Mold Movable Wall for Armrest Covering Shape Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for manufacturing interior trim panel parts, such as armrests, result in uneven comfort and incorrect positioning of style seams due to stretching during the mold closing process, leading to irregular profiles and aesthetics issues.
Innovation Solution
A method involving a mold with a movable concave wall that applies pressure to the covering during mold closure, ensuring it maintains the predetermined shape, and releasing pressure before plastic injection, combined with a stiffening insert to enhance rigidity and correct seam positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the mold is closed to stamp the coating and curve the part, then the convex shape is formed, but the coating stretches in two opposite directions causing thinner coating at the convex shape and irregular profile
Solution Approach 1:
The concave wall is positioned in advance (in the open mold position) to pre-support the coating at the convex shape location before the mold closing action occurs. This preliminary positioning prevents the coating from stretching during the stamping process, maintaining uniform thickness while still allowing the convex shape to be formed.
Solution Approach 2:
The concave wall acts as an intermediary element between the male and female mold parts. It provides localized support to the coating during the mold closing process, mediating the force application to prevent excessive stretching at the convex shape while still allowing the overall shaping to occur.
2Shape
If the mold is closed to stamp the coating, then the convex shape is formed, but style seams are incorrectly positioned due to stretching
Solution Approach 1:
The concave wall is positioned in advance to pre-support the coating at the convex shape location before the mold closing action occurs. This preliminary positioning prevents the coating from stretching during the stamping process, maintaining uniform thickness while still allowing the convex shape to be formed.
Solution Approach 2:
The concave wall acts as an intermediary element between the male and female mold parts. It provides localized support to the coating during the mold closing process, mediating the force application to prevent excessive stretching at the convex shape while still allowing the overall shaping to occur.
3Device complexity
If the concave wall is kept fixed during mold closing, then the mold structure is simple, but the coating stretches and deforms at the convex shape
Solution Approach 1:
The concave wall is made movable rather than fixed, allowing it to dynamically adjust its position during the mold closing process. It moves from the open mold position (projecting toward the male part) to the closed mold position (retracted), enabling it to provide support when needed while clearing the path for injection when required.
Solution Approach 2:
The mold structure is segmented by separating the concave wall from the main mold body, allowing independent movement of the concave wall. This segmentation enables the concave wall to perform its specific function of supporting the coating without constraining the overall mold closing and injection actions.
4Manufacturing precision
If the concave wall remains in extreme projection position during mold closing, then the coating is well supported, but it blocks the injection of plastic material
Solution Approach 1:
The concave wall is made movable rather than fixed, allowing it to dynamically adjust its position during the mold closing process. It moves from the open mold position (projecting toward the male part) to the closed mold position (retracted), enabling it to provide support when needed while clearing the path for injection when required.
Solution Approach 2:
The concave wall performs periodic movement through different positions: projecting during mold opening to support the coating, retracting during mold closing to allow injection, and potentially projecting again during ejection. This periodic action sequence ensures both coating support and successful material injection.
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 a regular profile and improved comfort by preventing deformation and correctly positioning the covering, resulting in a more aesthetically pleasing and functional interior trim panel.
Implementation Method 1
the displacement of the concave wall (27), from the position of extreme projection to the position of slight projection, is carried out by means of the prominent shape (19) of the male part (18) which pushes back this wall (27) when closing the mould
Data Source
Figure 1~3
Figure 4~5
Figure 6~7
AI summary
The method involves fixing a comfort covering by its end walls between female and male parts of a mold in a plane configuration. The covering is pressed by a prominent shape of the male part, and a part of the covering is bent to form a convex central wall (6). A plastic material is injected below the comfort covering. The pressure is applied on the covering part located with respect to the prominent shape of the male part for fixing the covering part against the prominent shape during closing of the mold. An independent claim is also included for a plastic material injection mold for fabricating a piece of an internal covering panel of a motor vehicle.