Abstract
In order to reduce the cost and weight of the soft-foamed instrument-panel (IP), we developed the new IP that the surface is compression-injected with back-foamed foil inserted and the substrate (PP) is integrally injected with the passenger-side airbag (PAB) door. We named it ‘IMX-IP’ which means that all components (‘X’) of the IP with different resins are made In a Mold. The development procedure of this technology was introduced (1) Design of the new injection mold through TRIZ application, (2) Optimization of the injection conditions and back foamed-foil for minimizing the foam loss and thickness deviation, (3) Development of CAE method for two-shot injection compression, (4) Reliability performance test and application to the mass production. The reduction of the processes through the two-shot molding with back foamed-foil inserted made it possible to enhance soft feeling on IP and reduce the cost and weight simultaneously. The airbag deployment, head impact, and heat aging tests were conducted using the IP of the new i20-car which will be mass-produced in 2015.
KEYWORDS – back foamed foil, injection compression, Multilayer foam, Integral PAB door