Method for Producing Surface-Treated Lightweight Components with High Natural Fiber Content and Integrated Fastening Elements

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This patent discloses an advanced process for manufacturing lightweight structural components with a high proportion of natural fibers. The process involves placing a semi-finished natural fiber product in an injection mold, pressing and forming it into shape, then partially overmolding it on one side with functional and fastening elements, and applying a finished surface layer to the visible side. This method enables the creation of natural-fiber reinforced plastic (FRP) parts with integrated fastening features and a customizable surface finish in a single or streamlined sequence, minimizing post-processing needs.

Use CasesContent extracted from patent full text and abstract with AI.

• Production of interior automotive trim and panels with integrated mounting features and decorative surfaces.
• Manufacturing of lightweight housing or casing components for consumer electronics or appliances, where a sustainable material is desired.
• Fabrication of furniture or building elements requiring both structural performance and attractive, durable surfaces.
• Creation of eco-friendly packaging solutions that require built-in fasteners or closures.
• Use in aircraft, marine, or train interiors for lightweight, robust, and aesthetically finished components.

BenefitsContent extracted from patent full text and abstract with AI.

• Significantly reduces the number of post-processing steps and finishing operations, saving time and cost.
• Enables a high degree of design freedom for the final shape, textures, and integrated features of the part.
• Supports high natural fiber content, making components more environmentally friendly and sustainable compared to traditional plastics.
• Allows for integrated addition of fastening elements and reinforcements exactly where needed, improving mechanical performance and assembly.
• Provides finished surface appearance and tactile qualities (such as soft touch or specific patterns) directly from the mold, enhancing product quality.

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Patent Abstract

A process is described for producing a lightweight component comprising natural fibres (FRP component), which has a visible side and a fastening side. In order to manufacture a lightweight FRP component with a high degree of design freedom, any desired type of surface, and substantially reduced cost for downstream operations, the following production steps are proposed according to the invention: a) insertion of a semifinished natural fibre product into an injection mould, b) a pressing and/or forming process, and also consolidation of the semifinished natural fibre product, to give a moulding in the injection mould, c) injection to add functional elements, in particular fastening elements, and/or reinforcing structures, onto the moulding on the fastening side of the lightweight component, into unoccupied spaces in the injection mould, the functional elements, in particular the fastening elements and/or the reinforcing structures being injected only onto a portion of the area of the fastening side, and d) applying the surface component in a prescribed region of the visible side of the moulding.