Integrated Injection Molded Slider for Vehicle Roof Pivoting
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Solution Overview
Problem
Existing vehicle roof mechanisms are complex and costly, requiring multiple components and additional coupling elements for reliable pivoting, which complicates assembly and increases production costs.
Innovation Solution
A method involving a deployment lever and a plastic slider formed by injection molding, where the plastic slider is coupled to the deployment lever without additional components, allowing for reliable pivoting and a cost-effective, space-saving guide mechanism for opening and closing vehicle roofs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional guide mechanisms with separate rotating elements and coupling elements are used, then reliable pivoting is achieved, but device complexity and production cost increase
Solution Approach 1:
The patent combines the rotating element and coupling element into a single integrated plastic component formed by injection molding. The deployment lever and plastic guide rail are molded together as one piece, eliminating the need for separate rotating elements and coupling elements. This merging maintains reliable pivoting functionality while significantly reducing the number of parts and assembly steps.
Solution Approach 2:
The plastic guide rail component serves multiple functions simultaneously: it acts as both the guide mechanism and the coupling element, while also providing the rotating functionality. This multi-functional design eliminates the need for separate dedicated components for each function, reducing overall device complexity.
2Reliability
If multiple separate components and coupling elements are used, then reliable connection is achieved, but assembly process complexity increases
Solution Approach 1:
The injection molding process creates a single integrated component where the deployment lever and plastic guide rail are formed as one piece. This eliminates multiple separate components that would need to be assembled, dramatically simplifying the assembly process while maintaining connection reliability through the integral design.
Solution Approach 2:
The injection molding process itself creates the functional connection between components during manufacturing, eliminating the need for separate assembly operations. The plastic material is molded directly onto the deployment lever, creating a self-contained unit that requires no additional assembly steps for connection.
3Strength
If additional coupling elements like bolts or rivets are used, then secure attachment is achieved, but production cost increases
Solution Approach 1:
The deployment lever and plastic guide rail are formed as a single integrated component through injection molding, eliminating the need for separate coupling elements like bolts or rivets. The integral design provides inherent attachment strength through the molded joint, while reducing production costs by eliminating additional fasteners and their associated assembly operations.
Solution Approach 2:
The injection molding process creates the structural connection during the primary manufacturing operation itself, without requiring subsequent fastening operations. The plastic material is molded directly onto the deployment lever, creating a self-contained attachment that eliminates the need for separate coupling elements.
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 method simplifies the assembly process and reduces production costs by eliminating the need for separate coupling elements, enabling a reliable and efficient mechanism for opening and closing vehicle roofs using only two rotating elements.
Implementation Method 1
applying the substance by injection molding at a predetermined position on the second end of the first element, thereby forming a second element
Implementation Method 2
The supplied substance has predefined material properties that ensure the plastic glider does not adhere to the release lever or can be easily removed. The plastic glider is made from a material combination of polyamide and carbon fiber and advantageously exhibits low friction with regard to adjacent surfaces
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A method for producing an arrangement (10) for a roof (3) for a vehicle roof (2) comprises providing a first element (12) and providing a pumpable substance with predetermined material properties. The method further comprises applying the provided substance by means of injection moulding at a predetermined position at a second end (14) of the first element (12) and thereby forming a second element (16) such that the second element (16) is coupled to the first element (12) and is pivotable relative to the first element (12) about an axis of rotation (A).