Two-Component Clip for Elasticity and Strength Balance
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Solution Overview
Problem
Existing lightweight fasteners face challenges in achieving a balance between elasticity and strength, and their manufacturing processes are often labor-intensive and require manual assembly, which can lead to inconsistencies and increased production time.
Innovation Solution
A lightweight fastener is designed using a two-component injection molding process, where the clip body is created from two different plastics with varying properties, allowing for precise control over elasticity and strength, and is produced in a single piece, eliminating the need for separate assembly of the fastening element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single plastic material is used for the clip body, then the manufacturing process is simple, but the clip cannot simultaneously achieve both elasticity and strength in different areas
Solution Approach 1:
The clip body is divided into multiple volume sections, each made from a different plastic material with specific properties. The first volume section uses a more elastic plastic for areas requiring flexibility, while the second volume section uses a stronger plastic for areas requiring structural integrity. This local differentiation of material properties resolves the contradiction between manufacturing simplicity and differential mechanical requirements.
Solution Approach 2:
The clip body is constructed as a composite structure with at least two volume sections made from different plastic materials. This composite approach allows the clip to combine the advantages of different materials - elasticity from the first plastic and strength from the second plastic - within a single integrated component, eliminating the need for separate assembly steps.
2Adaptability or versatility
If the fastening element is assembled separately into the clip body, then the manufacturing process is flexible, but the production time increases and assembly consistency decreases
Solution Approach 1:
The manufacturing process merges the formation of the clip body and the attachment of the fastening element into a single integrated injection molding operation. The fastening element is formed and attached to the clip body in the same manufacturing step, eliminating separate assembly operations. This combining of operations increases production speed and ensures consistent assembly quality while maintaining manufacturing flexibility.
Solution Approach 2:
The fastening element is pre-formed and positioned within the injection molding tool before the final clip body material is injected. This preliminary action allows the fastening element to be precisely positioned and securely attached during the molding process itself, rather than requiring separate post-assembly steps, thereby improving production efficiency and assembly consistency.
3Ease of operation
If the wall thickness is reduced to improve flexibility, then the elasticity improves, but the strength decreases
Solution Approach 1:
Different wall thicknesses and material properties are applied to different volume sections of the clip body based on local requirements. Areas requiring flexibility have thinner walls made from more elastic plastic, while areas requiring strength have thicker walls made from stronger plastic. This local optimization resolves the contradiction between flexibility and strength without compromising either property.
Solution Approach 2:
The use of composite plastic materials allows the clip to achieve both flexibility and strength through material selection rather than solely relying on wall thickness adjustments. The first plastic provides elastic properties for flexible areas, while the second plastic provides structural strength for load-bearing areas, enabling the clip to meet both requirements simultaneously.
Data Source
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AI summary
A lightweight fastener or clip comprises a clip body and a fastening element 32. The clip body essentially consists of a first leg and a second leg, which are connected to each other at one end by a web 45. The clip body itself is a single piece, but has at least two volume sections 61, 62, wherein the first section 61 consists of a first plastic and the second volume section 62 consists of a second plastic. The properties of the first and the second plastic differ in one or more criteria. A method for manufacturing such a clip body comprises manufacturing it as a single piece using a multi-component injection molding process from at least two plastics. The invention further comprises a method for manufacturing the lightweight fastener or clip.Clips by inserting a fastener 32 into an injection mold; encapsulating the fastener 32 and overmolding the fastener 32 in a multi-component injection molding process.