Vehicle Trim Panel with Integral Pivoting Closure Member
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Solution Overview
Problem
The existing methods for manufacturing vehicle trim elements with protruding structures, such as hooks and handles, require additional components and increased assembly time, leading to higher manufacturing costs, and often result in unsightly finishes due to the need for blanking plates to cover molding holes.
Innovation Solution
An integral protruding structure is molded as part of the trim panel, featuring a closure member that pivots to cover the aperture left by the molding tool, eliminating the need for separate components and allowing the aperture to be hidden without additional parts, with strengthening formations and a resilient detent for secure closure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate hook is attached with a screw to the trim panel, then the hook can be securely fixed, but additional components and assembly time are required, increasing manufacturing cost
Solution Approach 1:
The hook is merged with the trim panel as an integral molded structure, eliminating the need for separate hooks and screws. The closure member is also integrated into the panel, creating a unified component that reduces part count while maintaining secure fixation through the molded connection.
2Reliability
If a separate hook is used, then the hook can be securely fixed, but assembly time increases, affecting productivity
Solution Approach 1:
The hook and closure member are combined into the trim panel as integral features, allowing the entire assembly to be installed as one piece rather than requiring separate attachment steps for multiple components.
3Device complexity
If the molding tool extends through the panel to form the hook, then the hook can be formed integrally, but a hole is left in the panel requiring a blanking plate
Solution Approach 1:
The closure member is pre-formed as part of the integral molding process in a predetermined position that allows it to subsequently cover the aperture. This preliminary positioning during molding eliminates the need for separate blanking plates while maintaining component integration.
4Shape
If a blanking plate is fitted over the hole, then the hole is sealed and appearance is improved, but additional production and assembly costs are incurred
Solution Approach 1:
The closure member is merged with the trim panel as an integral feature, eliminating the need for separate blanking plates. The closure member serves dual purposes: sealing the aperture and providing a finished appearance, while reducing component count and manufacturing costs.
5Device complexity
If an integral protruding structure is formed, then additional components are eliminated, but the molding process becomes more complex requiring movable tool parts
Solution Approach 1:
The closure member is pre-formed in a predetermined position during the integral molding process, allowing the protruding structure to be created without requiring complex movable tool parts. The preliminary positioning of the closure member simplifies the molding process while achieving the desired integrated structure.
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 reduces manufacturing costs by eliminating the need for separate components and assembly work, while providing a robust and aesthetically pleasing finish by integrating the closure member directly into the trim panel.
Implementation Method 1
an integral closure member is connected to the panel, and is configured for pivoting movement from an open condition in which it extends away from the inner surface of the panel, to a closed condition in which it covers the aperture
Implementation Method 2
with strengthening formations and a resilient detent for secure closure
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A trim element (2) for a vehicle comprises a moulded panel (12) having an inner surface (14) that in situ faces towards a vehicle support structure and is hidden from view, and an outer surface (16) that in situ faces into the vehicle interior and is exposed to view. A hook (20) or grab handle (44, Fig. 7), integrally moulded part into trim element (2), extends outwards from the outer surface of the panel (12). An aperture (30) is formed adjacent to the hook. A closure member (32), integrally moulded into the trim element (2), has an integral live hinge (34) to the panel (12) and may be closed to cover the aperture (30). One or more panel support mountings (18, Fig.2) may be moulded onto the panel to ensure its retention when an adjacent curtain airbag (45, Fig. 1) is deployed.