Two-Shot Plastic Seal Clip for Automotive Flange Adaptation
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Solution Overview
Problem
Automotive seals with metal carriers are not well-suited to accommodate flange thickness variations during manufacturing, leading to inadequate sealing performance.
Innovation Solution
A seal comprising a plastic carrier with an elastomeric bulb and a snap-fitting plastic clip, formed using a multi-shot injection molding process, which engages the flange edge to provide secure retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal carrier is used to provide structural rigidity to the seal, then the seal gains strength and rigidity, but it becomes unable to accommodate flange thickness variations during manufacturing
Solution Approach 1:
The patent changes the material parameter from metal to plastic, which fundamentally alters the mechanical properties. Plastic carriers can elastically deform to accommodate flange thickness variations while maintaining sufficient structural rigidity through optimized geometry and material selection. This parameter change resolves the contradiction by making the carrier adaptable to manufacturing variations without sacrificing necessary strength.
Solution Approach 2:
The patent employs composite material construction by integrating the plastic carrier with an elastomeric sealing element. This composite structure combines the rigidity needed for structural support with the flexibility required to accommodate flange variations. The multi-material approach allows each component to contribute its optimal properties, resolving the contradiction between strength and adaptability.
2Adaptability or versatility
If a plastic carrier with elastomeric bulb is used instead of metal carrier, then the seal can accommodate flange thickness variations, but the structural rigidity may be reduced
Solution Approach 1:
The patent introduces dynamic characteristics by making the carrier itself flexible rather than rigid. The plastic carrier can elastically deform in response to flange thickness variations, providing a dynamic adaptation mechanism. This dynamic behavior allows the carrier to maintain structural integrity while accommodating manufacturing variations, resolving the strength-rigidity contradiction.
Solution Approach 2:
The patent segments the seal into distinct functional components: the plastic carrier for structural support and positioning, the elastomeric bulb for sealing and additional compliance, and the integrated clip for retention. This segmentation allows each component to optimize its specific function while working together as a system, maintaining overall structural rigidity while providing adaptability through the elastomeric elements.
3Ease of manufacture
If traditional metal seals are used, then manufacturing is straightforward, but the seals cannot adapt to flange thickness variations inherent in manufacturing processes
Solution Approach 1:
The patent uses composite materials (plastic carrier + elastomeric bulb) that can be manufactured as an integrated component using multi-shot injection molding. This process, while more complex than simple metal stamping, produces a highly reliable seal that adapts to flange variations. The integrated composite structure eliminates assembly steps and ensures consistent sealing performance, resolving the reliability issue despite increased manufacturing complexity.
Solution Approach 2:
The patent changes the material parameter from metal to plastic, enabling the seal to adapt to flange thickness variations through elastic deformation. This material parameter change directly addresses the reliability problem by making the seal tolerant of manufacturing variations, while the integrated molding process maintains ease of manufacture through automation and reduced assembly requirements.
Data Source
AI summary
A seal for an automobile body opening comprising a plastic carrier, an elastomeric bulb operably connected to the plastic carrier, and a plastic clip operably connected to, and extending away from, the plastic carrier for engagement to a flange for retaining the seal to the flange.