Trim Component Hidden Tear Pattern Manufacturing

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Solution Overview

Problem

Existing methods for manufacturing trim components require post-production cutting steps to create tear patterns, which can be visible and aesthetically unappealing, and do not efficiently integrate air bag deployment mechanisms.

Innovation Solution

A method involving spraying a foam layer with a predetermined pattern on a skin layer to create invisible tear patterns, eliminating the need for post-production cutting and allowing the skin layer to cover the gaps, thus hiding the tear pattern from view and enabling seamless integration with air bag modules.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If post-production cutting steps are used to create tear patterns, then the tear pattern can be precisely formed, but the tear pattern becomes visible and aesthetically unappealing

Engineering Contradiction:

Improvetear pattern formationVSAvoidaesthetic appearance

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The tear pattern is formed during the foam spraying process itself, before the skin layer is applied. The spray pattern is pre-programmed to create gaps in the foam layer that align with the desired tear pattern, eliminating the need for post-production cutting and hiding the tear pattern behind the skin layer.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The skin layer serves as an intermediary that covers the tear pattern in the foam layer. By positioning the skin layer over the foam layer with the pre-formed gaps, the tear pattern remains hidden from view while still functioning for air bag deployment.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If traditional stitching methods are used to create tear seams, then the structural integrity is maintained, but additional manufacturing steps and visible seams are required

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing steps

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The foam layer and skin layer are combined into a single integrated structure during the spraying process. The tear pattern is formed in the foam layer and covered by the skin layer, merging the structural function with the aesthetic function into one seamless component without requiring separate stitching operations.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The stitching operation is completely removed from the manufacturing process. Instead of stitching portions of the trim component to one another to create tear seams, the patent uses a sprayed foam layer with pre-formed gaps covered by a skin layer, eliminating the need for any stitching or post-production cutting steps.

Inventive Principle:

Principle #2Taking out (Extraction)

3Manufacturing precision

If mechanical cutting or laser cutting is used to create tear patterns after assembly, then the tear pattern can be precisely formed, but additional manufacturing time and equipment are required

Engineering Contradiction:

Improvetear pattern precisionVSAvoidmanufacturing efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The tear pattern is pre-formed during the foam spraying process before the skin layer is applied. The spray pattern is pre-programmed to create gaps in the foam layer that match the desired tear pattern, eliminating the need for subsequent cutting operations and improving manufacturing efficiency.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The mechanical cutting or laser cutting process is replaced with a sprayed foam process. Instead of using cutting equipment to create tear patterns after assembly, the patent uses a spray gun with a pre-programmed pattern to form gaps in the foam layer during the spraying process itself, eliminating the need for additional cutting equipment and steps.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 reduces manufacturing steps, ensures the tear pattern is hidden from the passenger compartment, and provides a structurally sound and aesthetically pleasing trim component that can effectively deploy air bags without visible seams.

Implementation Method 1

spraying a foam layer with a predetermined pattern on a skin layer to create invisible tear patterns

Methodology Applied

Scientific EffectSpray: Spray

Data Source

PatentUS9481338B2Method of manufacturing a trim component with hidden tear pattern and trim component with hidden tear pattern

Publication Date: 2016.11.01 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A method of manufacturing a trim component includes forming a skin layer of the trim component, and spraying a foam layer on the skin layer according to a first spray pattern that establishes a first gap in the foam layer arranged as a predetermined tear pattern. The skin layer extends across the first gap. A corresponding trim component has a skin layer with an outer surface and an inner surface opposite the outer surface, and a foam layer sprayed on the inner surface of the skin layer according to a predetermined spray pattern so that the foam layer has a first gap arranged as a predetermined tear pattern, with the skin layer extending across the first gap.