Vehicle Trim Speckle Pattern Molding With Embedded Plastic Elements
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Solution Overview
Problem
Current methods for producing vehicle trim parts with speckle or veining patterns, such as in-mold decoration and direct printing technologies, are costly and lack sustainability, often resulting in aesthetically unsatisfactory outcomes.
Innovation Solution
A method involving an injection mold with movable mold halves where plastic elements are arranged on the cavity surface to form a material-locking connection with injected plastic melt, creating a speckle or veining pattern, and devices with multiple nozzles or cartridges for simultaneous printing of lines or shapes on flat or curved surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If in-mold decoration or in-mold decoration label process is used to provide vehicle trim part with desired design, then the aesthetic appearance is improved, but the production cost increases and sustainability is reduced
Solution Approach 1:
The patent uses plastic elements as physical copies or representations of the desired pattern (speckle or veining) that are placed directly into the mold cavity. These elements replicate the appearance of expensive decorative foils but can be produced more simply and sustainably, thereby reducing production cost while maintaining aesthetic appearance.
Solution Approach 2:
The patent employs disposable plastic elements that can be easily manufactured, used once in the molding process, and then discarded or recycled. These inexpensive elements replace expensive, complex decorative foils and labels, significantly reducing production cost while achieving the desired aesthetic effect through their pattern-forming capability.
2Shape
If in-mold decoration or in-mold decoration label process is used to provide vehicle trim part with desired design, then the aesthetic appearance is improved, but sustainability is reduced
Solution Approach 1:
The patent enables the plastic elements to be either discarded after a single use or recovered and reused. This approach improves sustainability compared to traditional foil-based methods by allowing material recovery and reduction of waste. The elements can be made from recyclable materials and their systematic management reduces environmental impact while maintaining aesthetic appearance.
3Ease of manufacture
If direct printing tools such as fused filament fabrication or injection molding are used, then production cost is reduced, but the aesthetic result becomes unsatisfactory
Solution Approach 1:
The patent applies local quality by placing pattern-forming plastic elements only in specific locations within the mold cavity where the speckle or veining pattern is desired. This allows cost-effective production through simple element placement while achieving high aesthetic quality through the strategic positioning and design of these elements to create realistic patterns.
4Ease of manufacture
If plastic elements are arranged on cavity surface to form material-locking connection, then production cost is reduced and sustainability is improved, but the process complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-arranging the plastic elements on the cavity surface before the injection molding process begins. This preparation step, while adding some process complexity, enables cost-effective production by allowing the elements to be positioned optimally and ensures they will form the desired pattern. The elements are prepared in advance and then simply incorporated into the molding process.
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 allows for cost-effective production of vehicle trim parts with visible sustainable material patterns, enhancing aesthetic appeal and sustainability while reducing production costs.
Implementation Method 1
plastic elements are provided and arranged on a cavity surface in such a way that, during injection and/or hardening, the plastic elements connect in a material-locking manner with the injected plastic melt
Data Source
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AI summary
The present disclosure relates, inter alia, to a method for producing a vehicle trim part having a visible speckle and/or veining pattern on a visible side of the vehicle trim part visible from the outside comprising the steps of providing an injection mold with a first mold half and a second mold half, which are movable relative to one another between an open and a closed position of the injection mold, the injection mold forming a cavity between the first and the second mold half in the closed position; injecting a plastic melt into the cavity; hardening of the injected plastic melt to form the vehicle trim part; removing the vehicle trim part by opening the injection mold; wherein before the injecting of the plastic melt into the cavity plastic elements are provided and arranged on a cavity surface in such a way that, during injection and/or hardening, the plastic elements connect in a material-locking manner with the injected plastic melt and form a speckle and/or veining pattern on the visible side of the vehicle trim part.