Thermo-structural Composite Automotive Components
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Solution Overview
Problem
Traditional manufacturing processes for automotive interior components result in heavier parts with lower impact resistance, acoustic, and thermal performance, and higher production costs, due to the use of materials like polyurethane and polypropylene foams and injected plastics.
Innovation Solution
The integration of geometrically structured glass fibers and new MDI-derived chemical formulations in the thermo-structural composite processing, allowing for punctual reinforcements and high design flexibility, while maintaining or improving resistance, acoustic, and thermal characteristics, and enabling noble finishes and recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional polyurethane and polypropylene foams are used for manufacturing automotive interior components, then the parts have good design flexibility and physical strength, but they present plastic blades in conditions of deformation and rupture when subjected to strong impacts
Solution Approach 1:
The patent applies composite materials by combining thermoplastic polymers with natural fibers (wood or jute) and glass fibers to create a hybrid composite structure. This composite approach resolves the technical contradiction by providing both the design flexibility of polymers and the impact resistance of natural and glass fibers, eliminating the plastic blade effect while maintaining structural integrity under strong impacts
2Strength
If semi-flexible foams are used for manufacturing car interiors, then the parts have good impact-absorbing characteristics, but they have greater weight
Solution Approach 1:
The patent applies local quality by strategically placing natural fibers and glass fibers in specific regions of the composite where impact absorption is most needed, rather than uniformly distributing all materials throughout the structure. This allows the part to have excellent impact-absorbing characteristics in critical areas while minimizing overall weight through optimized material placement
Solution Approach 2:
The composite material system combines lightweight thermoplastic polymers with natural and glass fibers to achieve high impact absorption per unit weight, resolving the contradiction between weight and impact-absorbing characteristics
3Stability of the object's composition
If thermo-molded materials from molding several layers of fibers with resins are used, then the parts have structural integrity, but they result in heavier parts with lower impact resistance, acoustic and thermal performance
Solution Approach 1:
The patent applies parameter changes by utilizing the melting and re-solidification properties of thermoplastic polymers during molding, combined with the structural characteristics of natural and glass fibers. This allows the creation of a composite structure with optimal structural integrity and enhanced impact resistance, acoustic and thermal performance while controlling weight through precise parameter control during the molding process
4Strength
If traditional manufacturing processes are used for automotive interior components, then the parts have adequate structural properties, but they have higher production costs
Solution Approach 1:
The patent applies parameter changes by optimizing the molding process parameters for thermoplastic composite materials, including temperature, pressure, and cooling rates. These optimized parameters enable efficient production with reduced cycle times and material waste, thereby lowering production costs while maintaining adequate structural properties
Solution Approach 2:
The use of composite materials allows for the consolidation of multiple components into a single molded part, reducing assembly steps and production complexity. This integrated manufacturing approach lowers production costs while maintaining or enhancing structural 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 approach results in lighter, more impact-resistant, acoustically and thermally superior components with reduced production costs and the ability to incorporate high-level exterior finishes without compromising performance.
Implementation Method 1
When the foam is impacted, it can absorb and dissipate energy in two ways: i) by pneumatic damping (expulsion and re-entry of air trapped in cellular structures during deflection) and ii) mechanical damping (deflection of the cellular structure)
Implementation Method 2
The present improvement comes from the joining of various synthetic materials (F), which undergo a phase of couplings (union of materials), to subsequently be heated and pressed in specific molds (M) at temperatures and pressure suitable for the fusion of said elements
Implementation Method 3
When the foam is impacted, it can absorb and dissipate energy in two ways: i) by pneumatic damping (expulsion and re-entry of air trapped in cellular structures during deflection) and ii) mechanical damping (deflection of the cellular structure), with the face material also acting as a charge distributing mechanism to increase deceleration during the impact of a body
Implementation Method 4
Flexible and semi-flexible foams use water as a blowing agent and have mostly open cell structure... When the foam is impacted, it can absorb and dissipate energy in two ways: i) by pneumatic damping (expulsion and re-entry of air trapped in cellular structures during deflection)
Implementation Method 5
The present improvement comes from the joining of various synthetic materials (F), which undergo a phase of couplings (union of materials), to subsequently be heated and pressed in specific molds (M) at temperatures and pressure suitable for the fusion of said elements
Implementation Method 6
The manufacture of semi-flexible foams is more complex and involves other distinct additional steps... providing better interior comfort inside the vehicles
Data Source
AI summary
“IMPROVEMENT INTRODUCED IN THE PROCESS OF OBTAINING THERMO-STRUCTURAL COMPOSITES”, resulting from the union of various synthetic materials (F), which go through a phase of couplings (union of materials), to be subsequently heated and pressed into molds (M) of specific size for each part to be molded, at temperatures and pressure suitable for the fusion of these elements, featured by the fact that the thereto-structural composite (1) is obtained from the formation of the substrate (S), with the synthetic fiber molding (F), foams, etc., preferably Non-Woven (NW-TNT)+PE Film+Fiberglass+Semi-Rigid PU Foam embedded in a chemical formulation (FO) of Diphenylmethane Diisocyanate (MDI) in a ratio of 30% to 80% and Methylene Chloride (CM) in the ratio of 20% to 70%; and for processing the product, a catalyst prepared from Dabco Cristal in the ratio of 1% to 30% is used; by adding 70% to 99% water, said substrate (S) may, during the hot-molding phase, receive the addition of finishes (5) and, after the molding phase, receive the addition of minor and complementary structural elements (6).