Foldable Valve Cover Structure for Single-Station Acoustic Assembly
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Solution Overview
Problem
The manufacturing of covers for pressure-limiting valve arrangements in vehicles is complex and costly due to the need for separate steps and stations for producing the three-dimensional structure and applying sound absorption materials.
Innovation Solution
A cover is designed as a flat injection molded component that can be folded into a three-dimensional shape, allowing for the integration of sound absorption materials in a single manufacturing step, reducing the need for multiple stations and simplifying the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a three-dimensional cover structure is manufactured as an injection molded component, then the cover can provide the necessary silencer space, but the manufacturing complexity and costs increase due to requiring separate working stations for producing the housing and applying sound absorption materials
Solution Approach 1:
The cover is divided into a flat injection molded housing component and sound absorption material that are separately manufactured but integrated in a single working station, allowing independent optimization of each component while simplifying the overall manufacturing process
Solution Approach 2:
The manufacturing process merges the housing production and sound absorption material application into a single working station, eliminating the need for separate stations and reducing manufacturing complexity while maintaining the three-dimensional silencer space structure
2Productivity
If sound absorption materials are applied in a separate working step at different manufacturing stations, then the housing can be injection molded efficiently, but the overall manufacturing costs and installation outlay increase
Solution Approach 1:
The housing injection molding and sound absorption material application are combined in a single working station, allowing both operations to be performed simultaneously or sequentially without moving the component between stations, thereby reducing installation outlay and overall manufacturing costs while maintaining high productivity
3Ease of manufacture
If the cover is designed as a flat injection molded component that is folded into a three-dimensional shape, then sound absorption materials can be applied automatically in a single working station, but the manufacturing process requires a complex folding transformation
Solution Approach 1:
The housing is pre-formed as a flat injection molded component with integrated folding features and attachment points, allowing the folding into three-dimensional shape and sound absorption material application to occur in a single working station without requiring complex preliminary preparations
Solution Approach 2:
The flat injection molded housing is designed as a flexible structure that can be folded into a three-dimensional shape, enabling the transformation from flat to volumetric form while maintaining structural integrity and allowing automatic sound absorption material application during the folding process
Data Source
AI summary
A cover (1) for a pressure-limiting valve arrangement of a vehicle, wherein the cover (1) has at least one side wall (2a, 2b, 2c), preferably at least two side walls, and has a wall region (3) serving as a lid region of the cover (1), wherein the cover (1) is transferable from a state of manufacture into a state of use, wherein, in the state of manufacture, the at least one side wall (2a, 2b, 2c) and the wall region (3) serving as a lid region are situated at least substantially and/or at least regionally in a common plane, and wherein, in the state of use, the at least one side wall (2a, 2b, 2c) and the wall region (3) serving as a lid region are situated in mutually different planes.