Vehicle Interior Trim Connection Overmolding for Stable Plug Integration
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Solution Overview
Problem
Existing vehicle interior trim parts with integrated electrical or optical devices face issues of insufficient stability, vibration noise, and inadequate protection against environmental influences due to weak connection elements and additional manufacturing steps required for soldering connections.
Innovation Solution
A vehicle interior trim part featuring a carrier made of polymeric material with an electrical or optical device and a connection element on its rear side, where the conductor is overmolded by the polymeric material, providing a sealed and insulated connection that simplifies manufacturing and enhances stability and longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connection elements are used to connect electrical or optical devices to the carrier, then the devices can be connected to vehicle electronics, but the connection elements have insufficient stability and do not adequately protect electrical components
Solution Approach 1:
The patent merges the connection element with the carrier by integrally molding the connection element into the carrier structure. This eliminates separate connection components and creates a unified structure where the carrier itself provides the connection function, thereby improving stability without adding complexity.
Solution Approach 2:
The patent uses a composite structure combining the carrier material with sealing material to create an integrated connection element. This composite approach allows the connection element to benefit from both the structural properties of the carrier and the protective properties of the sealing material, enhancing both stability and protection.
2Reliability
If additional manufacturing steps are carried out to solder connecting plugs to heating mats, then electrical connections are established, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The patent incorporates connection elements directly into the carrier during the initial molding process, rather than adding them later. This preliminary integration eliminates subsequent soldering steps and simplifies the manufacturing process while maintaining reliable electrical connections through the integral design.
Solution Approach 2:
The patent replaces the mechanical soldering process with an integral molding process. Instead of using thermal and mechanical soldering operations, the electrical connections are established through the molded-in connection elements that create direct physical and electrical pathways, eliminating the need for separate soldering steps.
3Reliability
If connection elements are used to connect devices, then electrical or optical connections are established, but the connection elements do not provide adequate protection against environmental influences like moisture and vibrations
Solution Approach 1:
The patent merges the sealing function with the connection element by integrally molding the sealing material around the conductor within the carrier structure. This creates a unified protective enclosure that eliminates the need for separate sealing components, providing protection against moisture and vibrations without adding structural complexity.
Solution Approach 2:
The patent uses a molded sealing structure that forms a protective shell around the conductor and connection elements. This shell-like enclosure, created through integral molding, provides flexible yet effective protection against environmental influences while maintaining the simplicity of the overall structure.
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 solution results in a stable, durable vehicle interior trim part with improved electrical insulation and protection against corrosion and vibration noise, while simplifying the manufacturing process by integrating the conductor within the polymeric material during carrier production.
Implementation Method 1
The recess is filled at least in regions, in particular completely, by the polymeric material of the carrier in such a way that the conductor is at least partially surrounded, for example overmolded, by the polymeric material of the carrier
Data Source
AI summary
The application relates to a vehicle interior trim part (1) and a method for manufacturing a vehicle interior trim part (1). The proposed vehicle interior trim part (1) comprises a carrier (12) which has polymeric material and an electrical or optical device (2). The vehicle interior trim part (1) also comprises a connection element (3) arranged on a rear side (16) of the carrier (12) for connecting the electrical or optical device (2) and at least one conductor (4) which connects the electrical or optical device (2) to the connection element (3). The connection element (3) has a plug receptacle (6) which is configured to produce an electrically or optically conductive connection of a plug to the conductor (4). In addition, the connection element (3) has a recess (10) within which the conductor (4) is accommodated. The recess (10) is at least partially filled by the polymeric material of the carrier (12) in such a way that the conductor (4) is at least partially surrounded by the polymeric material of the carrier (12).