Vehicle Trim Panel Integrated Compression and Injection Molding
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Solution Overview
Problem
Current methods for manufacturing vehicle trim components lack efficiency in combining compression forming of fiber materials with injection molding of plastics, resulting in suboptimal structural integrity and increased manufacturing complexity.
Innovation Solution
A method involving heating a fiber panel with structural fibers and thermoplastic resin, compressing it into a mold to form a shape, and then injecting resin into voids to create a structural substrate with molded features, enhancing the component's strength and reducing manufacturing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If compression forming and injection molding are performed as separate processes, then each process can be optimized independently, but manufacturing time increases and process complexity increases
Solution Approach 1:
The patent combines compression forming and injection molding into a single integrated process where a fiber panel is compression-formed first, then resin is injected into voids within the same manufacturing cycle. This merging of processes reduces total manufacturing time while maintaining structural integrity through the sequential execution of both forming operations.
Solution Approach 2:
The fiber panel is compression-formed in advance within the mold before resin injection occurs. This preliminary action creates a pre-shaped substrate with controlled voids that guides the subsequent resin injection process, ensuring proper structural formation and reducing overall process time.
2Strength
If multiple separate manufacturing processes are used, then each process step can be independently controlled, but device complexity increases and manufacturing efficiency decreases
Solution Approach 1:
The patent integrates compression forming and injection molding into a single manufacturing system that uses one mold for both operations. The fiber panel is compression-formed in the mold, then resin is injected into voids in the same mold without removing the workpiece, thereby reducing device complexity while maintaining structural integrity.
3Ease of manufacture
If fiber panels are compression-formed without subsequent resin injection, then manufacturing is simpler, but structural integrity and dimensional accuracy are reduced
Solution Approach 1:
The patent applies resin injection locally to specific voids within the compression-formed fiber panel rather than treating the entire panel uniformly. This localized treatment enhances dimensional accuracy and structural integrity in critical areas while maintaining manufacturing simplicity through targeted resin application.
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 results in a vehicle trim component with improved structural integrity and reduced manufacturing time and complexity by integrating compression forming and injection molding in a single process, forming a robust and dimensionally accurate trim component.
Implementation Method 1
heating a fiber panel comprising a plurality of structural fibers
Implementation Method 2
compressing the fiber panel and the cover in the mold to form the fiber panel into a compression-formed component having a shape
Implementation Method 3
injecting resin into at least one void in the mold with the compression-formed component to form a structural substrate
Data Source
AI summary
A component for a vehicle interior is disclosed. The component may comprise a structural substrate comprising a fiber panel with at least one hole and a resin-formed structure; and a cover coupled to the fiber panel or the resin-formed structure. The fiber panel may be formed into a compression-formed component; the resin-formed structure may comprise a molded feature formed in the hole of the fiber panel. The resin-formed structure may reinforce the structural substrate. The fiber panel and the resin-formed structure may provide a substantially continuous structure. The resin-formed structure may extend along a surface of the fiber panel to form the resin-formed structure to the fiber panel. The cover may be applied to the fiber panel during compression molding. The component may comprise a trim panel, instrument panel, door panel, or other interior trim part. A method of manufacturing a vehicle trim component is also disclosed.