Thin Wall Tube Crimp Connection for Vehicle Closure
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Solution Overview
Problem
Current hold systems for vehicle closure panels are bulky, consuming valuable cargo space, and crimping or threading methods for thin tube walls are not feasible due to strength concerns, limiting the reduction of tube wall thickness for weight reduction and space optimization.
Innovation Solution
An extension mechanism with a crimp connection system that uses a clamping member to sandwich a deformed tube wall portion between the crimped end portion and a receiving indentation, enhancing the crimp connection's strength and feasibility for thinner tube walls, allowing for reduced wall thickness without compromising structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the wall thickness of tubes is reduced to reduce mass and diameter, then weight and space are improved, but the strength and integrity of connections are worsened
Solution Approach 1:
The connection structure is segmented into multiple functional zones: a reduced wall thickness section for weight reduction, a transition zone with gradually varying thickness, and a crimping zone with sufficient material. This segmentation allows the tube to have thin walls overall while maintaining adequate material at critical connection points.
Solution Approach 2:
The tube wall thickness is not uniform but varies locally to match functional requirements. The thinnest sections are placed where structural support is least needed, while thicker sections are positioned at connection zones. This local quality variation optimizes the strength-to-weight ratio by concentrating material only where structurally necessary.
2Ease of manufacture
If traditional crimping method is used on thin tube walls, then manufacturing simplicity is maintained, but connection strength is insufficient due to lack of tube material
Solution Approach 1:
The tube is pre-formed with a specific geometric profile including a crimping zone with increased wall thickness and a receiving groove positioned before the crimping operation. This preliminary preparation ensures that when standard crimping is applied, sufficient material is available at the exact location needed, transforming a potentially weak connection into a strong one without changing the crimping process itself.
Solution Approach 2:
The tube wall thickness parameter is changed locally at the connection zone, transitioning from a uniform thin-wall design to a variable thickness design. The crimping zone features increased thickness (e.g., 0.6-1.2mm vs. 0.3-0.5mm in other sections) and a specific geometric profile including a receiving groove, which together provide the material necessary for strong crimping while maintaining overall weight reduction.
3Strength
If threading is used instead of crimping for thin tube walls, then connection strength may be improved, but manufacturing complexity and minimum wall thickness requirements increase
Solution Approach 1:
The invention extracts and eliminates the threading operation from the manufacturing process, retaining only the simpler crimping operation. By pre-forming the tube with an optimized geometry including a crimping zone and receiving groove, the design removes the need for complex threading while achieving comparable or superior connection strength through the crimping process alone.
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 crimp connection system effectively maintains the strength of the attachment between the tube and the mating part, enabling thinner tube walls while reducing the overall size and weight of the hold system, thus optimizing space and performance.
Implementation Method 1
a clamping member having a body, at least a portion of the body positioned over the tube wall, such that the deformed portion is sandwiched between the portion of the body and the receiving indentation
Data Source
AI summary
A method for constructing an extension mechanism for a closure panel of a vehicle, the extension mechanism including an extension member housed in a body housing, such that the extension member extends and retracts with respect to the body housing as the closure panel is opened and closed, the extension mechanism having a first connection at one end for connecting the extension member to the vehicle and a second connection at the other end for connecting the body housing to the vehicle, the method comprising the steps of: overlapping a tube wall of the body housing with an end portion of the body housing, the end portion having a receiving indentation; receiving a deformed portion of the tube wall into the receiving indentation in order to form a crimp connection between the tube wall and the end portion; and positioning a clamping member having a body by at least a portion of the body over the tube wall, such that the deformed portion is sandwiched between the portion of the body and the receiving indentation.