One-Piece Cast Component Integrated Pivotable Attachment
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Solution Overview
Problem
Existing methods for creating pivotable attachments in cast components, such as film hinges, often result in unstable and costly solutions, particularly in plastic components, where achieving a long-term, durable pivotable connection is challenging due to material and manufacturing complexities.
Innovation Solution
A one-piece cast component with an integrated pivotable attachment featuring an axle rigidly connected to the housing via axial and radial connecting webs that break at predetermined points, allowing the attachment to pivot freely while remaining securely attached, and an optional locking mechanism for holding specific positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If film hinges are used to create pivotable attachments in plastic components, then the attachment can pivot, but the solution becomes unstable and costly due to material selection and manufacturing parameter adjustments
Solution Approach 1:
The connecting web is segmented into a breakable portion and a remaining portion. The breakable portion allows the attachment to pivot by breaking at a predetermined point, while the remaining portion stays attached to the housing to prevent complete separation. This segmentation enables the attachment to transition from a rigid one-piece structure to a pivotable joint.
Solution Approach 2:
The connecting web is pre-designed with a predetermined breaking point during the molding process. The dimensions and material properties are selected in advance so that the web breaks at the correct moment when the attachment pivots, eliminating the need for complex adjustment of material and manufacturing parameters during production.
2Ease of operation
If elastomers are used for movable elements in articulated attachments, then the attachment can pivot, but the cost increases significantly
Solution Approach 1:
The entire component including the attachment and housing is molded from the same material without using elastomers or different materials. This homogeneous material approach eliminates the need for expensive elastomeric movable elements while still achieving the desired pivotable functionality through the breakable connecting web design.
3Device complexity
If the attachment is rigidly connected to the housing, then the structure is simple, but the attachment cannot pivot
Solution Approach 1:
The connecting web transitions from a static rigid connection to a dynamic pivotable joint through controlled breaking. Initially, the web maintains a rigid connection for structural simplicity, but when the attachment pivots, the web breaks at the predetermined point to create a movable joint, combining the benefits of both rigid and articulated structures.
4Reliability
If the connecting webs are made strong to prevent axle removal, then the attachment remains secure, but the web cannot break to allow pivoting
Solution Approach 1:
The connecting web has different local properties: the breakable portion is designed with specific dimensions and material characteristics that allow it to break at a predetermined point, while the remaining portion maintains sufficient strength to prevent axle removal. This local differentiation enables both pivoting and secure attachment functions.
Data Source
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AI summary
The invention relates to a one-piece cast component (10) having at least one integrated attachment part (12), comprising at least one pin (20) which is rigidly connected to the attachment part (12); a housing (22) at least partially enclosing the pin (20) in a contactless manner; the pin (20) being arranged in the axial direction between two axial connecting webs (26) and being rigidly connected via the latter to the housing (22); the pin (20) being arranged in the radial direction between a plurality of radial connecting webs (34) and being rigidly connected via the latter to the housing (22); wherein the connecting webs (26, 34) are dimensioned in such a way that only the latter break at respective predetermined breaking points when pivoting the attachment part (12) for the first time relative to the housing (22), whereafter the attachment part (12), together with the pin (20), is mounted so as to be pivotable with respect to the housing (22), wherein the regions of the connecting webs that remain on the housing (22) after the breaking operation prevent the pin (20) from being removed from the housing (22). The invention further relates to a method for producing such a cast component (10) having an integrated attachment part (12).