Integrated Retainer Front Frame for Sunroof Deflector Assembly
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Solution Overview
Problem
The existing deflector mechanisms for sunroof apparatuses in vehicles are complex to assemble and costly due to the large number of components, particularly because the retainer is a separate entity from the frame and requires additional fixing steps.
Innovation Solution
A deflector mechanism where the retainer is formed integrally with the resin-made front frame, reducing the number of parts and eliminating the need for separate fixing, with the retainer also serving as a stopper for the sunshade panel, thereby simplifying assembly and reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the retainer is made as a separate component from the frame and fixed using bolts and nuts, then the structural strength and reliability are improved, but the number of parts increases, assembling complexity increases, and production cost increases
Solution Approach 1:
The retainer is integrated into the front frame as a unified component. The front frame includes a retainer portion that forms the retainer functionally, eliminating the need for a separate retainer component. This merging reduces the number of parts while maintaining structural integrity through the unified design of the front frame.
Solution Approach 2:
The front frame serves multiple functions: it provides structural support, guides the deflector mechanism, and includes an integrated retainer portion that performs the retention function. This multi-functionality consolidates several components into one, reducing assembly complexity while maintaining reliability.
2Reliability
If the retainer is made as a separate component and fixed with bolts and nuts, then the assembly is more robust and reliable, but the assembling process becomes more complex and time-consuming
Solution Approach 1:
The retainer and front frame are combined into a single integrated component. The front frame includes a retainer portion that is formed as part of the frame structure, eliminating the need for separate assembly steps involving bolts and nuts, thereby speeding up the assembling process while maintaining assembly robustness.
Solution Approach 2:
The retainer portion is pre-integrated into the front frame during frame manufacturing. This preliminary integration means that during final assembly, the retainer is already in place and properly positioned, eliminating the need for separate retainer installation steps and reducing overall assembly time.
3Ease of repair
If the retainer is made as a separate component requiring bolt and nut fixation, then the ease of repair and replacement is improved, but the production cost and number of parts increase
Solution Approach 1:
The retainer is integrated into the front frame, reducing the total number of parts that need to be manufactured, inventoried, and assembled. This integration simplifies the manufacturing process and reduces production costs while the modular front frame design still allows for efficient repair and replacement of the entire assembly if needed.
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 configuration reduces the number of parts and assembly steps, lowers production costs, and enhances the assembly process by integrating the retainer with the front frame, while also providing dual functionality as a fastener and stopper for the sunshade panel.
Implementation Method 1
urging means (coil springs) which are provided across the deflector and respective retainers and which urge the deflector upwardly
Data Source
AI summary
There is provided a deflector mechanism for a sunroof apparatus which can reduce the number of parts, assembling processes, and a production cost. The sunroof apparatus includes a pair of guide rails provided at both sides of an opening formed in a roof of a vehicle in a widthwise direction, a sunroof panel which slides along the guide rails, a resin-made front frame which interconnects front ends of the guide rails, and a deflector mechanism which ascends/descends along a front edge of the opening of the vehicle. The deflector mechanism includes a deflector including a pair of arms and a blade that connects these arms together, a pair of support members each of which supports a basal end of each arms, a retainer formed at a front frame, and an urging means which urges the deflector upwardly, and the retainer is formed together with the front frame.