Thermoplastic Encasement for Vehicle Camera Mount Stability
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Solution Overview
Problem
Existing carrier devices for indirect vision systems in vehicles face challenges with loose connections due to vibrations, thermal expansion, and corrosion, particularly in the connection between the support arm and the imaging device, which affects the reliability and durability of the system.
Innovation Solution
A carrier device where the support part is formed from a thermoplastically processable material, encasing the support arm with closed walls through thermoplastic forming, creating a rotationally fixed and stable connection by radial shrinkage, eliminating the need for mechanical aids like screws or clamps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If clamps or clamping devices are used to fix the carrier part on the support arm, then the connection is easy to assemble, but the connection loosens over time due to vibrations, thermal expansion and contraction processes, wind pressure
Solution Approach 1:
The patent replaces mechanical clamping connections with a chemical bonding process. The support arm is formed by thermoplastic forming, where molten thermoplastic material is molded around the support arm and then cooled to create a permanent bond. This substitutes the mechanical clamp system with a thermoplastic bonding system that eliminates loosening issues while maintaining ease of assembly through a single-forming process.
Solution Approach 2:
The patent utilizes parameter changes in the thermoplastic material during the forming process. The material transitions from a molten state (easy to mold around the support arm) to a solid state (creating a rigid, permanent connection). This phase change allows the material to adapt to the support arm geometry and then lock into place, providing both ease of assembly and long-term connection stability.
2Reliability
If screwing or pinning methods are used to mount the carrier part on the support arm, then the connection can be permanent, but the connection is susceptible to vibration, loosening, and fatigue fractures
Solution Approach 1:
The patent replaces mechanical fastening methods (screws, pins) with a thermoplastic bonding system. The molten thermoplastic material is injected around the support arm and bonds chemically and mechanically as it cools and solidifies. This creates a monolithic structure where the carrier part and support arm become integrated, eliminating the vibration susceptibility and loosening problems inherent in discrete mechanical fasteners.
Solution Approach 2:
The patent creates a composite structure where the thermoplastic material and the support arm form an integrated assembly. The thermoplastic material acts as both the bonding agent and the structural component, creating a composite connection that distributes stresses uniformly and eliminates stress concentration points that would lead to fatigue fractures in mechanical fasteners.
3Reliability
If traditional mounting options are used, then the connection can be made, but material pairings create contact corrosion risks and the connection adds mass to the system
Solution Approach 1:
The patent applies homogeneity by using the same thermoplastic material for both the carrier part and the bonding material. This creates a homogeneous material pairing throughout the connection, eliminating galvanic corrosion risks that arise from dissimilar metal contacts. The uniform material composition ensures consistent corrosion resistance and eliminates electrochemical degradation pathways.
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
The solution provides a secure, vibration-resistant, and permanent connection that maintains operational reliability over time, reducing the risk of loosening and corrosion, while simplifying the assembly and manufacturing process.
Implementation Method 1
thermoplastic forming at least the support arm closed-walled over a section thereof... the support part experiences radial shrinkage in the attachment area after the casting process, in particular, which leads to tension between the support arm and the support part
Data Source
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AI summary
A support device (2) for mounting an imaging device (4) of an indirect vision system on a vehicle is described, comprising a support arm (12) attachable to the vehicle and at least one support part (14) attachable to the support arm (12), wherein the support part (14) has connection means (18) for mounting the imaging device. The support part (14) is formed, at least in a mounting area with the support arm (12), from a thermoplastic material and, by thermoplastic forming, encompasses the support arm (12) in a closed-walled manner, at least over a partial section thereof. The support part (14) can be cast around the support arm (12) in the mounting area with the support arm (12), in particular by injection molding. An indirect vision system for a vehicle, comprising a support device (2) of the described type, is also described.