Perforated Fiber Composite Substrate Thermoforming
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Solution Overview
Problem
Existing methods for creating interior panels for motor vehicles using fiber reinforced composite substrates are impractical for nonporous or less porous constructions, as they do not facilitate effective thermoforming of a cover skin due to lack of porosity, unlike foam substrates.
Innovation Solution
A method involving heating a fiber reinforced composite blank, followed by compression molding with piercing pins to create a shaped, perforated substrate, allowing for subsequent thermoforming of a cover skin by vacuum removal of air through the substrate's holes, regardless of the substrate's porosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a foam substrate is used for interior panels, then the substrate is porous and facilitates effective thermoforming of cover skin, but the specific stiffness is reduced compared to fiber reinforced composite constructions
Solution Approach 1:
The invention introduces porosity to the fiber reinforced composite substrate by creating a foam core within the composite structure. This foam core provides the necessary porosity for vacuum thermoforming while the outer fiber reinforced composite layers maintain high specific stiffness, effectively resolving the contradiction between manufacturability and structural performance
Solution Approach 2:
The invention uses a composite construction combining foam core material with fiber reinforced composite skin layers. This composite structure integrates the porosity needed for thermoforming with the high strength-to-weight ratio of fiber reinforced composites, achieving both ease of manufacture and structural integrity
2Strength
If a nonporous fiber reinforced composite substrate is used, then high specific stiffness is achieved, but effective thermoforming of cover skin cannot be facilitated
Solution Approach 1:
The invention introduces a foam core within the fiber reinforced composite substrate to create porosity. This allows vacuum thermoforming to proceed effectively while the surrounding fiber reinforced composite structure maintains high specific stiffness, resolving the contradiction between these two requirements
3Reliability
If adhesive is applied to the substrate surface for thermoforming, then the cover skin can be joined to the substrate, but the process becomes complex and time-consuming
Solution Approach 1:
The invention extracts the adhesive application step from the thermoforming process by using vacuum pressure to directly bond the cover skin to the porous substrate. The vacuum process eliminates the need for separate adhesive application and curing steps, reducing process complexity while maintaining join strength
Solution Approach 2:
The invention replaces the chemical bonding mechanism of adhesives with a mechanical vacuum bonding system. The vacuum pressure creates a suction force that directly bonds the cover skin to the porous substrate, eliminating the need for adhesive chemicals and simplifying the manufacturing process
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 the practical covering of fiber reinforced composite substrates with a cover skin using thermoforming, overcoming the limitations of nonporous substrates and achieving a stiff, lightweight panel with improved manufacturing efficiency.
Implementation Method 1
a vacuum is pulled through the shaped, foam substrate which is porous to facilitate thermoforming the coverstock onto the surface
Implementation Method 2
heating a fiber reinforced composite blank to form a heated fiber reinforced composite blank
Implementation Method 3
The heated fiber reinforced composite blank is compression molded to shape and cool the heated fiber reinforced composite blank
Data Source
AI summary
Methods for making interior panels are provided. In one example, a method for making an interior panel comprises the steps of heating a fiber reinforced composite blank to form a heated fiber reinforced composite blank. The heated fiber reinforced composite blank is compression molded to shape and cool the heated fiber reinforced composite blank. The heated fiber reinforced composite blank is pierced with a plurality of pins during compression molding to form a shaped, perforated fiber reinforced composite substrate.