Trim Element Double Decoration Mold Wedge Holding
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Solution Overview
Problem
Existing methods for manufacturing molded parts with decorated surfaces limit the number of visual effects and lack a fluid connection between surface zones, resulting in an unsatisfactory aesthetic appearance.
Innovation Solution
A manufacturing method involving a mold with a first and second mold part, where a preformed decoration is held by a wedge and a flexible second decoration is positioned between the mold parts, allowing for back-injection of a substrate to create a visually appealing trim element with a robust and esthetic appearance by overlaying materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple films are arranged side by side in a mold to create different surface zones, then a molded part with multiple surface areas is obtained, but the number of visual effects is limited and the link between zones is not fluid
Solution Approach 1:
The decoration is divided into multiple independent films (first film, second film, third film) that can be arranged in different configurations within the same mold. Each film can provide different visual effects (metallic, matte, glossy, textured) and they can be positioned to create various surface zones, allowing versatile visual effects without requiring a completely different mold for each effect.
Solution Approach 2:
The mold is designed with multiple injection cavities (first cavity, second cavity, third cavity) that can accommodate different film types and configurations. The same mold structure can produce multiple visual effects by simply changing the film arrangement and injection parameters, making the mold multi-functional and adaptable to various decoration requirements.
2Manufacturing precision
If a carriage is moved to create a second cavity for introducing a second substrate, then a molded part with two surface zones is obtained, but the link between zones is not fluid
Solution Approach 1:
Multiple films and injection cavities are merged into a single integrated molding process. The first film, second film, and third film are all introduced and bonded simultaneously in one injection cycle, creating fluid transitions between surface zones without requiring separate molding operations or mechanical carriage movements.
Solution Approach 2:
The films are pre-positioned in the mold cavities before injection, with the second film arranged to bridge between the first and third cavities. This preliminary arrangement ensures that when injection occurs, the material flows continuously through all zones, creating fluid links between surface areas without requiring post-molding assembly or complex carriage movements.
3Manufacturing precision
If decorations are positioned against mold surfaces without proper holding mechanisms, then the decorating process is simple, but the decorations may shift during injection affecting precision
Solution Approach 1:
Adhesive layers are introduced as intermediary substances between the films and the mold cavity walls, and between overlapping film edges. These adhesive layers securely hold the decorations in their designated positions during the injection process, preventing any shifting or misalignment, while the application method remains simple by incorporating the adhesive into the film structure itself.
Data Source
AI summary
A manufacturing method for a trim element, which includes the following steps: supplying a mold in an open configuration which has a first mold part and a second mold part; positioning a first pre-formed decoration against the first mold part; positioning a wedge in contact with an edge of the first decoration; positioning a second flexible décor; closing the mold in a closed configuration, where the second decoration sits between the two mold parts; and back-injecting a substrate into the molding cavity, where the second decoration is pushed by the substrate against the first decoration. Also provided is an associated manufacturing device.