Vehicle Interior Parts Mold Draft Angle Optimization
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Solution Overview
Problem
Vehicle interior parts with embossed patterns formed through injection molding often suffer scratches during mold opening and product removal due to contact with the mold, leading to defects and reduced quality.
Innovation Solution
A method involving 3D modeling to determine optimal curvature and gradient angles for concave portions, preventing scratches by setting a draft angle larger than the limit angle derived from scratch occurrence data, and applying this in the molding process to enhance the external appearance and reduce manufacturing defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If injection molding is used to manufacture interior parts with embossed patterns, then manufacturing efficiency and integration are improved, but the embossed pattern surface is scratched during mold opening and product removal
Solution Approach 1:
The patent changes the geometric parameters of the concave portion by setting specific curvature radius (R1) and draft angle (α1) values. By optimizing these parameters, the mold can open and remove the product without scratching the embossed pattern surface, thus resolving the contradiction between manufacturing efficiency and surface quality.
Solution Approach 2:
The patent applies curvature to the concave portion by setting a specific curvature radius R1. This curved surface design allows the mold to smoothly separate from the product during opening, preventing scratches on the embossed pattern while maintaining manufacturing efficiency.
2Shape
If a concave portion is formed on the interior part surface, then aesthetic appearance is improved, but the concave surface is prone to scratching during mold movement
Solution Approach 1:
The patent optimizes the geometric parameters of the concave portion including curvature radius R1 and draft angle α1. These parameter changes ensure that the concave portion maintains its aesthetic appearance while being protected from scratches during mold opening and product removal.
Solution Approach 2:
The patent preliminarily designs the concave portion with optimized curvature and draft angle before molding. This preliminary action prevents scratch damage from occurring during the molding and demolding process, while still achieving the desired aesthetic appearance.
3Shape
If embossed pattern height is increased to enhance appearance quality, then aesthetic sense is improved, but the embossed pattern becomes more susceptible to damage and scratching
Solution Approach 1:
The patent optimizes the curvature radius R1 of the concave portion, which indirectly protects the embossed pattern. By setting appropriate curvature values, the mold opening process becomes smoother and less likely to cause damage to the embossed pattern, thus improving reliability while maintaining appearance quality.
Data Source
AI summary
A method of molding an interior part for a vehicle includes determining a 3D graphic sample model. A shape of the sample model has concave portions having curvatures determined through 3D modeling and gradients of an inner surface of each concave portion. A molded sample having the same general shape as the sample model is injection molded. Information related to scratch occurrence positions is acquired from the molded sample. Information of curvatures and gradients of the concave portions of the sample model are acquired and collected at positions on the sample model corresponding to the scratch occurrence positions. A limit angle and limit angle are determined by using the collected information and preset curvatures for the concave portion of a design of the interior part. The interior part having the concave portion with a shape based on the determined draft angle and the preset curvatures can then be injection molded.