Trim Article With Varied Density Lattice Core
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Solution Overview
Problem
Existing vehicle trim components require multiple materials to achieve varied density profiles, which complicates manufacturing and integration, especially when using additive manufacturing techniques.
Innovation Solution
A trim article is designed with an outer casing and core portion formed using additive manufacturing, incorporating multiple lattice matrices with varying density profiles to create a monolithic structure that provides both support and comfort, achieved by using interconnected links with different patterns and thicknesses within a common material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple material substrates are used to achieve varied density profiles, then the density profile requirements are met, but the manufacturing complexity and integration difficulty increase
Solution Approach 1:
The patent combines multiple material functions into a single material substrate by using an additive manufacturing technique that creates variated density profiles within one continuous material. This merging approach eliminates the need for multiple separate material substrates and their complex assembly, while still achieving the required varied density characteristics for different regions of the trim article.
Solution Approach 2:
The patent changes the density parameter of the material substrate through additive manufacturing processes, creating regions with different density values within a single continuous material. This allows the trim article to achieve varied density profiles without requiring multiple different materials, thereby simplifying manufacturing while meeting performance requirements.
2Manufacturing precision
If multiple material substrates are used to achieve varied density profiles, then the density profile requirements are met, but the integration difficulty increases
Solution Approach 1:
The patent merges multiple material substrates into a single integrated trim article using additive manufacturing. This creates a monolithic structure with varied density profiles that eliminates assembly steps and integration challenges associated with multiple separate components, while maintaining the required density variations for functional performance.
3Ease of manufacture
If single material is used with additive manufacturing, then manufacturing simplicity is improved, but achieving variated density profiles becomes difficult
Solution Approach 1:
The patent uses additive manufacturing technology to change the density parameter of a single material during the manufacturing process. By controlling the deposition and consolidation parameters of the additive manufacturing system, the patent creates regions with different density values within the same material substrate, achieving variated density profiles while maintaining manufacturing simplicity.
Solution Approach 2:
The patent applies local quality by creating specific density characteristics in specific regions of the trim article through additive manufacturing. Different areas of the single material substrate are manufactured with tailored density values to meet local functional requirements, such as varying support or comfort characteristics in different zones of the trim component.
Data Source
AI summary
A trim article includes an outer casing having an inner surface defining an interior portion of the outer casing. The outer casing includes a front surface having a plurality of through apertures disposed thereon. A core portion is disposed within the interior portion of the outer casing and includes first and second portions having variated densities relative to one another. The first and second portions include lattice matrices having variated patterns of interconnected links and associated cells that provide variated force deflection parameters between the first and second portions of the core portion. The outer casing and the core portion are integrated to define a monolithic structure comprised of a common material.