Multicolored Interior Trim Components with Fine Grain Structures
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Solution Overview
Problem
Existing processes for preparing interior trim components of motor vehicles with defined surface profiles cannot efficiently produce multicolored components with fine grain structures and narrow radii, as they require costly joining processes and result in added weight and material inefficiencies, while also failing to effectively replicate intricate grain patterns demanded by premium vehicle manufacturers.
Innovation Solution
A process involving two-dimensionally bonding decorative layers with defined surface and color profiles to a component support, where the visible sides are heated to a graining temperature and the back sides to a molding temperature, allowing for precise graining and subsequent trimming and positioning of the layers under reduced pressure before backing onto the support, enabling the creation of integral, multicolored components with improved haptic properties and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If existing processes are used to prepare interior trim components with defined surface profiles, then components can be produced with basic surface features, but they cannot efficiently produce multicolored components with fine grain structures and narrow radii, resulting in added weight and material inefficiencies
Solution Approach 1:
The decorative surface is divided into multiple separate decorative layers (first decorative layer and second decorative layer) that can be independently formed with different colors and grain structures. Each layer is molded separately with precise grain patterns, then bonded to the component support, eliminating material waste associated with post-production joining processes.
Solution Approach 2:
The decorative layers are pre-formed with defined grain structures and color profiles during the molding process itself, before being bonded to the component support. This preliminary formation of precise grain structures and color patterns in the molding stage eliminates the need for subsequent joining operations and reduces material waste.
2Adaptability or versatility
If existing processes are used to prepare interior trim components, then basic components can be produced, but costly joining processes are required for multicolored components, adding to manufacturing cost and complexity
Solution Approach 1:
Multiple decorative layers with different colors and grain structures are integrated into a single bonded assembly with the component support. The first and second decorative layers are simultaneously bonded to the support in one operation, creating a multicolored component with complex surface features without requiring separate joining processes for each layer.
Solution Approach 2:
The component consists of a composite structure combining a component support with multiple decorative layers of different materials, colors, and grain structures. This composite construction allows versatile multicolored designs while simplifying the manufacturing process, as all layers are bonded together in a single operation rather than requiring multiple sequential joining steps.
3Shape
If existing processes are used to prepare interior trim components with defined surface profiles, then basic surface features can be achieved, but fine grain formation and narrow radii are not effectively replicated
Solution Approach 1:
Each decorative layer is formulated with specific local properties including distinct color profiles and grain structures tailored to particular regions of the component. The first decorative layer has one color and grain pattern while the second has different color and grain characteristics, allowing precise replication of diverse surface features including fine grains and narrow radii in different locations.
Solution Approach 2:
The molding process parameters are optimized for each decorative layer to achieve precise grain formation and narrow radii. By controlling temperature, pressure, and molding time parameters during the formation of each layer, the process replicates intricate grain patterns and fine surface features with high accuracy before bonding the layers to the support.
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 process allows for the production of multicolored, integral interior trim components with enhanced grain formation and narrow radii, reducing material waste and cost, while achieving better haptic properties and precise grain replication, effectively competing with PUR skin technology.
Implementation Method 1
the respective visible sides 3a, 3b of the respective decorative layers 2a, 2b are heated to the respectively desired graining temperatures in the range of from 180 to 220° C.
Implementation Method 2
the back sides of the decorative layers 2a, 2b are heated to the respective molding temperatures in the range of from 130 to 170° C.
Implementation Method 3
a process for the preparation of interior trim components of motor vehicles from a component support 1 and at least two decorative layers 2a, 2b two-dimensionally bonded thereto
Data Source
AI summary
A process for preparing interior trim components of a motor vehicle from a support having at least two decorative layers, wherein in a first step the decorative layers are heated to a specific temperature range and are e ared b molding, in a second step the decorative layers are trimmed, and in a third step the decorative layers are positioned in mutual orientation and fixed by reduced pressure, and in a fourth step the decorative layers are transferred to a backing mold and molded with component support (1) on the surface opposite.