Vehicle Trim Skin Rib Fixing for Reinforcement Positioning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Reinforcement elements in vehicle interior trim parts, such as dashboards, tend to float during back foaming, leading to unpredictable positioning and potential damage to tools used for opening introductions.
Innovation Solution
Incorporating elevated portions or rib-shaped features on the molded skin to fix the reinforcement elements in place, either on the visible or rear side, ensuring they remain positioned during the foaming process, which can be manufactured as part of the skin or applied later.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If reinforcement elements are arranged in the foaming tool at the points of intended bends, then the bends of the molded skin can be defined with exact positioning, but the reinforcement elements float up on the back foaming causing position variation and potential tool damage
Solution Approach 1:
The patent applies preliminary action by pre-attaching fixing means to the molded skin before the foaming process. These fixing means (elevated portions or recesses) are prepared in advance on the molded skin surface, allowing the reinforcement elements to be securely positioned and fixed before back foaming occurs, thereby preventing floating and position variation during the foaming process
Solution Approach 2:
The patent introduces an intermediary solution by using fixing means as a mediator between the molded skin and the reinforcement elements. These fixing means (either elevated portions or recesses) act as an intermediate structure that secures the reinforcement elements to the molded skin, preventing direct contact issues and ensuring stable positioning during foaming without compromising the bending definition
2Reliability
If reinforcement elements are fixed to the molded skin using elevated portions, then the reinforcement elements remain positioned during back foaming, but the molded skin structure becomes more complex
Solution Approach 1:
The patent applies merging by integrating the fixing means directly into the molded skin structure. The elevated portions or recesses are formed as integral parts of the molded skin during the molding process, combining the skin structure and fixing features into a single component. This reduces overall device complexity compared to separate attachment methods while maintaining reliable reinforcement element positioning
3Ease of manufacture
If additional plastic is applied to manufacture means for fixing on the molded skin, then fixing features can be easily added, but the manufacturing process time increases
Solution Approach 1:
The patent applies preliminary action by incorporating the fixing features during the initial molded skin manufacturing process rather than as a separate subsequent step. The elevated portions or recesses are formed simultaneously with the molded skin through mold design or rotational sintering variations, eliminating the need for separate application steps and maintaining manufacturing efficiency
Solution Approach 2:
The patent merges the fixing feature manufacturing with the molded skin manufacturing process. By integrating the formation of elevated portions or recesses into the primary molding or rotational sintering operation, the patent achieves both the molded skin and its fixing means in a single process cycle, thereby maintaining productivity while enabling easy addition of fixing capabilities
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
Prevents unwanted movement of reinforcement elements, maintaining precise bend positioning and preventing tool damage by embedding the elements securely within the foam layer.
Implementation Method 1
manufacture a molded skin by spraying onto a mold
Implementation Method 2
by rotational sintering for manufacturing a vehicle interior trim part
Implementation Method 3
the molded skin and a carrier likewise previously manufactured are inserted into a foaming tool and back-foamed
Data Source
AI summary
A vehicle interior trim part having a molded skin, an intermediate layer, a substrate, at least one reinforcing element arranged in the intermediate layer, and at least one fixing element formed as a part of the skin which acts to fix the position of reinforcing element so that its position cannot inadvertently change as the vehicle interior trim part is being produced. The fixing element is formed as at least one rib-shaped, elevated portion from the same material as the remaining molded skin. A method for producing the vehicle interior trim part is also provided.