Injection Moulded Panel Integrally Molded Mounting Members
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing injection moulded panels for vehicle interiors require complex and material-intensive mounting systems, often necessitating multiple components and orientations, which can lead to incorrect mounting and increased complexity.
Innovation Solution
An injection moulded panel with integrally moulded mounting members, including a detent and resilient clip, that apply a biasing force to secure low mass articles in a snap-fit configuration, allowing single-handed mounting without additional fasteners and ensuring correct orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If integrally moulded support lugs and screw connections are used to secure articles to the panel, then the mounting is secure and reliable, but the material usage increases significantly and the manufacturing complexity increases
Solution Approach 1:
The mounting system is divided into separate functional elements: mounting lugs that provide structural support and resilient clips that provide securing force. This segmentation allows each component to be optimized independently, reducing overall material usage while maintaining mounting security through the distributed function of multiple smaller elements rather than one large complex structure
Solution Approach 2:
The mounting system transitions from rigid screw connections to a compliant resilient clip mechanism. By changing the mechanical parameter from rigid to elastic, the system achieves reliable mounting through elastic deformation and recovery, using less material while maintaining secure attachment through the biasing force of the resilient elements
2Reliability
If screw fasteners are used to mount articles to the panel, then secure attachment is achieved, but the number of components increases and the mounting process becomes more complex
Solution Approach 1:
The mounting lug and resilient clip are combined into a single integrally moulded unit on the panel. This merging eliminates the need for separate screw fasteners and multiple discrete components, reducing the overall component count while maintaining secure attachment through the integrated structure that combines support and securing functions in one element
Solution Approach 2:
The resilient clip mechanism is self-contained and self-actuating. The elastic deformation of the resilient element automatically provides the securing force without requiring external fasteners or additional components. The system serves itself by using the inherent elastic properties of the moulded material to create the mounting force, eliminating the need for separate screw fasteners
3Adaptability or versatility
If multiple mounting orientations are allowed, then mounting flexibility is improved, but the risk of incorrect mounting increases
Solution Approach 1:
The mounting lugs and resilient clips are positioned asymmetrically on the panel, creating a unique geometric relationship between the mounting features and the article. This asymmetric arrangement provides mounting flexibility for different article positions while simultaneously preventing incorrect orientations, as the asymmetric features only align correctly in one specific orientation, ensuring mounting correctness
4Reliability
If traditional screw mounting is used, then secure attachment is achieved, but the mounting process requires two hands and support jigs, reducing productivity
Solution Approach 1:
The resilient clip mechanism is self-contained and self-actuating. The elastic deformation of the resilient element automatically provides the securing force without requiring external fasteners or additional components. The system serves itself by using the inherent elastic properties of the moulded material to create the mounting force, eliminating the need for separate screw fasteners
Solution Approach 2:
The resilient clips are pre-formed during panel manufacturing with built-in elastic energy stored in their curved geometry. This preliminary action during moulding creates the mounting force in advance, so that during assembly the article simply needs to be inserted and the pre-stored elastic energy automatically secures it, eliminating the need for manual screw tightening and support jigs
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 material usage, simplifies the mounting process, eliminates the need for jigs, and ensures secure, single-orientation attachment of articles, minimizing the risk of incorrect fitment and reducing the number of components required.
Implementation Method 1
a resilient clip engageable with a second mounting portion of the mounted article... configured in use to generate a biasing force acting generally in a second direction opposite the first direction when biased inwardly towards the detent
Data Source
AI summary
Panel 100 (Fig. 3) has an integrally moulded mounting 102 for securing an article 1 to the panel. Mounting 102 comprises a pair of spaced mounting members 104, 106 for engagement with the article. At least one of the mounting members 106 applies a resilient biasing force to article 1 so as to hold the article in engagement with other mounting member 104. One of the mounting members 104 may be a generally hook-shaped detent for engagement in an aperture 12 in the article and the other may be a resilient arm for engagement in a further aperture 12'. The mounting may be configured such that the article can only be secured to the panel in a single orientation ("poka-yoke" or mistake-proof assembly). The mounting may also be configured to secure the article to the panel with a "snap" fit. Application may be vehicle dash panel.