Non-Woven Trim Panel with Perforated Film
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Solution Overview
Problem
Current methods for forming vehicle interior trim panels fail to balance aesthetic appeal with structural integrity and durability while also aiming to reduce vehicle weight, as they often require multiple steps and materials that increase complexity and mass.
Innovation Solution
A method involving a non-woven material heated with a decorative film having specific perforation characteristics, which is then processed in a forming tool with a thermoplastic resin injection to create a lightweight, structurally sound trim panel with a uniform surface finish, eliminating the need for secondary tooling and adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional methods are used to form vehicle interior trim panels with multiple materials and steps, then structural integrity and durability are maintained, but vehicle weight increases and manufacturing complexity increases
Solution Approach 1:
The patent combines multiple materials (non-woven substrate, decorative film, thermoplastic resin) and manufacturing operations (heating, laminating, forming, injecting) into a single integrated forming tool and process. The forming tool includes both heating elements for the non-woven material and injection molding capabilities for the thermoplastic resin, allowing simultaneous lamination and structural formation in one step, thereby reducing vehicle weight while maintaining manufacturing feasibility.
Solution Approach 2:
The patent uses a composite structure consisting of a non-woven material layer, a decorative film layer with specific perforation characteristics, and a thermoplastic resin layer. This multi-layer composite material provides both aesthetic appearance (through the decorative film) and structural integrity (through the thermoplastic resin), while the lightweight non-woven substrate reduces overall weight compared to traditional solid plastic panels.
2Weight of moving object
If a decorative film with high porosity is used to reduce mass, then vehicle weight is reduced, but structural integrity may be compromised
Solution Approach 1:
The decorative film has spatially varying properties with perforations strategically distributed across the film. The perforations have specific characteristics (area of 1.0×10^-5 to 4.0×10^-5 square inches, density of 200 to 350 per square inch, porosity of 0.25% to 0.90%) that allow weight reduction in non-critical areas while maintaining structural integrity in load-bearing regions. The thermoplastic resin is injected to provide structural support where needed.
Solution Approach 2:
The composite structure combines the lightweight but porous decorative film with the structurally sound thermoplastic resin. The resin is injected through the perforated film to bond the layers together and provide the necessary structural strength, while the film itself contributes to aesthetic appearance and weight reduction. This composite approach allows simultaneous optimization of both weight and strength.
3Manufacturing precision
If multiple processing steps are used to achieve aesthetic appearance and structural integrity, then product quality is improved, but manufacturing time and complexity increase
Solution Approach 1:
The patent merges the lamination process and the structural forming process into a single integrated operation using a forming tool that combines heating elements with injection molding capabilities. The non-woven material is heated and laminated to the decorative film while simultaneously the thermoplastic resin is injected to form the structural backbone, achieving both aesthetic surface finish and structural integrity in one processing cycle rather than separate steps.
Solution Approach 2:
The non-woven material is pre-heated to a predetermined temperature before being placed in the forming tool, and the decorative film is pre-positioned on the heated material. This preliminary preparation ensures that when the forming tool closes and injection occurs, the materials are already in the optimal state for bonding and forming, reducing the time required during the actual molding cycle and improving surface finish quality.
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
The method produces trim panels with improved appearance, defined grain, uniform gloss, and reduced mass, achieving structural integrity and durability while minimizing material usage and processing steps, thus addressing the need for lightweight and aesthetically pleasing interior components.
Implementation Method 1
heating the non-woven material to a predetermined temperature
Implementation Method 2
heating the non-woven material to a predetermined temperature
Implementation Method 3
applying a decorative film to a first surface of the heated non-woven material to create a bilaminate
Implementation Method 4
heating the cavity
Implementation Method 5
injecting a thermoplastic resin into the forming tool such that the thermoplastic resin is adhered to at least a portion of a second surface of the non-woven material
Implementation Method 6
the thermoplastic resin is adhered to at least a portion of a second surface of the non-woven material
Data Source
AI summary
A method of forming a trim panel is provided. The method includes the steps of: heating a non-woven material to a predetermined temperature; applying a decorative film having perforations to a first surface of the heated material to create a bilaminate; placing the bilaminate layer into a cavity of a tool such that the decorative film is facing the cavity; heating the cavity; and injecting a thermoplastic resin into the tool such that the thermoplastic resin is adhered to a second surface of the material, the second surface being opposite to the first surface.