Automotive Trim Foam Cavity Insertion Process

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Solution Overview

Problem

Conventional automotive trim device manufacturing processes, such as 'foam in place,' require protective housings for sensitive mechanical and electrical elements, increasing material costs and mass, while still risking foam intrusion and binding issues.

Innovation Solution

The process involves forming a foam body with a cavity in a mold using a tooling mandrel, then inserting functionality-conferring and frame elements after foam formation, allowing for reduced material usage and cost without exposing sensitive components to liquid foam.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If protective housing is added to shield sensitive elements from liquid foam, then reliability is improved, but device complexity and material costs increase

Engineering Contradiction:

Improveprotection of sensitive elementsVSAvoidstructural complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The foam body is formed in advance with a cavity prepared for the sensitive elements, but the elements themselves are inserted only after the foam has cured. This preliminary preparation of the foam structure without immediately placing sensitive components prevents foam intrusion while maintaining structural integrity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The sensitive functionality-conferring elements are extracted from the foam-forming process entirely. They are inserted into the pre-formed foam body after curing, separating the foam formation process from the element placement process and eliminating the need for protective housings.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If protective housing is added to shield sensitive elements from liquid foam, then reliability is improved, but weight increases

Engineering Contradiction:

Improveprotection of sensitive elementsVSAvoidmass of trim device

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The protective housing is completely removed from the design. Instead of adding a housing around sensitive elements, the elements are simply inserted into the foam body after curing, eliminating unnecessary weight while maintaining protection through the foam's inherent properties.

Inventive Principle:

Principle #2Taking out (Extraction)

3Productivity

If foam is poured in place with mechanism already positioned, then manufacturing efficiency is improved, but risk of foam intrusion and binding increases

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidfoam intrusion and binding

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The foam body is formed preliminarily with a cavity, and only after the foam has cured are the sensitive elements inserted. This separates the foam-forming process from the element-placement process, maintaining manufacturing efficiency while eliminating foam intrusion risks.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The sensitive elements are extracted from the foam-forming process entirely, being inserted only after curing. This eliminates their exposure to liquid foam while still allowing for efficient manufacturing through the foam-in-place method.

Inventive Principle:

Principle #2Taking out (Extraction)

4Reliability

If protective housing is added to shield sensitive elements, then reliability is improved, but material costs increase

Engineering Contradiction:

Improveprotection of sensitive elementsVSAvoidmaterial costs

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The protective housing material is completely eliminated from the design. The sensitive elements are inserted directly into the foam body after curing, removing the need for additional housing materials and reducing overall material costs.

Inventive Principle:

Principle #2Taking out (Extraction)

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 reduces manufacturing costs and overall mass of the trim device while protecting sensitive components by preventing foam intrusion, enhancing design flexibility and reducing material waste.

Implementation Method 1

dispensing a liquid foamable polymeric composition into the molding cavity; expanding the liquid foamable polymeric composition to produce a foam body element in the molding cavity

Methodology Applied

Scientific EffectFoam expansion: Foam

Data Source

PatentUS20210331359A1Automotive trim device

Publication Date: 2021.10.28 PROPRIETECT LP

AI summary

The present invention relates to an automotive trim device and a process for making the same. The automotive trim device comprises a foam body with a cavity, into which a mechanism comprising both functionality-conferring elements and a frame element can be inserted. The foam body is manufactured from liquid foam and uses tooling for the inner core. After the foam body has formed, the tooling is removed and the mechanism can be inserted into the foam body, thereby preventing the mechanism from being exposed to liquid foam. An advantage of the present invention is that the automotive trim device can be used with electrical and/or mechanical devices containing components sensitive to the intrusion and curing of liquid foamable materials. The process may also provide mass and cost savings due to reductions in scrap and material, as compared to other known methods of manufacture.