Automotive Door Protector Insert for Stable Die Molding
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Solution Overview
Problem
Existing protectors with sensors for automobile panels face challenges in stable die molding and water cut-off functionality due to air entrapment and adhesive issues during the manufacturing process, leading to inefficient sealing and increased costs.
Innovation Solution
The protector incorporates a non-conductive insert with specific channel and pressing parts to securely hold wire harnesses, preventing air entrapment and eliminating the need for adhesives, while allowing die-molding material to fill in and secure the components, ensuring stable die molding and improved water cut-off performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If adhesive is used to fix wire connection parts, then positioning is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent replaces the adhesive bonding system with a mechanical positioning system. The insert includes positioning protrusions that fit into corresponding recesses in the mold, providing mechanical positioning without adhesives. This eliminates the need for adhesive application, curing time, and associated quality control steps.
Solution Approach 2:
The insert acts as an intermediary component between the wire connection parts and the mold. It provides a structured interface with positioning features that guide and secure the wire connection parts during die molding, replacing the need for adhesive bonding while maintaining stable positioning.
2Ease of operation
If adhesive is used for fixing, then positioning is achieved, but manufacturing time and cost increase
Solution Approach 1:
The mechanical positioning protrusions enable immediate positioning upon insertion, eliminating the adhesive curing time required for bonded joints. The wire connection parts are positioned and secured in a single mechanical action during mold closure, reducing the manufacturing cycle.
Solution Approach 2:
The positioning protrusions are pre-formed on the insert before the die molding process begins. This preliminary preparation of positioning features eliminates the need for post-molding adhesive application and curing, allowing the wire connection parts to be positioned and fixed in one continuous operation.
3Manufacturing precision
If complex positioning structures are added, then positioning accuracy is improved, but device complexity increases
Solution Approach 1:
The insert incorporates positioning protrusions at specific critical locations where positioning is needed, rather than creating a uniformly complex structure throughout. This localized approach provides necessary positioning accuracy only where required, maintaining simplicity in other areas of the component.
Solution Approach 2:
The positioning function is segmented into discrete protrusion features on the insert, each handling a specific positioning task. This segmentation allows for simple, focused positioning elements rather than a monolithic complex positioning system, making the overall structure easier to manufacture and analyze.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enhances the stability of the die-molding process, prevents air entrapment, and maintains effective water cut-off functionality without increasing manufacturing costs, resulting in a more reliable and efficient protector with improved sealing.
Implementation Method 1
the lower terminal part is subjected to die molding; the feeding ports receive and feed the die-molding material into the second channel during die molding
Data Source
AI summary
A protector with a sensor couples to a sliding door. A first end of an insert is inserted in and fills up a space on a hollow part of the protector. A second end of the insert includes a support member and a lid. Top ends of core wires and top ends of two leads are fit in first channels on the support member. Covered parts and a wire harness are fit in a second channel. The second channel is formed between the support member and the lid and is continuous with the first channels. The support member and the lid include feeding ports to receive and feed die-molding material into the second channel during die molding.