Cover Anchor Clip Structure for Weld-Line Breakage Resistance
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Solution Overview
Problem
Existing cover anchor clips are prone to damage at weld lines formed during the injection molding process, which can lead to breakage under external load due to weld lines extending in the same direction around through holes.
Innovation Solution
Incorporating a plate thickness changing portion between the gate mark and through holes, shaped as a curved line, straight line, or angular portion, to ensure weld lines extend in different directions, thereby reducing the likelihood of clip damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If through holes are formed in the base section for foam body retention, then the clip can be retained in the foam body, but weld lines develop around the through holes and the clip becomes liable to break under external load
Solution Approach 1:
The base section is designed with a curved surface instead of a flat plate, creating a three-dimensional domed structure. This curvature redistributes stress away from the weld lines around the through holes, preventing stress concentration and reducing the likelihood of breakage while maintaining foam body retention through the holes.
Solution Approach 2:
The base section is given different thicknesses at different locations, with greater thickness at critical areas around the through holes. This local reinforcement strengthens the weld line regions without adding unnecessary weight or complexity elsewhere, directly addressing the breakage vulnerability at specific locations.
2Strength
If the base section is made thicker to prevent breakage, then strength increases, but manufacturing complexity and material usage increase
Solution Approach 1:
The curved, domed shape of the base section provides structural strength through its geometry rather than requiring uniform thickness increases. The arch-like structure naturally distributes loads, achieving high strength-to-weight ratio and simple manufacturing through a single molded piece.
Solution Approach 2:
Instead of making the entire base section uniformly thick, the design applies localized thickness variations only where needed for strength. This maintains manufacturing simplicity while providing reinforcement at critical stress points, avoiding unnecessary material usage and complexity.
Data Source
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AI summary
A cover anchor clip (10) comprising a base section (14) having a plate shape extending in one direction, that is formed with through holes (36, 38) into which a foam body enters, and that is configured to be retained in the foam body; and an anchor portion (34) including a pair of extension portions (50) that extend upward from a surface of the base section (14) and that are disposed facing each other, and a pair of anchor claws (52) that are formed at respective leading ends of the pair of extension portions (50), and that are configured to anchor an anchored member (118) attached to a cover for covering the foam body by sandwiching the anchored member (118) therebetween. The through holes (36, 38) formed at the base section (14) are aligned in the one direction, and a plurality of hole-rows (46, 48) formed by the through holes (36, 38) aligned in the one direction are separated by a spacing in an intersection direction intersecting the one direction. A gate mark (40) that indicates an injection port for resin material during molding being formed at the back face of the base section (14) between adjacent hole-rows of the hole-rows (46, 48). A plate thickness changing portion (42, 44, 142, 144) at which a thickness of the base section changes being formed between the gate mark (40) and the through holes (36, 38), as viewed from a back face of the base section along a plate thickness direction of the base section (14).