Integrated Composite Conduit for Faster Vehicle Tubing Assembly
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Solution Overview
Problem
The assembly of tubing, such as for windshield wiper fluid, onto vehicle components like liftgates using mechanical fasteners increases manufacturing complexity and assembly time.
Innovation Solution
Integration of a conduit with vehicle components during an over molding process, where tubing material is encapsulated by resin, potentially surrounded by foam, to form an integrated conduit that protrudes from the component's surface, simplifying the manufacturing process and reducing assembly time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tubing is attached to vehicle components using mechanical fasteners, then the tubing can be securely connected, but the manufacturing complexity and assembly time increase
Solution Approach 1:
The patent merges the tubing attachment function directly into the vehicle component structure by forming an integrated conduit as part of the molded component. This eliminates the need for separate mechanical fasteners and reduces assembly steps while maintaining secure connection through the molded integration of the conduit into the component body.
Solution Approach 2:
The molded conduit serves multiple functions: it provides the fluid passage, acts as its own mounting structure, and integrates with the vehicle component as a unified element. This multi-functionality eliminates the need for separate fastening mechanisms while ensuring reliable connection.
2Reliability
If tubing is attached using mechanical fasteners, then the connection can be secured, but the assembly time increases
Solution Approach 1:
The tubing and vehicle component are merged into a single integrated unit through the molded conduit. This eliminates separate assembly steps for attaching fasteners and reduces assembly time while maintaining secure connection through the integrated structure.
Solution Approach 2:
The conduit is pre-formed as an integral part of the vehicle component during the molding process, before assembly. This preliminary integration eliminates the need for subsequent fastening operations and significantly reduces assembly time.
3Productivity
If tubing is integrated during over molding process, then manufacturing complexity and assembly time are reduced, but the tubing must be securely encapsulated in resin
Solution Approach 1:
The molding process applies different properties to different regions: the conduit area receives precise resin encapsulation to secure the tubing, while other areas of the component maintain their standard molded structure. This localized precision ensures proper tubing encapsulation without compromising overall manufacturing efficiency.
Solution Approach 2:
The integrated conduit structure combines the tubing material with the resin matrix in a composite arrangement. The resin encapsulates and secures the tubing while maintaining the structural integrity of the overall component, achieving both manufacturing efficiency and encapsulation precision.
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
This method reduces manufacturing complexity and assembly time by embedding tubing within the vehicle component, ensuring secure and efficient integration of fluid and electrical conduits without the need for additional fasteners, enhancing the manufacturing efficiency and product integration.
Implementation Method 1
the tubing material is encapsulated by the resin and formed integrally with the composite component
Implementation Method 2
the tubing material is surrounded by a foam material, and the tubing material and the foam material are over molded with the first surface
Data Source
AI summary
An injection molded composite component includes a groove extending from a first surface of the composite component and a tubing material placed within the groove and formed integrally with the composite component such that the tubing material forms an integrated conduit on the first surface of the composite component.