Trunk Liner Molding Single Cavity Process

Solution Overview

Problem

The existing methods for manufacturing trunk liner components in motor vehicles require two separate molds, leading to increased manufacturing costs and excess scrap material.

Innovation Solution

A method where the trunk top coat and spacer members are formed in the same mold, reducing the number of molds needed and minimizing scrap production by being operatively connected during assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If two separate molds are used to create the trunk liner, then the trunk liner can be formed with distinct top coat and spacer members, but the number of molds increases and scrap material is generated

Engineering Contradiction:

Improvetrunk liner formationVSAvoidnumber of molds

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent combines the top coat member and spacer member into a single integrated molding process using one mold that forms both components simultaneously. The mold includes a first cavity for the top coat member and a second cavity for the spacer member, allowing both parts to be formed in one operation rather than requiring separate molds and assembly steps.

Inventive Principle:

Principle #5Merging (Combining)

2Ease of manufacture

If two separate molds are used to create the trunk liner, then the trunk liner components can be formed independently, but excess scrap material is created

Engineering Contradiction:

Improvecomponent independenceVSAvoidscrap material

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The patent combines the top coat member and spacer member into a single integrated molding process using one mold that forms both components simultaneously. The mold includes a first cavity for the top coat member and a second cavity for the spacer member, allowing both parts to be formed in one operation rather than requiring separate molds and assembly steps.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS7798549B2Trunk liner method and apparatus

Publication Date: 2010.09.21 HONDA MOTOR CO LTD

AI summary

A trunk compartment may include a trunk lining having a trunk top coat member and a trunk spacer member. The trunk coat top member may have an inner surface that may define a portion of the trunk lining and an outer surface. A trunk spacer member may be operatively connected to the trunk coat top member and the vehicle frame. The trunk coat top member and the trunk spacer member may be formed in the same mold.