Inner Belt Hook Interlock for Trim Panel Attachment
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Solution Overview
Problem
Current vehicle door window assembly methods using metal clips for attaching inner belt weatherstrips and trim panels are prone to corrosion, add weight, and require complex assembly processes, leading to misalignment and increased costs.
Innovation Solution
A U-shaped inner belt with rigid hooks that interlock with the trim panel, eliminating the need for metal clips by using a locking datum feature to secure the components together, reducing weight and assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal clips are used to secure the inner belt and trim panel together, then the components can be firmly attached, but the assembly becomes prone to corrosion and gains unwanted weight
Solution Approach 1:
The patent removes metal clips from the assembly entirely and replaces them with an integrated plastic attachment system. The inner belt and trim panel are designed with complementary attachment features (protrusions and recesses) that interlock without requiring separate metal fasteners, thereby eliminating corrosion susceptibility while maintaining attachment strength.
Solution Approach 2:
The patent employs a composite construction where the inner belt and trim panel are made from different plastic materials with complementary properties. The attachment features are molded directly into these plastic components, creating a corrosion-free composite assembly that maintains structural integrity without metal fasteners.
2Strength
If metal clips are used to secure the inner belt and trim panel, then the components can be firmly attached, but the overall assembly weight increases
Solution Approach 1:
The patent eliminates metal clips from the assembly and replaces them with lightweight plastic attachment features that are molded directly into the inner belt and trim panel. This extraction of heavy metal components significantly reduces overall assembly weight while maintaining adequate attachment strength through the integrated plastic interlocking system.
Solution Approach 2:
The patent changes the material parameter from metal to plastic for the attachment features, which fundamentally alters the weight characteristic. The plastic materials used have significantly lower density than metal, thereby reducing assembly weight while the geometric design of the attachment features compensates to maintain sufficient attachment strength.
3Strength
If clips are deformed to secure the inner belt and trim panel together, then the components can be firmly attached, but the assembly process becomes time-consuming and expensive
Solution Approach 1:
The patent divides the attachment function into separate molded features on the inner belt and trim panel components. These pre-formed attachment features (protrusions and recesses) are created during the molding process itself, eliminating the need for post-assembly deformation operations and enabling rapid assembly through simple interlocking.
Solution Approach 2:
The attachment features are pre-formed during the molding process of the inner belt and trim panel components, rather than being created during assembly. This preliminary action of forming the attachment geometry in advance eliminates time-consuming deformation operations and speeds up the assembly process while maintaining attachment strength.
4Ease of manufacture
If separate assembly steps are used for the inner belt and trim panel, then each component can be manufactured independently, but the manufacturing cost and complexity increase
Solution Approach 1:
The patent merges the attachment function into the basic structure of the inner belt and trim panel components themselves. The attachment features are integrated into the molded parts rather than being separate elements, which simplifies the overall assembly process while allowing the components to remain independently manufacturable through standard molding processes.
Data Source
AI summary
An inner belt is received on an associated vehicle flange. A U-shaped gripping portion of the inner belt is formed by first and second legs dimensioned for receipt on opposite faces of the flange. Rigid spaced hooks extend from a body of the inner belt and form upturned cavities that engage with similar hook portions formed on an associated inner trim panel. An end datum feature constrains longitudinal movement between the inner belt and the inner trim panel, while cooperating horizontal leg portions of both the inner belt and inner trim panel restrain the components from relative vertical movement.