Overmolded Liftgate Bracket With Open Mounting Surface
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Solution Overview
Problem
Conventional designs using compression limiters or rivet nuts in threaded fastener joints increase complexity, cost, and assembly time, and mechanical fasteners without overmolding add extra costs and assembly complexity, particularly in applications like thermoplastic liftgates.
Innovation Solution
An overmolded bracket with an open mounting surface eliminates the need for compression limiters or rivet nuts by maintaining an open hole for tether routing and direct hardware attachment, reducing complexity and cost through a cost-effective overmolding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If compression limiters or rivet nuts are used in threaded fastener joints, then the joint robustness is improved, but the device complexity and cost increase
Solution Approach 1:
The patent combines the bracket and the molded panel into a single integrated component through overmolding. The bracket is molded directly onto the panel, eliminating the need for separate compression limiters or rivet nuts. This merging of components maintains joint robustness while reducing device complexity and cost.
Solution Approach 2:
The patent uses composite construction by overmolding a plastic bracket onto a metal reinforcement or directly onto the panel. This creates a hybrid component that combines the strength of metal with the molding capabilities of plastic, achieving robust joints without additional fasteners.
2Ease of manufacture
If mechanical fasteners without overmolding are used, then the assembly process is simpler, but extra costs and assembly complexity are added
Solution Approach 1:
The bracket and molded panel are combined into a single integrated component through the overmolding process. This eliminates the need for separate mechanical fasteners and reduces the number of assembly steps, thereby simplifying both manufacturing and assembly processes while reducing device complexity.
3Adaptability or versatility
If the bracket is overmolded, then the integration with molded panel is improved, but the mounting surface may be compromised
Solution Approach 1:
The mounting holes and open mounting surfaces are designed and prepared in the bracket before the overmolding process. The bracket is first formed with the necessary mounting features, then the molded panel is attached. This preliminary preparation ensures that the mounting surface integrity is maintained while achieving good integration.
Solution Approach 2:
The overmolding process is applied selectively to specific areas of the bracket, preserving the open mounting surfaces and holes where hardware attachment is needed. The molding material is applied in a way that maintains the local quality and functionality of the mounting areas while providing integration benefits.
Data Source
AI summary
A liftgate (10) for a vehicle having at least one overmolding bracket (28) with at least one open mounting surface on the bracket for liftgate hardware attachments. In addition, overmolding the bracket (28) and maintaining at least one hole (26) for tether routing. The liftgate allows the overmolding of the bracket (28) and maintains a lower cost fastener joint that does not require extra components or special components such a compression limiters and rivet nuts or brackets that cannot be overmolded.