Integrated Carrier Plate and Conductor Structure for Motor Vehicle Door Locks

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Solution Overview

Problem

The separate production of carrier plates and conductor structures for motor vehicle door lock component carriers incurs increased costs and is error-prone due to separate transportation and electrical contacting processes.

Innovation Solution

A combined plastic injection and metal casting process is used to produce the component carrier, integrating the conductor structure and carrier plate in a single injection-molding tool, followed by sealing with a potting compound for protection and durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If separate production of carrier plate and conductor structure is used, then manufacturing flexibility is maintained, but production costs increase and manufacturing complexity increases

Engineering Contradiction:

Improveproduction costVSAvoidmanufacturing process complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent combines the production of the carrier plate and conductor structure into a single integrated injection molding process. The mold includes both a cavity for the carrier plate and a separate injection unit for the conductor structure, allowing both components to be manufactured simultaneously as one piece, thereby reducing production costs and eliminating separate assembly steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The injection molding tool is designed with multi-functionality, serving both to produce the carrier plate and to form the conductor structure within the same tool. This universal tooling approach eliminates the need for separate production lines and reduces overall manufacturing complexity despite the integrated nature of the process.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If separate production and transportation of conductor structure and carrier plate is used, then production flexibility is maintained, but error-proneness increases and productivity decreases

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidassembly error rate

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

By integrating the production of both components in one process, the patent eliminates the transportation and separate assembly steps that lead to errors. The conductor structure and carrier plate are formed together in the same mold, ensuring proper alignment and connection without manual intervention, thus improving both productivity and reliability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The conductor structure is pre-formed within the mold cavity during the same injection process that creates the carrier plate. This preliminary formation ensures that the conductor structure is already in its final position and configuration before the carrier plate solidifies, preventing assembly errors and reducing rework.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If integrated production process is used, then production costs are reduced, but manufacturing precision requirements increase

Engineering Contradiction:

Improveproduction costVSAvoidmold design precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The integrated mold is segmented into distinct functional zones: a cavity for the carrier plate and a separate injection unit for the conductor structure. This segmentation allows each zone to be optimized independently for its specific requirements while maintaining overall integration, thereby managing precision requirements without sacrificing the cost benefits of integrated production.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs parameter changes in the injection molding process, such as controlling injection pressure, temperature, and timing, to ensure that both the carrier plate and conductor structure are formed with the required precision simultaneously. By adjusting these parameters, the process achieves high manufacturing precision while maintaining the cost advantages of integrated production.

Inventive Principle:

Principle #35Parameter changes

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 integrated process reduces production costs and manufacturing effort, providing a mechanically stable and durable component carrier that is protected from environmental influences, while eliminating the need for separate production and assembly steps.

Implementation Method 1

the conductor structure and the carrier plate are produced in a combined plastic injection and metal casting process

Methodology Applied

Scientific EffectMetal casting: Melting

Implementation Method 2

the carrier plate is usually produced in a plastic injection mold

Methodology Applied

Scientific EffectPlastic injection:

Implementation Method 3

the carrier plate including the conductor structure and with the electrical/electronic components mounted thereon are sealed by means of a potting compound

Methodology Applied

Scientific EffectSealing:

Data Source

PatentUS11401740B2Component carrier for electrical/electronic parts for attachment in a motor vehicle door lock

Publication Date: 2022.08.02 KIEKERT AG

AI summary

A component carrier for electrical/electronic parts for attachment in a motor-vehicle door lock. Said component carrier is equipped with at least one carrier plate of plastic and with a metal conducting-track structure for electrically contacting the parts. According to the invention, the conducting-track structure and the carrier plate are produced in a combined plastic injection-molding and metal casting method.