Vehicle Trim Part One-Shot Injection Molding Process
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing trim parts for vehicle interiors require additional process steps to achieve stability, leading to increased costs and longer production times, as they typically involve separate manufacturing and assembly of decorative and structural elements.
Innovation Solution
A method involving a three-component 'one-shot' process where a third component is inserted into a stationary mold, and the second component is injected between the first and third components, securing their connection through adhesion and positive locking, allowing for simultaneous formation of surface and structure in a single station, using a breathing-embossing-ventilating process to minimize internal stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If separate manufacturing and assembly of decorative and structural elements is used, then manufacturing flexibility is maintained, but production time increases and costs rise
Solution Approach 1:
The patent combines the manufacturing of decorative elements (second component) and structural elements (third component) into a single injection molding process at one station. The decorative component is first molded, then the structural component is molded in the same cavity without removing the first component, creating a integrated part with both aesthetic and structural functions in one operation.
Solution Approach 2:
The patent performs preliminary actions by first molding the decorative component and preparing the cavity with release agents or coatings before introducing the structural component. This preliminary preparation ensures that when the structural component is molded over the decorative one, proper adhesion and separation characteristics are achieved without requiring additional assembly steps later.
2Stability of the object's composition
If separate manufacturing of structural elements is used, then structural stability can be optimized, but additional assembly steps are required
Solution Approach 1:
The patent merges the production of structurally optimized components with decorative elements by molding the structural component (third component) directly over the decorative component (second component) in the same cavity. This creates a monolithic structure where the structural element provides necessary stability while being integrated with the decorative surface, eliminating separate assembly operations.
Solution Approach 2:
The patent implements a nested structure where the third structural component is molded around and integrates with the second decorative component, which itself is integrated with the first component. This nested arrangement allows each component to fulfill its specific function while being structurally unified, with the structural component providing stability from the outside while containing the decorative elements within.
3Manufacturing precision
If multiple components are assembled separately, then manufacturing precision can be controlled, but connection stability between components decreases
Solution Approach 1:
The patent eliminates connection interfaces between separate components by molding the second and third components in direct contact within the same cavity. This creates a unified structure where the connection is formed during the molding process itself through material interlocking and adhesion, rather than through separate joining operations, thereby maximizing connection strength while maintaining precise positioning.
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 production time and costs by integrating decorative and structural elements in a single station, enhancing the stability and quality of trim parts while minimizing internal stresses through the use of foaming processes.
Implementation Method 1
the second component is introduced into an intermediate space between the first and third components by means of an injection process and thus poured onto the first component
Implementation Method 2
a foaming process is carried out for pouring or injection using a 'breathing-embossing-ventilation' process or an 'embossing-ventilation' process
Implementation Method 3
the mold is slightly open for a filling phase, the so-called 'breathing,' and opens further during the filling phase
Implementation Method 4
Subsequent closing of the mold causes an 'embossing' effect, which is advantageously followed by a renewed opening of the mold. This significantly minimizes and effectively distributes internal stresses in the cavity
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The method involves providing a trim part partially made of synthetic material and comprising trim components (10, 11). First component is inserted into a movable die (20). Third trim component (12) is inserted into a stationary die (21) before over molding with the first component. The dies are moved toward and/or away from each other after subsequent overmolding and/or during subsequent perfusion, where properties of dies are interchangeable from stationary and movable relative to one another. An independent claim is also included for a trim part.