Multi-Stage Projectile Molding for Vehicle Interior Inserts
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Solution Overview
Problem
Current methods for producing vehicle interior components from resin materials are limited in efficiency and complexity, particularly in creating multi-section components with precise dimensions and structural integrity using traditional extrusion techniques.
Innovation Solution
A method involving a multi-stage projectile element and water pressure to push the projectile through a mold containing resin material, allowing for the formation of complex structures with metal inserts and varying diameters, enhancing the structural integrity and precision of the components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional extrusion techniques are used to produce vehicle interior components from resin materials, then the production process is simpler, but the manufacturing precision and structural integrity of multi-section components are limited
Solution Approach 1:
The production method is divided into distinct stages corresponding to different sections of the mold cavity. The projectile element travels through multiple cavity sections, with each section forming a different portion of the final multi-section component. This staged approach enables precise dimensional control for each section while maintaining overall structural integrity.
Solution Approach 2:
Metal inserts are pre-placed into the mold cavity before the resin material is injected. The inserts are positioned in advance at their final locations, ensuring precise positioning and reliable connections between metal and plastic parts without requiring complex post-processing operations.
2Productivity
If high-pressure water flow equipment is used to push the projectile element through the mold, then the productivity is improved, but the operational costs increase
Solution Approach 1:
The patent utilizes water as a propellant medium to push the projectile element through the mold cavity. The water flow is contained within the cavity and acts on the projectile element to drive it forward, eliminating the need for external high-pressure water flow equipment and reducing operational costs while maintaining high productivity.
Solution Approach 2:
The resin material itself serves as the medium to transmit the pushing force to the projectile element. As the resin is injected into the cavity, it automatically pushes the projectile forward without requiring separate propulsion systems, thereby reducing equipment complexity and operational expenses.
3Adaptability or versatility
If a single-stage projectile element is used, then the device complexity is reduced, but the ability to produce multi-section components with varying diameters is limited
Solution Approach 1:
The projectile element is divided into multiple stages, with each stage corresponding to a different cavity section. Each stage of the projectile has dimensions matched to the specific cavity section it traverses, enabling the production of multi-section components with varying diameters while maintaining adaptability across different product configurations.
Solution Approach 2:
Different stages of the projectile element have different dimensional characteristics tailored to specific cavity sections. The projectile's local geometry is optimized for each section it passes through, enabling precise formation of components with varying diameters and complex cross-sectional profiles.
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 the efficient production of multi-section vehicle interior components with improved structural integrity and precision, reducing the need for high-pressure water flow equipment and lowering operational costs while ensuring reliable connections between metal and plastic parts.
Implementation Method 1
providing water into the cavity to push the projectile element through the insert into resin in the cavity
Data Source
AI summary
A method of producing a structure for a component for a vehicle interior may comprise providing a mold with an insert in a cavity, providing resin into the cavity, providing water into the cavity to push a projectile element through the insert into resin in the cavity, pushing the projectile element through the insert and resin across the cavity. The structure may comprise the insert and molded resin. The insert may comprise a metal insert (pipe, tube, etc.). The projectile element may comprise a multi-stage projectile element with a base stage separable from a front stage during forming of the structure. The structure may comprise a second section and a first section with a larger inner diameter than the second section. The insert may be provided in the first section. The base stage may remain in the formed resin structure between the first and second section.