Overmolded Bodywork Connector with Integrated Sensor Tracks

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Solution Overview

Problem

The existing methods for manufacturing motor vehicle body parts with integrated sensors and electrical connections are labor-intensive and costly, requiring manual welding and cable installation, which increases the risk of corrosion and limits the placement of sensors due to rigid cable paths.

Innovation Solution

The integration of an overmolded electrical connection layer with flexible, conductive tracks within the thermoplastic material, where connection plates act as both supports and connectors, eliminating the need for welding and allowing direct sensor fixation, reducing entry points for corrosive agents, and enabling more complex curvature integration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual welding and cable installation are used to integrate sensors into bodywork parts, then sensors can be installed on existing structures, but assembly time and labor costs increase significantly

Engineering Contradiction:

Improvesensor installation reliabilityVSAvoidassembly time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent merges the sensor support structure (clipping bracket) and the electrical connection system (cable tray with connectors) into a single integrated component molded directly into the bodywork part. This eliminates the need for separate welding and cable installation operations, reducing assembly time while maintaining reliable sensor installation and electrical connections.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The clipping brackets and cable trays are pre-integrated into the bodywork part during the injection molding process before final assembly. This preliminary action allows sensors to be directly clipped and connected without requiring subsequent welding or cable routing operations, significantly reducing assembly time.

Inventive Principle:

Principle #10Preliminary action

2Adaptability or versatility

If multiple separate components (clipping brackets, cable trays, connectors) are used to support sensors, then functional requirements are met, but the number of assembly operations and labor requirements increase

Engineering Contradiction:

Improvesensor support functionalityVSAvoidassembly complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Multiple separate components (clipping brackets, cable trays, connectors) are merged into a single integrated structure molded as one piece with the bodywork part. This maintains all necessary sensor support functions while eliminating the complexity of assembling multiple separate components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated structure serves multiple functions simultaneously: it provides mechanical support for sensors via clipping brackets, routes electrical cables through integrated trays, and provides connection points for electrical connectors. This multi-functionality reduces the need for separate components while maintaining adaptability for various sensor installations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Strength

If welding is used to attach clipping brackets to the bodywork part, then secure sensor mounting is achieved, but local thickness reduction and weight savings are lost

Engineering Contradiction:

Improvesensor mounting strengthVSAvoidbodywork part weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The clipping brackets are merged into the bodywork part structure during injection molding, eliminating the need for separate welding operations. This allows the use of thinner material at bracket locations since the structural integrity is provided by the molded integration rather than welded joints, achieving both secure mounting and weight reduction.

Inventive Principle:

Principle #5Merging (Combining)

4Object-affected harmful factors

If rigid cable trays are used to connect sensors to electrical sources, then cable protection is provided, but flexibility in sensor placement locations is limited

Engineering Contradiction:

Improvecable protectionVSAvoidsensor placement flexibility

Core Design Contradiction:

Object-affected harmful factorsVSAdaptability or versatility

Solution Approach 1:

The patent replaces rigid cable trays with flexible cable conduits or thin-walled protective channels that can be molded directly into the bodywork part. These flexible structures provide cable protection while allowing the cable to bend and route to various sensor locations, significantly increasing placement flexibility compared to rigid trays.

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentEP3727942B1Moulded bodywork component comprising integrated connector elements, and associated manufacturing method

Publication Date: 2022.03.30 COMPAGNIE PLASTIC OMNIUM SA

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AI summary

A bodywork component (1) for a motor vehicle forming an outer skin and produced by injecting a thermoplastic material comprising: - a ribbon cable (2) supporting, on one of the faces of same, electrically conductive tracks and, - one or more connection plates (3) in electrical continuity with said electrically conductive tracks (2) and each comprising connection means (34) for connection to one or more sensors (6), characterised in that the ribbon cable (2) and the connection plates (3) are overmoulded in the thermoplastic material forming the bodywork part (1).