Shape Memory Window Encapsulation for Vehicle Body Fit
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Solution Overview
Problem
The existing vehicle window encapsulation structures face challenges in achieving a consistent adaption with vehicle environment members due to manufacturing tolerances and non-standardized designs, leading to inefficient production processes and product quality issues, including gaps and deformation over time.
Innovation Solution
Incorporating a memory alloy member in the vehicle window encapsulation structure that undergoes phase transitions at different temperatures to preset deformation amounts, allowing for precise adaptation to vehicle body environment members, reducing trial-and-error modifications and enhancing production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pre-deformation amount is reserved to absorb manufacturing tolerances, then adaption effect between tongue and vehicle environment member is improved, but product size fluctuates in wide range and standardization cannot be realized
Solution Approach 1:
The patent changes the material parameter from ordinary metal to shape memory alloy, which has unique thermodynamic properties allowing it to transform between austenite and martensite phases. This enables the tongue to automatically adjust its deformation state based on temperature, achieving both precise adaption and standardized design through material property utilization rather than experience-based pre-deformation
Solution Approach 2:
The shape memory alloy tongue performs self-adjustment through automatic phase transformation in response to temperature changes. The material itself serves the function of adapting to different manufacturing tolerances without requiring external intervention or manual reconfiguration, enabling standardized components to achieve customized fit automatically
2Manufacturing precision
If pre-deformation amount is determined by experience and evaluation, then adaption effect can be achieved through trial and error, but workload is large and delivery time cannot be controlled
Solution Approach 1:
The patent replaces the mechanical trial-and-error adjustment system with a thermodynamic system based on shape memory alloy phase transformation. Instead of mechanically modifying molds through milling, welding, or core replacement, the solution uses temperature-controlled phase transitions to achieve the desired deformation, dramatically reducing production time and eliminating iterative mold modifications
Solution Approach 2:
The patent utilizes the phase transition characteristics of shape memory alloy between austenite and martensite phases. During manufacturing, the alloy is heated to transform to austenite phase for easy molding, then cooled to transform to martensite phase where it exhibits superelasticity and can automatically adjust to absorb tolerance variations, eliminating the need for repeated trial and error
3Manufacturing precision
If multiple mold modifications are performed to achieve adaption, then attachment or gap meeting adaptation requirement can be achieved, but manpower and material resources are consumed and modification time cannot be determined
Solution Approach 1:
The patent performs preliminary action by pre-setting the shape memory alloy's transformation temperature and phase transition characteristics during material selection and initial molding. The tongue is designed with predetermined deformation capacity that automatically activates under specific temperature conditions, eliminating the need for subsequent mold modifications such as milling, repair welding, or surface descending
4Ease of manufacture
If conventional encapsulation structure is used, then manufacturing process is simple, but elasticity is lost due to aging and temperature change causing gap generation
Solution Approach 1:
The patent employs shape memory alloy, which is a composite material system combining multiple metal elements with specific crystal structures. This material integrates both the ease of manufacturing through conventional molding processes and superior reliability through its ability to retain elastic properties over time and across temperature variations, overcoming the limitations of ordinary metals that lose elasticity due to aging
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 memory alloy member enables the encapsulation structure to adapt seamlessly to vehicle body environment members, shortening production time, improving product quality, and ensuring consistent fit without repeated adjustments.
Implementation Method 1
the memory alloy member is deformable according to the preset deformation amount between a high-temperature phase shape and a low-temperature phase shape
Implementation Method 2
a memory alloy member disposed in the encapsulation member, wherein a deformation amount is preset for the memory alloy member
Data Source
AI summary
The present disclosure provides a vehicle window encapsulation structural member, a vehicle window, and a method for manufacturing the vehicle window encapsulation structural member. The vehicle window encapsulation structural member comprises an encapsulation member (1) and a memory alloy member (2) disposed in the encapsulation member (1), a deformation amount is preset for the memory alloy member (2), and the memory alloy member (2) is deformable according to the preset deformation amount between a high-temperature phase shape and a low-temperature phase shape, so that the encapsulation member (1) in a mounted state is adaptive to a vehicle body environment member (3). The present disclosure optimizes the reliability of the adaptability between the vehicle window encapsulation structure and the vehicle body environment member, saves the cost, and increases the feedback and the modification rate of the vehicle window encapsulation structure for the adaptation degree.