One-Piece Vehicle Carrier End Support Eliminates Wind Noise
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Solution Overview
Problem
Existing vehicle article carrier cross bars with two-piece end supports are costly to produce, aesthetically unappealing, and generate wind noise due to seams between molded plastic parts.
Innovation Solution
A one-piece end support for vehicle article carriers is developed, comprising a hollowed-out neck portion, an intermediate portion, and a flange, integrally formed using a mold tool with moveable cores to eliminate the need for separate components, reducing manufacturing costs and wind noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the end support is constructed with two separate molded plastic parts, then it is easier to manufacture each individual part, but it produces aesthetically unappealing seams and generates wind noise
Solution Approach 1:
The patent merges two separate molded plastic parts (main body portion and cover) into a single integrated end support component. This is achieved through a molding process that forms both portions simultaneously as one piece, eliminating the seam between parts and thereby reducing wind noise generation while maintaining manufacturing feasibility through integrated mold design
2Ease of manufacture
If the end support is constructed with two separate molded plastic parts, then it allows for modular assembly, but it increases production costs and creates visible seams
Solution Approach 1:
The patent combines the main body portion and cover into a single molded component, reducing device complexity by eliminating the need for separate parts and assembly operations. The integrated design simplifies the overall structure while maintaining all necessary functional features in one piece
3Ease of manufacture
If the end support is constructed with two separate molded plastic parts, then it simplifies the molding process for each part, but it requires additional assembly operations and fasteners
Solution Approach 1:
The patent merges the molding of two separate parts into a single simultaneous molding operation. The integrated mold design allows both the main body portion and cover to be formed in one cycle, eliminating subsequent assembly operations and fastener installation, thereby significantly improving production efficiency
Data Source
AI summary
A one piece end support for use with a cross bar of a vehicle article carrier system. The one piece end support may have a hollowed out neck portion adapted to receive an end of a cross bar. A hollowed out intermediate portion is provided which extends non-parallel to, but is integrally formed with, the neck portion. A flange portion is adapted to be secured to a support rail of the vehicle article carrier system. The flange portion may be integrally formed with the intermediate portion.