Compression-Formed Vehicle Trim Panel with Integrated Airbag Chute
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Solution Overview
Problem
The manufacturing process of vehicle trim components with integrated airbag chute assemblies is labor-intensive and costly due to methods like vibration welding and machining grooves, which increase production time and costs.
Innovation Solution
A compression-formed vehicle trim component with a fiber panel and resin structure that supports an airbag module, where the airbag deploys through a recess formed by contact with a door, eliminating the need for separate coupling and machining, and using a mold process to form the component with integrated support structures and resin injection for reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vibration welding or separate coupling methods are used to attach the airbag chute assembly to the instrument panel, then the airbag can be securely mounted, but the manufacturing process becomes time-consuming and labor-intensive
Solution Approach 1:
The airbag chute assembly is integrated directly into the compression-formed trim component, merging two previously separate components (trim component and chute assembly) into a single monolithic structure. This eliminates the need for separate mounting operations while maintaining secure attachment, thereby resolving the contradiction between mounting reliability and manufacturing efficiency.
Solution Approach 2:
The airbag chute assembly is pre-formed as an integral part of the trim component during the compression molding process itself, rather than being attached as a separate step. This preliminary integration of the mounting structure into the base manufacturing process eliminates subsequent assembly operations, improving productivity while ensuring reliable mounting.
2Ease of operation
If machining grooves are performed on the instrument panel to facilitate airbag deployment, then the airbag door can separate properly, but the manufacturing process becomes more complex and costly
Solution Approach 1:
The deployment groove feature is integrated directly into the compression-formed trim component, combining the structural element with the deployment functionality. This eliminates the need for separate machining operations to create grooves, as the feature is formed during the initial molding process, thereby simplifying manufacturing while maintaining deployment functionality.
Solution Approach 2:
The manufacturing process parameters are changed from post-forming machining operations to in-mold feature creation. By utilizing the compression molding process to directly form the deployment grooves and door separation features, the manufacturing complexity is reduced while achieving the same functional result.
3Manufacturing precision
If separate assembly steps are used to attach the airbag chute assembly, then proper positioning can be achieved, but the production time and costs increase
Solution Approach 1:
The airbag chute assembly and trim component are merged into a single integrated part, eliminating the need for separate positioning and attachment steps. The precise positioning is achieved through the molding process itself, which inherently provides accurate feature placement, thereby reducing production cycle time while maintaining positioning accuracy.
Solution Approach 2:
The manufacturing approach changes from multi-step assembly with positioning operations to a single-step compression molding process. This parameter change in the manufacturing process eliminates time-consuming positioning and attachment operations while maintaining precise feature placement through mold-based geometry control.
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 time and costs by integrating the airbag chute assembly directly into the trim component, providing a smooth outer surface and enhancing structural rigidity while facilitating efficient airbag deployment without visible seams or additional assembly steps.
Implementation Method 1
a structure formed from a second material molded on the back side of the panel
Implementation Method 2
The panel may comprise a compression-formed component
Data Source
AI summary
A vehicle interior component is disclosed. The component may be a trim component configured to support an airbag module providing an airbag configured to be deployed through an opening into the vehicle interior. The trim component may comprise a panel comprising a first material and providing a front side and a back side; and a structure formed from a second material molded on the back side of the panel. The panel may comprise a compression-formed component. The compression-formed component may be configured to provide the opening through a door established upon deployment of the airbag to facilitate deployment of the airbag. The structure may be configured to support the airbag module and to direct the airbag toward the door during deployment of the airbag. The compression-formed component may comprise a feature formed within the panel configured to establish the opening at the door to be created by the airbag at the feature upon deployment of the airbag from the airbag module so that the airbag will deploy through the panel at the opening. A method of manufacturing a vehicle trim component is also disclosed. The method includes disposing a fiber panel within a mold cavity and aligning an airbag chute assembly with the fiber panel and compressing the fiber panel within the mold cavity to form the fiber panel into a desired shape. At least a portion of the fiber panel is compressed between a surface of the mold cavity and a surface of the airbag chute assembly.