Interior Trim Lining Two-Step Pressing with Localized Cooling
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Solution Overview
Problem
Existing methods for producing interior trim parts for vehicles do not effectively ensure a haptically and optically advantageous shape for the user-side surface, lacking in surface structure and three-dimensional geometry.
Innovation Solution
A method involving a two-step process using a first pressing tool to deform a carrier layer made of molded fiber material and a decorative film, with cooling to stabilize the surface structure, followed by a second pressing tool for further shaping, achieving a surface with controlled roughness and geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single-step pressing process is used to form interior trim parts, then the manufacturing process is simple and fast, but the surface structure and three-dimensional geometry are insufficient
Solution Approach 1:
The pressing process is divided into two distinct steps: a first pressing step that forms the basic shape and a second pressing step that creates the final surface structure and three-dimensional geometry. This segmentation allows each step to optimize for its specific function, resolving the contradiction between process simplicity and surface quality.
Solution Approach 2:
The first pressing step performs preliminary shaping of the trim part, creating a pre-formed structure that prepares the material for the second pressing step. This preliminary action enables the second step to focus on creating the final surface structure without having to perform all forming operations simultaneously.
2Stability of the object's composition
If the decorative film is cooled rapidly to stabilize surface structure, then the surface structure is maintained, but drapability is reduced
Solution Approach 1:
Cooling is applied selectively to specific regions of the decorative film where surface structure stability is most critical, rather than cooling the entire film uniformly. This localized cooling maintains surface structure in key areas while preserving drapability in other regions that require flexibility for forming operations.
Solution Approach 2:
The cooling process is applied periodically or in stages rather than continuously, allowing the decorative film to alternate between cooling periods (for surface structure stabilization) and warmer periods (for maintaining drapability). This periodic action resolves the contradiction between stability and adaptability.
3Shape
If the carrier layer and decorative film are pressed at high temperature to reach yield point, then the materials deform properly, but surface structure of decorative layer is compromised
Solution Approach 1:
Different temperature conditions are applied to different layers: the carrier layer is heated to its yield point for proper deformation, while the decorative film is kept at a lower temperature that preserves its surface structure. This localized temperature control allows each layer to respond appropriately to the pressing process without compromising the other.
Solution Approach 2:
The pressing process is segmented into two steps with different temperature profiles: the first pressing step uses higher temperature to deform the carrier layer, while the second pressing step uses lower temperature to form the surface structure of the decorative film. This temporal and thermal segmentation resolves the contradiction between material deformation and surface structure preservation.
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 method produces interior trim parts with a structured surface that maintains its shape and optical appeal, offering improved haptic experience and geometric stability while minimizing drapability loss.
Implementation Method 1
applying a cooling medium to the first surface of the intermediate product by means of a cooling device and thereby cooling at least one partial thickness region of the cross section of an intermediate product section of the intermediate product located on the first surface of the intermediate product in order to stabilize the surface structure of the first surface of the intermediate product
Implementation Method 2
setting a temperature at which the yield point of the materials of both semi-finished products is reached
Data Source
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AI summary
Producing interior trim part comprising a carrier component and a decorative film, comprises carrying out first compression and deformation of a semifinished product provided for the formation of the carrier layer, and a semifinished product provided for the formation of the decorative layer, for forming a structure of a first surface of the decorative layer, cooling at least one thick partial region of cross-section of a decorative layer section of obtained intermediate product, and carrying out second compression and further deformation of the carrier layer and the decorative layer. Producing interior trim part comprising a carrier component made of a fiber molding material, preferably a natural fiber molding material, and a decorative film, comprises carrying out first compression and deformation of a semifinished product provided for the formation of the carrier layer, and a semifinished product provided for the formation of the decorative layer, in a first pressing tool having two tool parts, for forming a structure of a first surface of the decorative layer, and an intermediate product having a first deformation state, cooling at least one thick partial region of cross-section of a decorative layer section of the intermediate product by cooling a first surface of it using a cooling medium, and carrying out second compression and further deformation of the carrier layer and the decorative layer in a second pressing tool having two tool parts, for forming a process end product having a second deformation state. The thick partial region of decorative layer section located on the surface of the decorative layer present in the second pressing tool, exhibits a lower temperature than the temperature of the thick partial region of the decorative layer-section during deformation in the first pressing tool, due to cooling. An independent claim is also included for a device for producing the interior trim part, comprising the first pressing tool having two tool parts respectively exhibiting a molding contour surface for forming an intermediate product having a first deformation state from a semifinished product for forming the carrier component and a semifinished product for forming the decorative layer, a cooling device having a dispensing device for applying the cooling medium on the first surface of the intermediate product for cooling the first surface, and the second pressing tool having two tool parts respectively having a molding contour surface for forming an interior trim part having a second deformation state, where the second deformation state is caused by a contour-shaping of the intermediate product.