Vehicle Interior Trim Structure With Perforated 3D Décor Layer
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Solution Overview
Problem
Existing interior trim parts with three-dimensional structures on soft surface materials suffer from poor quality in terms of contour accuracy, height, and surface resistance due to inadequate planar surface structure, and the printing process is complex and expensive.
Innovation Solution
An interior trim part comprising a carrier made of thermoplastic material with elevations and a perforated décor layer, where the elevations are enclosed by the décor layer, forming a three-dimensional structure, with the elevation component being separate and made of a higher-quality material than the carrier, and attached via gluing or welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If inks or pastes are added to the décor layer by digital printing or screen printing to create a three-dimensional structure, then design elements can be applied to the interior trim part, but the contour accuracy, height of the three-dimensional structure, and surface resistance are poor
Solution Approach 1:
The patent divides the interior trim part into separate components: a base layer and a décor layer with cut-out patterns. The three-dimensional effect is achieved by stacking and offsetting these layers rather than attempting to print complex 3D structures directly onto a soft surface, thereby improving contour accuracy and structural definition.
Solution Approach 2:
The patent introduces an intermediate structural layer with geometric patterns that acts as a scaffold between the base layer and the décor layer. This intermediary layer provides the necessary structural support and precision for the three-dimensional effect, overcoming the limitations of printing directly on soft materials.
2Shape
If inks or pastes are added to the décor layer by digital printing or screen printing to create a three-dimensional structure, then design elements can be applied to the interior trim part, but the surface resistance is poor
Solution Approach 1:
The patent uses composite construction with multiple layers (base layer, structural layer with geometric patterns, and décor layer) to achieve both the three-dimensional effect and improved surface resistance. The combination of rigid structural elements and the décor layer creates a more durable surface than printing alone.
3Shape
If the décor layer is made of soft surface material and inks or pastes are added to create a three-dimensional structure, then design elements can be applied, but the printing process is complex and the materials are expensive
Solution Approach 1:
Instead of using complex printing processes to create three-dimensional structures, the patent uses simpler die-cutting or stamping processes to create patterned layers that are stacked to form the 3D effect. This replaces expensive and complex printing operations with more straightforward manufacturing techniques.
4Manufacturing precision
If elevations are formed by separate elevation components attached to the carrier, then high-quality materials can be used for the elevations while keeping the carrier cost-effective, but the manufacturing process involves multiple steps including fastening
Solution Approach 1:
The patent segments the interior trim part into a base layer, separate elevation components, and a décor layer. This segmentation allows each component to be optimized independently - the carrier can use cost-effective materials while the elevations use high-quality materials for better appearance and durability.
Solution Approach 2:
The patent combines multiple manufacturing steps (creating the base layer, attaching elevations, and applying the décor layer) into an integrated assembly process. While each step is distinct, they are coordinated to create a unified structure that achieves both cost-effectiveness and high 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
The solution provides a durable and easily manufacturable three-dimensional structure with improved quality and design options, reducing gaps and dust accumulation while controlling costs by using cheaper materials for the carrier and higher-quality materials for the elevations.
Implementation Method 1
a carrier (14) being made of a thermoplastic material and having a first surface, a second surface, and at least one elevation (24) arranged on the first surface
Implementation Method 2
a perforated décor layer (28) applied to the first surface and forming at least one hole (30), the hole (30) having a shape such that the elevation (24) is enclosed by the décor layer (28)
Implementation Method 3
attached via gluing or welding
Data Source
Figure 1A~1F
Figure 2A~2F
Figure 3A~3H
AI summary
The present disclosure is directed to an interior trim part (10) of or for a vehicle (12), comprising a carrier (14) being made of a thermoplastic material and having a first surface (16), a second surface (18), at least one elevation (24) arranged on the first surface (16), and a perforated decor layer (28) applied to the first surface (16) and forming at least one hole (30), the hole (30) having a shape such that the elevation (24) is enclosed by the decor layer (28) and protruding the decor layer (28), thereby forming a three-dimensional surface structure (32). Furthermore, the present disclosure relates to a vehicle (12) comprising such an interior trim part (10) and a method for manufacturing such an interior trim part (10) .