Air Deflector Molded Part Plastic Deformation Sections
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Solution Overview
Problem
Existing air guiding devices for motor vehicles, such as wind deflectors, face issues with large manufacturing tolerances and deformation during the injection molding process, leading to inaccurate dimensional accuracy and potential exposure of metal inserts in the overmolded plastic layer.
Innovation Solution
A structure-reinforcing molded part with strategically introduced plastic deformation sections, achieved through embossing, to maintain specified geometric dimensions and reduce elastic restoring forces, ensuring accurate dimensional accuracy and cost-effective mass production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a metal bracket is used as a structure-reinforcing molded part for the exhibitor or base part, then the deflector element can be attached before injection molding, but the metal bracket has relatively large component tolerances and undergoes flexible deformation during injection molding, leading to deformation of the overmolded exhibitor or base part
Solution Approach 1:
The patent changes the material parameter from metal to plastic for the structure-reinforcing molded part. This plastic material has different mechanical properties that prevent the flexible deformation and elastic restoring forces experienced by metal brackets during injection molding, thereby maintaining dimensional accuracy while still providing the necessary attachment capability for the deflector element
Solution Approach 2:
The patent uses a composite structure where a plastic molded part with embedded reinforcement elements (such as fiberglass or metal inserts) combines the attachment capability of metal with the dimensional stability of plastic. This composite approach allows the part to be firmly attached to the deflector element while resisting deformation during the injection molding process
2Strength
If a metal bracket is overmolded with thermoplastic elastomer, then the deflector element can be fixed, but elastic restoring forces occur during injection molding that deform the overmolded metal bracket and change wall thickness
Solution Approach 1:
The patent changes the material parameter from metal to plastic for the structure-reinforcing molded part. This plastic material has different mechanical properties that prevent the flexible deformation and elastic restoring forces experienced by metal brackets during injection molding, thereby maintaining dimensional accuracy while still providing the necessary attachment capability for the deflector element
Solution Approach 2:
The patent incorporates reinforcement elements (such as fiberglass matting or metal inserts) within the plastic molded part before injection molding. These reinforcement elements act as a cushioning structure that prevents wall thickness changes and maintains dimensional stability during the injection molding process, while still allowing the deflector element to be firmly attached
3Productivity
If the metal insert rests against the injection mold during injection molding, then the molding process can proceed, but areas of the metal insert become visibly exposed on the overmolded plastic layer
Solution Approach 1:
The patent changes the material parameter from metal to plastic for the structure-reinforcing molded part. This plastic material has different mechanical properties that prevent the flexible deformation and elastic restoring forces experienced by metal brackets during injection molding, thereby maintaining dimensional accuracy while still providing the necessary attachment capability for the deflector element
Solution Approach 2:
The patent incorporates reinforcement elements (such as fiberglass matting or metal inserts) within the plastic molded part before injection molding. These reinforcement elements act as a cushioning structure that prevents wall thickness changes and maintains dimensional stability during the injection molding process, while still allowing the deflector element to be firmly attached
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 improved dimensional accuracy and reduced manufacturing tolerances, maintaining consistent wall thicknesses and optimizing production efficiency and cost savings by compensating for elastic deformations and bending moments in the molded part.
Implementation Method 1
the molded part has a large number of deformation sections spaced apart from one another, which can each be produced by local plastic deformations of the molded part
Implementation Method 2
the flexurally elastic restoring forces inherent in the molded part can be equalized
Data Source
AI summary
The present invention relates to a structurally reinforcing molded part for an air guide device (10) of a motor vehicle, which has a partially curved profile and which, in order to maintain predetermined geometric outer contours and geometric tolerances, has a plurality of spaced-apart plastically deformed deformation sections (42, 44; 46, 48). The invention also relates to an air guide device, preferably designed as a wind deflector, which has a dimensionally accurate molded part.