Pre-assembled Inner Garnish Module for Automotive Door Assembly
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Solution Overview
Problem
The assembly of automotive vehicle components is costly and complex, requiring multiple operators and separate attachment points, which increases production costs and tolerance stack-up issues, while also affecting the vehicle's appearance and fit.
Innovation Solution
An inner garnish assembly module system that integrates an inner garnish trim, primary door seal, glass seal, and inner beltline weatherstrip as a pre-assembled unit, where the components are mechanically or adhesively secured together before installation, reducing the number of parts and operators needed, and incorporating an anti-trap sensor/switch for enhanced safety and aesthetics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple separate components (primary seal, glass run, inner belt, garnish) are assembled individually on the vehicle assembly line, then each component can be installed independently, but the number of operators and attachment points increases significantly, raising production costs and complexity
Solution Approach 1:
The patent combines multiple separate components (primary seal, glass run, inner belt, and garnish) into a single pre-assembled module. This module is then installed as one unit on the vehicle, reducing the number of operators and attachment points required while maintaining the functional integrity of each individual component.
Solution Approach 2:
The components are pre-assembled into a module before being supplied to the OEM for final installation. This preliminary assembly step allows for better quality control and tolerance management while simplifying the final vehicle assembly process by reducing the number of installation steps required.
2Manufacturing precision
If multiple separate components are assembled individually, then each component can be optimized independently, but tolerance stack-up issues arise and the overall fit and appearance deteriorate
Solution Approach 1:
By combining multiple components into a single pre-assembled module, the patent eliminates tolerance stack-up issues that would arise from assembling multiple separate components. The module is manufactured as an integrated unit with controlled internal tolerances, ensuring consistent fit and appearance when installed on the vehicle.
3Strength
If multiple attachment points are used for separate components, then each component can be securely fastened, but the vehicle structure becomes more complex and costly
Solution Approach 1:
The patent reduces the number of attachment points required by combining multiple components into a single module. The module uses a minimized set of attachment points with enhanced fastening mechanisms to secure all integrated components, thereby simplifying the vehicle structure while maintaining secure attachment.
4Productivity
If separate components are assembled on the assembly line, then flexibility in installation is maintained, but assembly time and labor costs increase significantly
Solution Approach 1:
The components are pre-assembled into a module before being supplied to the OEM. This preliminary assembly reduces the time required during final vehicle assembly, as the entire module can be installed in one operation rather than requiring multiple separate installation steps for each component.
Solution Approach 2:
By combining multiple components into a single module, the patent reduces the number of assembly operations required on the vehicle assembly line. This merging of components directly reduces assembly time and labor costs while improving productivity.
Data Source
AI summary
A one-piece inner garnish assembly module system (MS) joins an inner garnish molding (IG), primary seal (PS), glass run (GR), and inner beltline weatherstrip (IB) into a single component prior to installation of the module system on a vehicle. The garnish is secured to the glass run along the A and B pillars, and the interconnecting header portion of a vehicle door. In addition, the primary seal is operatively associated or secured to the garnish, and may be pin-mounted to the door, or mechanically connected, and/or adhesively secured to the door.