Vehicle Accessory Mount Tooling for Rib Formation
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Solution Overview
Problem
Existing tooling systems for forming vehicle components with accessory mounting features often encounter shape or tool path interferences, necessitating the addition of extra slides, increasing complexity and cost, while maintaining a maximum wall thickness.
Innovation Solution
A method and tool assembly where two tools with specific surfaces are oriented at an acute angle relative to each other to form a mold cavity that integrates a rib and planar bearing surface for the mounting feature, allowing the formation of the accessory mount without requiring a third tool, thus maintaining the maximum wall thickness and reducing tooling complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If existing tooling systems are used to form accessory mounting features, then the mounting feature can be formed, but shape or tool path interferences occur requiring additional slides, increasing complexity and cost
Solution Approach 1:
The patent introduces a rotational dimension by rotating the first tool relative to the second tool during the molding process. This rotational movement allows the mold cavity to form complex mounting features with integrated ribs and planar bearing surfaces that would otherwise require additional slides, thereby reducing tooling complexity while maintaining manufacturing precision
2Manufacturing precision
If existing tooling systems are used to form accessory mounting features, then the mounting feature can be formed, but additional slides are required, increasing cost
Solution Approach 1:
The patent merges the functions of multiple tools by integrating the formation of the mounting feature, integrated rib, and planar bearing surface into a single mold cavity formed by two rotating tools. This consolidation eliminates the need for additional slides, reducing tooling cost while maintaining the precision required for proper mounting feature formation
3Manufacturing precision
If additional slides are added to form mounting features, then the mounting feature can be formed, but tooling complexity increases
Solution Approach 1:
The patent employs dynamic rotational movement of the first tool relative to the second tool during the molding process. This dynamic approach allows the mold cavity to adapt and form complex geometries including integrated ribs and planar bearing surfaces without requiring additional static slides, thereby reducing tooling complexity while achieving the desired mounting feature precision
Data Source
AI summary
A vehicle component, and a method and tool for forming the component are provided. First and second tools with first and second surfaces, respectively, are provided. The first tool is translated along a first axis towards the second tool such that the first and second surfaces cooperate to define a mold cavity configured to form an accessory mount feature with an aperture. The second surface is configured to form an integrated rib extending outwardly from an upper surface of the mount feature to a planar bearing surface surrounding the aperture with the planar bearing surface oriented at an acute angle relative to the upper surface. The first axis is substantially parallel to the upper surface.