Two-Piece Frame Assembly With Integrated Seal For Tonneau Panels
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Solution Overview
Problem
Existing tonneau cover frame assemblies face challenges in manufacturing and assembly, particularly when dealing with enclosure panels of varying thicknesses, as they require high force to insert into channels due to friction issues and often necessitate adhesives or mechanical fasteners, which can lead to misalignment and complex geometries that are difficult to manufacture.
Innovation Solution
A 2-piece frame assembly with a coupling mechanism and integrated seals, where the enclosure panel is sandwiched between upper and lower members, allowing for easy assembly and accommodation of different panel thicknesses without adhesives or mechanical fasteners, and featuring a bulb seal for additional sealing and vibration reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a one-piece frame assembly is used, then manufacturing precision and structural integrity are improved, but die-lock conditions occur during manufacturing and tooling costs increase
Solution Approach 1:
The frame assembly is divided into two separate frame members (first frame member and second frame member) that can be manufactured independently and then joined together. This segmentation eliminates die-lock conditions during manufacturing of individual pieces and reduces tooling complexity while maintaining the structural integrity of the complete frame assembly.
2Manufacturing precision
If enclosure panels are inserted into channels with tight tolerances, then manufacturing precision is improved, but high insertion force is required due to friction
Solution Approach 1:
The frame assembly is segmented into two members with an integrated seal positioned between them. This allows the enclosure panel to be compressed against the seal rather than forced into a tight channel, reducing insertion force while maintaining manufacturing precision through the sealing mechanism.
Solution Approach 2:
An integrated seal acts as an intermediary between the frame members and enclosure panel. The seal accommodates manufacturing tolerances in panel thickness and channel dimensions, allowing panels to be installed with lower force while maintaining a precise, sealed fit.
3Strength
If adhesives or mechanical fasteners are used to join frame members, then structural strength is improved, but alignment precision deteriorates due to wiping of adhesive
Solution Approach 1:
The seal is integrated directly into the frame members rather than being a separate component. This merging ensures proper alignment between the frame members and enclosure panel during assembly, as the integrated seal guides the panel into correct position while providing the necessary sealing and bonding function.
4Device complexity
If a single frame assembly design is used, then device complexity is reduced, but adaptability to different panel thicknesses deteriorates
Solution Approach 1:
The integrated seal provides a dynamic, compliant interface between the frame members and enclosure panel. The seal can deform and adapt to accommodate varying panel thicknesses within a range, allowing a single frame assembly design to work with multiple panel specifications without requiring complex adjustable mechanisms.
Data Source
AI summary
A frame assembly that includes a first frame member, a seal, a second frame member, and a coupling mechanism. The first frame member includes a first extension and a second extension. The seal extends between a surface of the first extension and a surface of the second extension. The second frame member includes a third extension. The coupling mechanism is adapted to connect together the first frame member and the second frame member. After the first frame member and the second frame member are connected together, the first extension, the second extension, and the third extension cooperate to form a channel. The channel is adapted to receive a tonneau cover enclosure panel.