Vehicle Trim Fiber Panel With In-Mold Resin Edge Features
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Solution Overview
Problem
The existing process of manufacturing vehicle trim components through compression forming and injection molding is time-consuming due to the need for trimming edges and transferring components between molds, leading to excess material waste and increased setup costs.
Innovation Solution
A method involving concurrent compression forming and injection molding, where a fiber panel is heated, compressed into a mold to form a shape, and resin is injected into voids to create a structural substrate with integrated molded features, such as ribs and connectors, eliminating the need for separate molds and trimming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If compression forming and injection molding are performed sequentially using separate molds, then each process can be optimized independently, but the manufacturing time increases and material waste occurs due to trimming and transfer operations
Solution Approach 1:
The patent combines compression forming and injection molding into a single concurrent process using an integrated mold system. The compression mold and injection mold are merged into one device that can perform both operations simultaneously on the same workpiece, eliminating the need for separate molds and transfer operations between them.
Solution Approach 2:
The integrated mold system performs multiple functions: it can compress form the fiber panel, inject resin into voids, and create molded features all in one setup. This multi-functional approach allows the same mold to handle what previously required two separate molding processes and transfers.
2Manufacturing precision
If edge trimming is performed after compression forming, then dimensional accuracy is achieved, but material waste increases and manufacturing complexity increases
Solution Approach 1:
The mold cavity is designed with precise dimensional specifications that define the final edge geometry. The compression forming process shapes the fiber panel to match the mold cavity dimensions, and the injection molding process fills voids up to the precise mold boundaries, achieving dimensional accuracy without requiring post-forming trimming operations.
3Ease of manufacture
If components are transferred between molds, then each mold can be specialized for its specific function, but setup costs increase and manufacturing time increases
Solution Approach 1:
The patent merges the compression mold and injection mold into a single integrated mold assembly. This eliminates the physical transfer of components between separate molds and reduces setup complexity, while maintaining the specialized functionality of both molding processes through dedicated cavities and mechanisms within the integrated system.
4Reliability
If ancillary components are formed in a second mold, then component integration is achieved, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The patent combines the formation of the main component and ancillary components into a single concurrent molding process. The integrated mold system allows resin to be injected into voids that form both the main component structure and ancillary features simultaneously, achieving full component integration without requiring a second separate molding operation.
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 time, minimizes material waste, and enhances the structural integrity of the trim components by integrating molded features directly during the molding process.
Implementation Method 1
the panel is heated to induce the thermoplastic resin to liquefy
Implementation Method 2
As the fiber panel cools, the thermoplastic solidifies, establishing a substantially rigid composite panel
Implementation Method 3
Liquid resin may be injected into each of the additional cavities to form the desired ancillary components
Data Source
AI summary
A component for a vehicle interior is disclosed. The component may comprise a structural substrate comprising a fiber panel and a structure comprising a resin. The fiber panel may comprise a thickness along a periphery; the structure may comprise a border of the structural substrate along the thickness of the periphery of the fiber panel. The periphery of the fiber panel may comprise an edge; the structure may be formed on the edge. The fiber panel may comprise a compression-formed fiber panel. The fiber panel may comprise a plurality of fibers and a resin configured to bind the fibers. The structure may comprise a feature providing an ancillary component; the feature may comprise a molded resin. The structure may be formed in a hole in the fiber panel. The component may comprise at least one of a center console; floor console; door panel; instrument panel; headliner; overhead console; sun visor.