Vehicle Roof Element Functional Component Attachment
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Solution Overview
Problem
Existing methods for attaching functional components to vehicle roof elements, such as sliding roof covers, face challenges in producing complex geometries with polyurethane materials due to the high effort required for foaming molds and limited geometries achievable with dish-like mold parts.
Innovation Solution
The method employs multiple mold surfaces, allowing for the shaping of curable materials in an open system, where a first mold surface forms outer contours and a second mold surface defines further sections, enabling the creation of complex geometries without the need for closed molding tools, and ensuring high positional accuracy and precision in attaching functional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a foaming mold is used to attach polyurethane to the cover, then sealing action is achieved, but the effort involved in producing the foaming molds is great
Solution Approach 1:
The mold is divided into two separate mold parts instead of using a complete closed foaming mold. The first mold part has a mold surface that contacts the cover, while the second mold part has a mold surface that contacts the first mold part. This segmentation allows the mold to be simpler to manufacture while still achieving the necessary sealing action through the coordinated action of both mold parts.
2Ease of manufacture
If a dish-like mold part is used to hold flowable polyurethane, then the mold is simple to manufacture, but only few geometries are possible
Solution Approach 1:
By dividing the mold into two separate parts with各自独立的 mold surfaces, the system can achieve more complex geometries than a single dish-like mold part. Each mold part can be independently manufactured with specific geometries, and their combination allows for versatile shaping of the polyurethane while keeping individual mold parts relatively simple.
Solution Approach 2:
The invention transitions from a single-sided dish-like mold to a two-sided mold system. The second mold part provides shaping from the opposite side, adding a new dimension to the molding process. This enables complex geometries that cannot be achieved with a single mold part, as both surfaces work together to define the final shape.
3Adaptability or versatility
If a closed molding tool is used to produce complex geometries, then geometry complexity is achieved, but the system becomes more complex
Solution Approach 1:
Instead of using a complete closed molding tool, the invention uses two separate mold parts that are simpler in design. The first mold part has an opening accessible from the environment, and the second mold part is positioned adjacent to it. This segmented approach reduces the complexity of the overall molding system while still enabling complex geometries through the coordinated action of the two mold surfaces.
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 allows for the production of complex geometries with reduced effort, enabling precise and strong attachment of functional components like rails and sealing lips to vehicle roof elements, enhancing both functionality and visual appearance while maintaining sealing integrity.
Implementation Method 1
applying a curable material in a low-viscosity state which is molded in sections
Implementation Method 2
a polyurethane frame or other polyurethane formations are formed which firmly adhere to the cover
Data Source
AI summary
A method of attaching functional components to a roof element of a vehicle is provided. The method including the steps of: applying a curable material in a low-viscosity state which is molded in sections by a first mold surface, wherein a second mold surface is used for further shaping sections of the curable material, and wherein an opening remains accessible towards an environment through which the curable material is introduced.