Soft Upper Trim for Vehicle Door Switch Assembly
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Solution Overview
Problem
Conventional vehicle door switch devices embedded in hard substrates damage the transparent skin and require post-processing, which is costly and affects the vehicle's appearance, making it difficult for drivers to check lock/unlock symbols from outside.
Innovation Solution
A method for manufacturing a soft upper trim with a light guide plate and foam molding, where a recessed groove and protrusion groove are formed in the upper substrate, allowing a light guide plate with symbols to be assembled, and a transparent skin is applied using a vacuum membrane press, maintaining the transparency and hidden switch module's functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a switch device is embedded in a hard substrate with transparent skin, then the switch functionality is achieved, but the transparent skin is damaged and requires costly post-processing
Solution Approach 1:
The door trim is divided into multiple substrates (upper substrate, center substrate, lower substrate) that are connected through screws. The switch device is embedded only in the hard lower substrate, while the transparent skin is laminated on the upper substrate and foam assembly, avoiding direct contact with the switch device and preventing damage to the transparent skin.
Solution Approach 2:
The switch device is extracted from the upper substrate assembly and embedded only in the hard lower substrate. This separation allows the transparent skin to be applied independently on the upper substrate without being damaged by switch installation operations.
2Ease of operation
If holes are formed in transparent skin and foam for switch insertion, then the switch can be mounted, but the transparent skin continuity is broken and appearance is degraded
Solution Approach 1:
The door trim is segmented into multiple substrates where the switch device is mounted on the lower substrate, and the transparent skin is applied on the upper substrate. This segmentation allows the transparent skin to maintain its continuity and luxurious appearance while the switch functionality is preserved on the lower substrate.
3Ease of operation
If the switch device is embedded in the upper substrate, then the switch is accessible, but the transparent skin cannot be applied smoothly over the switch area
Solution Approach 1:
The door trim is divided into an upper substrate for the transparent skin and a lower substrate for the switch device. This segmentation resolves the conflict by allowing the transparent skin to be applied smoothly on the upper substrate while the switch device remains accessible on the lower substrate through screw connections.
4Stability of the object's composition
If a hard substrate is used for switch embedding, then the switch structure is stable, but the luxurious feeling and transparency are reduced
Solution Approach 1:
The door trim combines hard lower substrate for switch stability with upper substrate covered by transparent skin for luxurious feeling. The segmentation allows each substrate to fulfill its specific function: the lower substrate provides structural stability for the switch, while the upper substrate with transparent skin provides the desired luxurious appearance and transparency.
Solution Approach 2:
The door trim uses a composite structure combining hard substrate (for switch stability) with transparent skin and foam (for luxurious feeling). This composite approach allows the system to simultaneously achieve structural stability and aesthetic quality by combining materials with complementary properties.
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 ensures the continuity and smoothness of the transparent skin, allows drivers to check symbols from outside, simplifies the manufacturing process, and enhances the external appearance by preventing foam adhesion and requiring no separate hole boring, while using compatible materials for improved transmittance and adhesion.
Implementation Method 1
attaching a transparent skin on the upper surfaces of the protrusion groove, the light guide plate, and the foam in a vacuum membrane press
Data Source
AI summary
Provided is a soft upper trim of a vehicle door, in which an upper substrate, foam, and a transparent skin are laminated, and particularly, to a soft upper trim for switch assembly of a vehicle door, in which a switch, which is configured to preserve continuity of a transparent skin and display lock and unlock symbols on the transparent skin, is easily assembled to an upper substrate, and a method of manufacturing the same.