Vehicle Roof Drive Cable Holder With Molded Guide Tube Integration
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Solution Overview
Problem
Existing methods for manufacturing power cable holders for vehicle roofs are complex, costly, and require additional fastening elements, leading to increased space requirements and visibility issues in transparent roofs.
Innovation Solution
A method involving a mold-based process where a guide tube is surrounded by plastic to form a cohesive drive cable holder directly attached to the component, eliminating the need for additional fasteners and allowing for a more integrated, space-efficient design using foaming processes like RIM, which maintains the guide tube's integrity and supports the drive cable system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional manufacturing methods are used to attach guide tubes to plastic components, then the guide tube can be securely fastened, but additional fastening elements (rivets, screws, adhesive bonds) are required which increase device complexity and space requirements
Solution Approach 1:
The guide tube is integrally formed with the plastic component through co-injection molding, merging two previously separate elements (guide tube and holder) into a single integrated structure. This eliminates the need for separate fastening elements while maintaining secure attachment, directly resolving the contradiction between fastening security and device complexity
Solution Approach 2:
The guide tube is positioned and secured within the plastic component during the molding process itself, before the component is removed from the mold. This preliminary attachment action eliminates the need for subsequent fastening operations, reducing both device complexity and the number of required fastening elements
2Reliability
If conventional manufacturing methods are used with separate attachment steps, then the guide tube can be secured to the component, but additional process steps and tools are required which increase manufacturing complexity and costs
Solution Approach 1:
The manufacturing process merges the guide tube attachment step with the plastic component molding step into a single integrated operation. The guide tube is positioned in the mold and co-injected with the plastic material, eliminating the need for separate attachment processes and tools, thus improving ease of manufacture while maintaining attachment stability
Solution Approach 2:
The guide tube is positioned and secured during the molding process itself, performing the attachment action preliminarily before component completion. This eliminates subsequent attachment steps and tooling requirements, simplifying the manufacturing process while ensuring stable attachment from the outset
3Reliability
If traditional fastening methods are used, then the guide tube can be securely mounted, but the installation space requirement increases and visibility is reduced in transparent roofs
Solution Approach 1:
The guide tube and mounting structure are merged into a single integrated component through co-injection molding. This eliminates the need for separate fastening elements that would occupy additional space, reducing installation volume while maintaining mounting security through the integral design
Solution Approach 2:
The invention extracts and eliminates the need for separate fastening elements (rivets, screws, adhesive bonds) from the assembly. By integrating the attachment function directly into the molded component, the solution removes extraneous parts that consume installation space, thereby reducing overall volume while preserving mounting security
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 approach reduces manufacturing steps and costs, minimizes installation space, and enhances visibility by eliminating the need for traditional fasteners, while providing a stable and flexible drive cable holder that meets safety standards for head injury factors.
Implementation Method 1
A plastic is introduced into the mold. In the mold, the plastic completely surrounds the guide tube radially, at least in sections. The plastic comes into contact with a surface of the component in the mold. This forms the drive cable holder
Data Source
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AI summary
The invention relates to a method for producing a drive cable holder (100) for a vehicle roof (200), comprising the following steps: providing a component (110) for the vehicle roof (200); positioning the component (200) in a moulding tool (105); providing a guide tube (101) for a drive cable (104); positioning the guide tube (101) in the moulding tool (105); introducing a plastic (106) into the moulding tool (105) such that the plastic (106) completely radially surrounds the drive cable (104) at least in sections and such that the plastic (106) comes into contact with a surface (111) of the component (110); and thereby forming the drive cable holder (100) which is secured to the component (110).