Molded Component Breaking Feature for Rear View Assembly Adaptability
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Solution Overview
Problem
Existing exterior rear view assemblies require unique designs and manufacturing for different sizes and shapes, leading to increased tooling and manufacturing costs, as well as incompatible assembly shapes and sizes, which hinder the use of components across various applications.
Innovation Solution
A molded component with a predetermined breaking feature allows coupling to structural shells in two states, enabling adaptation to differently sized and shaped assemblies, reducing the need for unique components and manufacturing forms, and facilitating efficient assembly through a method that involves coupling sections and attachment elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If unique designs and manufacturing are used for different sizes and shapes of exterior rear view assemblies, then the assemblies can be optimized for specific applications, but the tooling and manufacturing costs increase
Solution Approach 1:
The molded component is designed with a breaking feature that allows it to function in multiple configurations, enabling a single universal component to replace multiple size-specific components. This multi-functional design allows the same component to be used across different exterior rear view assembly sizes and shapes, reducing the need for unique tooling and manufacturing processes for each application.
Solution Approach 2:
The molded component incorporates a breaking feature that divides the component into separable sections. This segmentation allows the component to be manufactured as a single piece but configured in multiple ways after manufacturing, enabling adaptability to different applications without requiring multiple unique manufacturing processes.
2Adaptability or versatility
If multiple unique components are manufactured for different applications, then each component can be optimized for its specific use, but the variety of parts increases and assembly efficiency decreases
Solution Approach 1:
A single molded component design with a breaking feature serves multiple applications, reducing the variety of parts that need to be managed and assembled. This universal component can be configured for different sizes and shapes, improving assembly efficiency by reducing the complexity of selecting and assembling application-specific components.
3Ease of manufacture
If a single molded component design is used for different sizes and shapes, then manufacturing costs are reduced, but the ability to optimize for specific applications is limited
Solution Approach 1:
The breaking feature segments the molded component into configurable sections, allowing a single manufacturing process to produce a component that can be adapted to specific application requirements. The segmentation enables post-manufacturing configuration without requiring multiple unique manufacturing processes.
Solution Approach 2:
The breaking feature introduces dynamic configurability to an otherwise static molded component. The component can be configured in different states after manufacturing, allowing optimization for specific applications while maintaining a single manufacturing process.
Data Source
Figure 1A~1B
Figure 2
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AI summary
The present invention provides a molded component, in particular internal skeleton structure, for a road vehicle exterior rear view assembly, comprising: a first coupling section and a second coupling section, wherein the first coupling section and second coupling section are each configured to be coupled to a structural shell, a predetermined breaking feature, wherein the breaking feature is formed and configured in such a way to allow for coupling the component to the structural shell in two different states wherein in the first state of the component the breaking feature structurally connects the first coupling section and second coupling section for coupling to the structural shell in one part, and in the second state of the component the first coupling section and/or second coupling section are adapted in position by means of the breaking feature in a predefined way for coupling to the structural shell in at least two parts. Furthermore, the invention provides an exterior rear view assembly and a method of assembling an exterior rear view assembly.