Integrally Formed Blow Molded Bracket With Living Hinge
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Solution Overview
Problem
Conventional methods for mounting brackets on blow molded components, such as air intake ducts and air filter housings, require additional steps and materials, increasing production costs and cycle times.
Innovation Solution
Integrally forming brackets during the blow molding process, using a mold with a living hinge and undercut features, allowing the bracket to rotate and lock securely onto the component, eliminating the need for separate bracket fabrication and attachment processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If brackets are separately fabricated and attached to blow molded components using conventional methods, then the brackets can be securely mounted, but additional materials and production steps are required, increasing production costs and cycle times
Solution Approach 1:
The bracket is integrated directly into the blow molded component as a single piece, eliminating separate fabrication and attachment steps. The mold includes a bracket portion that forms the bracket integrally with the main component body, and a latch portion that engages with the bracket to secure it during molding. This merging of the bracket into the component itself resolves the contradiction by achieving secure mounting without additional materials or post-molding assembly steps.
2Ease of manufacture
If brackets are separately fabricated and attached to blow molded components, then mounting functionality is achieved, but additional components and assembly steps are required, increasing device complexity
Solution Approach 1:
The bracket is formed as an integral part of the blow molded component, eliminating the need for separate bracket components. The mold design includes a bracket portion that creates the bracket structure and a latch portion that forms the securing mechanism, both as single-integrated features with the main component body. This integration reduces device complexity while maintaining mounting functionality.
3Reliability
If conventional attachment methods are used for brackets, then brackets can be secured to components, but additional materials such as glue, screws, or welding materials are required, increasing production costs
Solution Approach 1:
The bracket and its attachment mechanism are formed from the same material as the main component body in a single blow molding process. The mold includes a bracket portion and a latch portion that work together to secure the bracket integrally with the component, eliminating the need for separate adhesives, fasteners, or welding materials. This integration reduces production costs while maintaining reliable bracket attachment.
Data Source
AI summary
Blow molded plastic components are disclosed having integrally formed brackets, formed together with the component in the molding step. A method of blow molding is disclosed for integrally forming brackets onto a blow molded component. More specifically, the disclosures relates to a blow molded plastic component having a bracket formed integrally in the blow molding process and configured to rotate onto and lockably engage undercut features or lugs formed integrally on the outer surface of the blow molded component, all features formed during the molding process.