Multi-Layer Plastic Components from One Tool with Variable Foam Contours
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Solution Overview
Problem
Existing methods for producing multi-layer vehicle interior components require separate tools for different variants, leading to high production costs and limitations in creating distinct contours and flexible surfaces.
Innovation Solution
A method involving a foaming tool with a carrier part and a spacer layer of varying contour stability, using different foam materials and a silicone spacer layer to produce variants with defined contours and flexible areas, allowing the same tool to be used for both.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate tools are used for different variants, then manufacturing precision and variant-specific design requirements are met, but device complexity and production costs increase
Solution Approach 1:
The patent applies universality by designing a single foaming tool that can produce multiple variants of trim parts with different decorative layers and foam thicknesses. The tool includes a removable spacer layer that can be configured differently to accommodate various decorative layers (leather, plastic skin, spacer fabric) and achieve different foam layer thicknesses, eliminating the need for separate dedicated tools for each variant while maintaining manufacturing precision
Solution Approach 2:
The patent segments the tool structure into modular components: a carrier part, a removable spacer layer, and a decorative layer. The spacer layer can be selectively removed or retained depending on the desired variant, allowing the same tool to produce different configurations. This segmentation enables flexible adaptation to various design requirements without requiring completely different tooling for each variant
2Productivity
If a thin decorative layer is used, then productivity and cost are improved, but manufacturing precision and design quality for special variants are reduced
Solution Approach 1:
The patent applies preliminary action by using a spacer layer that is placed in the tool before foaming. This spacer layer pre-defines the thickness of the foam layer and the positioning of the decorative layer. By preparing this spacing structure in advance, the process ensures precise control over decorative layer thickness and positioning without requiring complex real-time adjustments, thereby maintaining both productivity and manufacturing precision
3Shape
If foam layer thickness is reduced for special variants, then design requirements are met, but device complexity increases due to need for separate tools
Solution Approach 1:
The patent applies dynamics by making the spacer layer removable and reconfigurable. The spacer layer can be dynamically adjusted or removed based on the desired foam thickness for different variants. This dynamic capability allows the same tool to produce both thick-foam and thin-foam variants by simply changing the spacer layer configuration, eliminating the need for separate dedicated tools for different foam thicknesses
4Ease of manufacture
If a spacer fabric layer is inserted directly into the foaming tool, then ease of manufacture is improved, but manufacturing precision is reduced due to foam penetration and hardening
Solution Approach 1:
The patent introduces a protective layer as an intermediary between the spacer fabric and the expanding foam. This protective layer prevents the foam from directly contacting and penetrating the spacer fabric, which would otherwise cause hardening and distortion of the fabric structure. The protective layer acts as a mediator that allows the spacer fabric to maintain its intended contour-defining function while being exposed to the foaming process, thus preserving both ease of manufacture and manufacturing precision
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
Enables cost-effective production of multi-layer components with distinct contours and flexible surfaces using the same tool, maintaining a soft feel while achieving high contour accuracy and gap quality.
Implementation Method 1
The space between is then filled with foam
Implementation Method 2
WO 86/05439 a method and a device are known for producing components from foamed plastic material
Implementation Method 3
a plastic skin 2, which is no longer visible from the outside of the finished component. Its production requires a separate tool
Data Source
Figure 1a~2b
AI summary
The invention relates to a method for selectively producing a first or a second variant of a multi-layer plastic component, wherein both variants have a carrier part (1), a decorative layer (2, 4, 5), and a foam layer (3) between the carrier part and the decorative layer, wherein the thickness of the decorative layer of the first variant is less than the thickness of the decorative layer of the second variant and the thickness of the foam layer of the first variant is greater than the thickness of the foam layer of the second variant, the foam layer is produced in a foaming tool, which has a first tool half, into which the carrier part is inserted before the foaming process. In order to produce the first variant, the decorative layer of the first variant is inserted into the second tool half of the foaming tool before the foaming process. In order to produce the second variant, a spacing layer (6) is inserted into the second tool half of the foaming tool before the foaming process, wherein, after the foaming process, the spacing layer is removed from the foam layer and the decorative layer of the second variant is applied to the foam layer. The foam layer (3) comprises at least one first section (3a) having a higher contour stability than a second section (3b).