Sunroof Bracket Hooks for Headliner Corner Wrapping
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Solution Overview
Problem
The existing sunroof bracket technologies for vehicles face issues with fabric peeling and wrinkles during the wrapping process of headliner corner portions, leading to quality degradation and increased manufacturing costs due to the need for additional padding to prevent peeling.
Innovation Solution
A sunroof bracket with hooks formed on the surface, specifically at corner portions, to securely catch the fabric between the base and the headliner, eliminating the need for additional padding and enhancing the wrapping process by preventing peeling and detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional padding is attached to prevent fabric peeling at corner portions, then the quality of the headliner is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent extracts the essential function of the padding (preventing fabric peeling) and integrates it directly into the sunroof bracket structure through hooks. Instead of adding a separate padding component, the bracket itself is modified with hook structures that perform the same protective function, thereby eliminating the need for additional padding while maintaining headliner quality.
Solution Approach 2:
The patent merges the function of the padding with the sunroof bracket by forming hooks directly on the bracket surface. The bracket and the anti-peeling structure become a single integrated component, reducing the number of parts from two (bracket + padding) to one (bracket with integrated hooks), thus simplifying the device while improving reliability.
2Reliability
If additional padding is attached to prevent fabric peeling at corner portions, then the quality of the headliner is improved, but the manufacturing cost increases
Solution Approach 1:
The patent removes the need for separate padding materials and attachment processes by extracting the anti-peeling function and embedding it into the bracket structure. This eliminates the cost of purchasing, storing, and installing additional padding components, thereby reducing manufacturing costs while maintaining headliner quality.
Solution Approach 2:
By combining the bracket and anti-peeling structure into a single integrated component, the manufacturing process is simplified. Instead of two separate manufacturing and assembly steps (making bracket + making padding + assembling them), the hooks are formed directly on the bracket during its manufacturing process, reducing labor and assembly costs.
3Ease of manufacture
If hooks are formed on the sunroof bracket to catch fabric, then the wrapping process becomes more efficient and manufacturing cost is reduced, but the device complexity increases
Solution Approach 1:
The hooks are pre-formed on the sunroof bracket during its manufacturing process, before the bracket is installed in the vehicle. This preliminary formation of the hook structures means that no additional complex assembly steps are required during vehicle production - the brackets are simply installed with their hooks already in place, maintaining manufacturing efficiency while providing the necessary fabric-catching function.
Data Source
AI summary
By forming hooks on a sunroof bracket to allow a headliner portion wrapping an opening to be fixedly caught thereon, it is possible to prevent a portion subjected to a wrapping process from being easily peeled or detached, thereby improving the quality of the headliner. In particular, by forming the hooks one-to-one on at least corner portions of the opening to allow portions on which it is difficult to perform the wrapping process due to the occurrence of overlapping when the wrapping process is performed and which are easily peeled or separated even after the process to be caught thereon, it is possible to further improve the quality of the headliner.