Vehicle Trim Panel Electronics With Post-Formed Component Placement

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Solution Overview

Problem

Existing In-Mold Electronics (IME) technology faces challenges in accurately positioning electronic components relative to pictograms on trim panels, especially on complex three-dimensional surfaces, leading to potential malfunctions and increased costs due to the need for specialized attaching means and components that can withstand thermal and mechanical stress.

Innovation Solution

The method involves dividing the electrical circuit printing into two steps: a two-dimensional printing process for flat areas and a three-dimensional printing process for complex areas, ensuring accurate definition of electrical conductive pads even on curved surfaces. Electronic components are attached after the thermoforming process, avoiding exposure to stress and allowing the use of common components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If electronic components are attached to the film before thermoforming, then the components are fixed in position, but the components and attaching means are exposed to thermal and mechanical stress causing deformation and potential malfunction

Engineering Contradiction:

Improvepositioning accuracy of electronic componentsVSAvoidfunctional reliability of electronic components

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent applies preliminary action by printing the electrical circuit pattern on the film before thermoforming, while postponing the attachment of electronic components until after thermoforming. This allows the circuit pattern to be established in advance while avoiding exposure of fragile components to thermal and mechanical stress during the forming process.

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If a single three-dimensional printing process is used for the entire electrical circuit, then the process is simplified, but positioning accuracy on complex curved surfaces is compromised

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidpositioning accuracy on curved surfaces

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent segments the electrical circuit into two parts: a first electrical circuit printed using a two-dimensional printing process on flat areas, and a second electrical circuit printed using a three-dimensional printing process on complex curved surfaces. This segmentation allows each printing method to be optimized for its suitable surface type, achieving both process efficiency and positioning accuracy.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies local quality by selecting different printing processes based on the local surface characteristics. Two-dimensional printing is used for flat areas where it provides sufficient accuracy and efficiency, while three-dimensional printing is used for curved surfaces where it provides the necessary positioning accuracy despite increased process complexity.

Inventive Principle:

Principle #3Local quality

3Reliability

If specialized attaching means and components are used to withstand thermal and mechanical stress, then component reliability is maintained, but production costs increase

Engineering Contradiction:

Improvefunctional reliability under stressVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent uses preliminary action by completing the circuit pattern printing before thermoforming, then attaching standard electronic components after the stress-inducing process is complete. This eliminates the need for specialized stress-resistant components and attaching means, allowing the use of conventional, cost-effective parts while maintaining reliability.

Inventive Principle:

Principle #10Preliminary action

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 approach ensures precise positioning of electronic components relative to pictograms, reduces the risk of malfunctions, and lowers production costs by eliminating the need for specialized components and reducing thermal and mechanical stress on the film and components.

Implementation Method 1

said first sheet being formed according to a three-dimensional shape in such a way that said first area has a three-dimensional shape

Methodology Applied

Scientific EffectThermoforming:

Implementation Method 2

a plastic material is injected on said first sheet in order to form a carrier sheet covering said first electronic component

Methodology Applied

Scientific EffectInjection molding:

Data Source

PatentUS20250168990A1Method for manufacturing trim panels for vehicles having an electronic function

Publication Date: 2025.05.22 GRP ANTOLIN ING SA

AI summary

Method for manufacturing trim panels for vehicles having an electronic function comprising the steps of providing a first sheet comprising a flexible flat plastic film having a first area being flat; a first printing step by a two-dimensional printing process for configuring an electrical conductive track on the first sheet; forming the first sheet according to a three-dimensional shape in such a way that the first area has a three-dimensional shape; a second printing step by fluid dispensing or pad printing for configuring an electrical conductive pad on the first area; attaching an electronic component to the electrical conductive pad; injecting a plastic material on the first sheet forming a carrier sheet; and providing a decorative covering on the carrier sheet comprising a pictogram configured for cooperating with the electronic component.