Multi-Film Junction Structure for Vehicle Center Fascia
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Solution Overview
Problem
Conventional multi-film junction structures in vehicle center fascias face issues with resin contamination and instability at the boundary between films of different colors, leading to defective module housings.
Innovation Solution
A multi-film junction structure is designed with an upper mold having a protrusion and a first film with an extension that surrounds a coupling portion of a second film, preventing resin from moving to the boundary by forming an injection molding space between the molds, ensuring a stable junction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If films of different colors are attached to an injection molded panel before injection molding, then interior decoration with multiple colors is achieved, but resin concentrates on the boundary between films causing contamination and defects
Solution Approach 1:
The invention divides the film structure into multiple segments: the first film is divided into a first extension and a second extension, while the second film is divided into a first coupling portion and a second coupling portion. These segments are arranged in sequence to form a multi-color film structure that prevents resin concentration at boundaries.
Solution Approach 2:
The protrusion formed by the first extension of the first film acts as an intermediary structure between the first film and the second film. This protrusion prevents resin from concentrating at the boundary between different colored films during injection molding, thereby eliminating contamination while maintaining the multi-color decorative effect.
2Stability of the object's composition
If films are attached to the mold surface before injection molding, then the module housing is formed with integrated films, but the junction between film ends is unstable
Solution Approach 1:
The first extension of the first film is nested within the space between the first coupling portion and the second coupling portion of the second film. This nested arrangement creates a stable junction structure where the films are interlocked, preventing displacement or separation at the boundary.
Solution Approach 2:
The invention applies different structural configurations to different parts of the film assembly: the first extension protrudes to prevent resin concentration, while the second extension and coupling portions are arranged to ensure stable junction. This localized structural differentiation achieves both contamination prevention and junction stability.
Data Source
AI summary
A multi-film junction structure includes an upper mold having a downwardly extending protrusion formed at a lower surface thereof to allow a recess to be defined in resin that is injected therearound. A first film is attached to a part of the lower surface of the upper mold and a side surface and lower surface of the protrusion, the first film having an extension extended from the lower surface of the protrusion by a predetermined length. A second film is attached to a remaining lower surface of the upper mold and an opposite side surface of the protrusion, the second film having a coupling portion located inside the extension of the first film, wherein the extension is bent upwardly. Additionally, a lower mold is provided having a recess facing the protrusion of the upper mold while being spaced apart from the protrusion, the lower mold defining an injection molding space together with the upper mold for allowing resin to be introduced and injection molded in the space.