Layered Vehicle Panel Grain Structure Using Sink Marks for Gradation
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Solution Overview
Problem
Existing vehicle panel designs face limitations in achieving fine irregularities on the molding surface of the mold, restricting the degree of freedom for design expression.
Innovation Solution
A vehicle panel comprising multiple layers, each molded using different molds, with varying grained surface heights and sink marks, allowing for a wider range of design expression through continuous gradations in appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If finer irregularities are formed on the molding surface of the mold by machining, then the degree of freedom for design expression is improved, but the manufacturing complexity and cost increase due to machining limitations
Solution Approach 1:
The mold surface is segmented into multiple regions with different grained surface heights (first grained surface, second grained surface, third grained surface). Each region can be independently designed and molded, allowing complex overall patterns to be created through simpler localized surface treatments rather than requiring the entire mold surface to be machined with fine irregularities.
Solution Approach 2:
Different regions of the mold surface are given different grained surface characteristics (different heights and patterns). The first region has a first grained surface, the second region has a second grained surface, and the third region has a third grained surface with smaller grained surface height. This local differentiation allows design expression in each region without requiring complex machining of the entire surface.
2Ease of manufacture
If a single-layer structure is used, then the manufacturing process is simpler, but the design expression and aesthetic appeal are limited
Solution Approach 1:
The invention transitions from a single-layer structure to a multi-layer structure with different grained surface heights. The first layer provides a base grained surface, while the second layer adds another dimension of surface variation with its own grained surface pattern. This dimensional addition enables richer design expression while maintaining the simplicity of the injection molding process itself.
Solution Approach 2:
The vehicle panel uses a composite structure with multiple layers, each having different grained surface characteristics. The first layer and second layer are molded from plastic materials with different surface treatments, creating a composite structure that achieves complex aesthetic effects through the combination of simpler individual layers rather than requiring a single complex layer.
3Manufacturing precision
If sink marks are eliminated through optimized molding, then the surface quality is improved, but the design freedom is reduced as sink marks cannot be utilized as design elements
Solution Approach 1:
The invention converts sink marks, which are traditionally considered defects to be eliminated, into beneficial design elements. The third grained surface region specifically utilizes sink marks to create a third grained surface with smaller grained surface height, transforming a manufacturing imperfection into a deliberate aesthetic feature that enhances design expression.
Data Source
AI summary
A vehicle panel includes a first layer formed from plastic and molded using a first mold, and a second layer formed from plastic and molded on a front surface of the first layer using a second mold. The second layer has a front surface including surface regions continuous with one another in a predetermined direction. The surface regions include a first region and a second region. A first grained surface molded using the first mold is formed in a region of the front surface of the first layer corresponding to the second region. A second grained surface molded using the second mold is formed in the first region. A third grained surface having a smaller grained surface height than second grained surface is formed in the second region. The third grained surface includes a sink mark resulting from molding of the second layer on the first grained surface.