Elastic Bridging Element for Small-Gap Light-Tight Assembly
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Solution Overview
Problem
Existing systems for bridging a gap between two adjacent components, such as a door trim and a door tube structure, face issues with tolerance compensation, high assembly forces, and light-tightness, particularly when trying to maintain a small gap dimension.
Innovation Solution
A system that uses an elastically formed bridging element with a specific thickness and deformability, featuring first and second abutment surfaces, to minimize the distance between components while allowing for tolerance compensation and low assembly forces, ensuring light-tightness even with a small gap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hard bridging element is used, then assembly forces are high and light-tightness cannot be guaranteed, but tolerance compensation is poor
Solution Approach 1:
The patent changes the material parameter of the bridging element from hard/rigid to elastic/compliant. This allows the bridging element to deform during assembly, reducing assembly forces while maintaining contact pressure for light-tightness. The elastic modulus and geometry are optimized to achieve both low assembly force and effective sealing.
Solution Approach 2:
The patent employs an elastic bridging element that functions as a flexible component. This flexible element can conform to tolerances and maintain sealing contact without requiring high assembly forces, directly resolving the contradiction between light-tightness and assembly force.
2Manufacturing precision
If an elastic bridging element is used, then tolerance compensation is good and assembly forces are low, but gap size increases
Solution Approach 1:
The patent optimizes the geometric parameters of the elastic bridging element, specifically its thickness and elasticity modulus, to achieve a balance between tolerance compensation capability and gap dimension. The thickness is carefully selected to provide sufficient compliance for tolerance absorption while limiting the maximum gap size.
Solution Approach 2:
The elastic bridging element is designed with sufficient elasticity to handle expected tolerance variations, but the geometry is constrained to prevent excessive gap formation. The element provides just enough compliance to accommodate tolerances without allowing excessive movement that would increase gap size.
3Reliability
If an elastic bridging element is used, then light-tightness is achieved, but gap dimension increases due to required tolerances
Solution Approach 1:
The patent carefully selects and optimizes the material and geometric parameters of the elastic bridging element to achieve light-tightness with minimal gap. The elasticity modulus, thickness, and profile geometry are optimized to provide sealing contact while maintaining a small nominal gap dimension.
Solution Approach 2:
The flexible bridging element maintains continuous contact with both components, ensuring light-tightness while its compliance allows it to function effectively in a smaller gap than rigid elements would require. The flexibility enables sealing without needing a large clearance.
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 system effectively maintains a small gap between components, reduces assembly forces, and ensures light-tightness, thereby improving the quality of the gap dimension while accommodating tolerances.
Implementation Method 1
the bridging element being formed elastically at least in some areas
Data Source
AI summary
A system for bridging a distance between two adjacent components is disclosed, the system including a first component and a second component arranged at a distance from the first component. The system further includes a bridging element arranged to bridge the distance between the first component and the second component. The bridging element may be elastic at least in certain regions and include a first region which is fastened to the first component. The bridging element further has a second region which has a first bearing surface extending towards the first component and a second bearing surface extending towards the second component. A thickness of the bridging element may be defined by the distance between the first contact surface and the second contact surface and selected such that the bridging element limits the distance to a minimum distance.