries by deformation and stripping actions. The flexibility enables the mould inserts to conform to and release from undercuts and complex shapes that would be impossible to demould from rigid structures, while still maintaining sufficient rigidity during the moulding process to ensure surface accuracy.

Inventive Principle:

Principle #30Flexible shells and thin films

4Productivity

If mould inserts abut against walls angularly, then productivity is improved by preventing plastic creep, but manufacturing precision may worsen due to potential gaps

Engineering Contradiction:

Improveproduction efficiencyVSAvoidedge finish quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The flexible mould inserts are designed as consumable or easily replaceable components. While they may show wear or develop gaps over time, they can be quickly replaced rather than requiring complex adjustments or repairs. This approach maintains high productivity by minimizing downtime, and the flexible material compensates for minor dimensional variations better than rigid alternatives would.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Data Source

PatentUS8142705B2Method for producing a moulded skin and mould arrangement therefore

Publication Date: 2012.03.27 RECTICEL AUTOMOBILSYSTEME GMBH

AI summary

A method for manufacturing molded flexible plastic skins (9, 24, 27, 34) differing in their shape from each other, each skin being molded against a mold surface (2) of a mold (1), comprises the steps: —providing a mold surface (2) matching the shape of the skin to be molded by using a first mold surface provided by the mold itself or by altering the first mold surface by placing one or more mold inserts covering only a part of the first mold surface onto said mold surface and thereby providing an alternative second mold surface, —applying a plastic compound to be brought to shape by the mold surface (2) provided, —bringing to shape the plastic compound applied to the mold surface (2), and —demolding the molded skin (9) from the effective mold surface (2).