Vehicle Door Cladding With Living Hinge for One-Piece Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Vehicle door claddings increase manufacturing costs and assembly time due to their multi-part design, which complicates the process and raises costs.
Innovation Solution
A cladding design featuring a monolithic structure with a living hinge, formed by injecting multiple polymer portions through strategically activated gates in an injection molding process, allowing for a single-piece construction that couples to opposing sides of a vehicle component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a multi-part cladding design is used, then the cladding can effectively conceal edges and openings, but the manufacturing cost and assembly time increase
Solution Approach 1:
The patent merges multiple separate cladding parts into a single monolithic structure formed by one continuous polymer piece. The living hinge connects what would traditionally be separate components, allowing the entire cladding assembly to be manufactured as one piece through injection molding, thereby reducing manufacturing cost and eliminating assembly steps while maintaining the functional complexity of concealing edges and openings
2Productivity
If a multi-part cladding design is used, then the cladding can effectively conceal edges and openings, but the assembly time increases
Solution Approach 1:
The patent combines multiple cladding components into a single monolithic structure that attaches to the vehicle door in one assembly operation. The living hinge integrates what would be separate parts, allowing the entire cladding assembly to be installed as one piece, thereby reducing assembly time and improving productivity while preserving the functional complexity of the design
3Ease of manufacture
If a monolithic structure with living hinge is used, then manufacturing and assembly costs are reduced, but the structural complexity increases
Solution Approach 1:
The patent employs parameter changes in the injection molding process, specifically controlling the timing of gate activation and polymer injection rates. By activating gates at different times and adjusting injection parameters, the process manages the flow of polymer through the mold to create the living hinge structure with appropriate thickness and flexibility, thereby achieving the desired manufacturing precision despite the structural complexity
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 reduces manufacturing and assembly costs while maintaining durability and aesthetics, as the living hinge design effectively conceals edges and openings without the need for multiple parts.
Implementation Method 1
The first polymer portion, the second polymer portion, and the third polymer portion flow through the mold to form a monolithic structure
Data Source
AI summary
Aspects of the present disclosure related to a vehicle cladding. The cladding includes a first portion, a second portion, and a living hinge formed between the first portion and the second portion thereby forming a monolithic structure. The first portion and the second portion are operable to couple to opposing sides of a vehicle component.