Vehicle Interior Trim Part Segmented Support Structure
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing interior trim parts for vehicle passenger compartments aim to reduce production steps and costs while providing a pleasant tactile experience, but they often require complex processes and materials that are not efficient in combining aesthetics and functionality.
Innovation Solution
A multi-part structure where a molded part with a decorative wear layer is combined with a separate support structure held by connecting elements, allowing for flexible production methods and varying tactile perceptions by using different materials and connection types such as welding, latching, or screwing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If foam is injected into a chamber of the interior trim part to create a support structure, then the tactile perception is improved, but the production complexity increases
Solution Approach 1:
The interior trim part is divided into separate functional components: a molded part with wear layer and carrier layer, and a separate support structure made from foam blank. This segmentation allows each component to be manufactured independently using optimized processes, then assembled together, reducing overall production complexity while maintaining tactile quality.
Solution Approach 2:
The foam blank is pre-formed before assembly into the final product. By preparing the support structure in advance as a separate component with appropriate shape and properties, the main molding process is simplified and tactile perception is ensured without adding complexity to the primary production line.
2Strength
If foam is cut from a block and formed in a thermoplastic process with pressure and heat, then the support structure is created, but the production time increases
Solution Approach 1:
The support structure is manufactured as a separate component from the main molded part. This allows parallel production of the foam blank and the molded part, followed by assembly, thereby reducing total production time while maintaining the required support structure strength through dedicated forming processes.
3Productivity
If a multi-part structure with separate support element is used, then the production effort is reduced, but the device complexity increases
Solution Approach 1:
The interior trim part consists of a molded part and a separate support structure that can be produced independently and assembled. This segmentation enables each component to be optimized for its specific manufacturing process and allows parallel production, increasing productivity despite the additional assembly step.
Solution Approach 2:
The separate support structure design allows the same molded part to be used with different support structures depending on the application requirements (luxury vs. basic equipment), providing versatility and reducing development effort for different product variants.
Data Source
Figure 1a~1b
Figure 2a~2c
Figure 3a~3c
AI summary
The inner paneling unit (1) has a shaped part (2) having a connection element, which is attached on a carrier layer (6) of a back side of inner paneling unit. A supporting structure is formed as separate supporting element (4) and is held by the connection element of the shaped part. An independent claim is also included for a method for producing inner paneling unit.