Vehicle Lining Element with Translucent Zones and Fiber Reinforcement
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Solution Overview
Problem
Current methods for manufacturing vehicle cabin lining elements are inefficient, leading to high weight, high costs, and limited translucent characteristics for illumination, and require frequent modifications for individual lighting concepts.
Innovation Solution
A method involving a positive molding tool with a textile membrane, pre-impregnated fibers, and a matrix material, where the textile membrane is pre-tensioned and covered airtightly for curing, creating a fiber-reinforced lining element with integrated frame elements for structural support and translucent properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If individual ceiling panels with integrated illumination devices are used, then illumination functionality is provided, but weight increases and modification becomes complex
Solution Approach 1:
The illumination function is segmented from the structural ceiling panel. The lining element serves only as a structural support component, while illumination devices can be independently added, removed, or modified without replacing the entire panel assembly.
Solution Approach 2:
The lining element is designed as a universal structural component that can support various illumination concepts. The same basic lining structure accommodates different lighting configurations, making the system adaptable without requiring weight-intensive custom panels for each illumination scenario.
2Strength
If traditional manufacturing methods are used, then structural integrity is achieved, but weight increases and manufacturing cost increases
Solution Approach 1:
A thin textile membrane serves as the base structure, providing sufficient structural integrity when combined with fiber reinforcement. This thin-film approach replaces heavier traditional panel materials while maintaining strength through the tensioned membrane structure and embedded fibers.
Solution Approach 2:
The lining element combines a textile membrane with fiber-reinforced composite materials. This composite construction achieves high structural integrity and strength-to-weight ratio, providing necessary strength while minimizing weight compared to traditional homogeneous materials.
3Strength
If fiber reinforced components are applied to all regions, then structural strength increases, but translucent characteristics are reduced
Solution Approach 1:
Fiber reinforced components are applied locally only in regions requiring structural support, such as load-bearing areas or regions needing shape definition. Areas intended for illumination maintain the translucent textile membrane without fiber overlay, allowing light transmission while providing strength where needed.
4Manufacturing precision
If a positive molding tool is used, then surface finish quality improves, but manufacturing complexity increases
Solution Approach 1:
Instead of using a negative mold that requires the textile to be formed around it, a positive molding tool is used where the textile is laid flat and the desired shape is built up by applying fibers and matrix material directly onto the positive form. This inverted approach simplifies the molding process while achieving high surface finish quality.
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 method results in lighter, cost-effective, and translucent lining elements with improved structural integrity and reduced weight, facilitating easier integration and modification for vehicle cabins while maintaining effective illumination.
Implementation Method 1
curing the matrix material of the semi-finished product
Implementation Method 2
evacuating the space between the molding tool and the covering means
Data Source
AI summary
A method for manufacturing a lining element is provided. The method comprises laying a textile membrane onto a positive molding tool, applying first fibers and a matrix material onto at least one first region of the textile membrane for creating a semi-finished product of a framework supported textile, providing at least one sealing element along outer edges of the molding tool, covering the textile membrane and the at least one sealing element in an air tight manner by a covering means, evacuating the space between the molding tool and the covering means and curing the matrix material by heating the semi-finished product. Thereby, a lining element with a low weight and at the same time a sufficient directional stability is provided that furthermore allows to easily recycle the components of the lining element.