Vehicular Interior Member Three-Component Joining
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Solution Overview
Problem
Existing methods for fixing three resin components together, such as thermal welding or using tapping screws, result in increased weight, man-hours, and potential backlash and noise due to displacement during shaking.
Innovation Solution
A vehicular interior member design where a first and second component made of thermoplastic resin are joined by welding, with a middle component inserted through a projection and fitted with a claw portion, reducing the need for additional parts and enhancing strength and rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If three resin components are fixed by thermal welding with the middle component non-welded, then the joining process is simplified, but the middle component displaces under strong shaking causing backlash and noises
Solution Approach 1:
The joining method is segmented into two distinct mechanisms: thermal welding for the first component and claw fitting for the middle component. This segmentation allows each joining method to be optimized for its specific function, with the claw fitting providing positional stability for the middle component without requiring complex welding procedures
Solution Approach 2:
The claw portion acts as an intermediary mechanical feature that mediates between the middle component and the through hole. This claw-fitting mechanism serves as a mediator that prevents displacement of the middle component while maintaining the simplicity of the overall joining process
2Strength
If tapping screws are used to fix three components, then the joining strength is improved, but the number of parts and weight increase
Solution Approach 1:
The joining function is merged into the component design itself through integrated projection portions and claw portions. This eliminates the need for separate fastening components like tapping screws, thereby reducing part count and weight while maintaining joining strength
Solution Approach 2:
The components are designed with self-contained joining features (projections and claws) that perform the fastening function inherently. This self-service approach eliminates the need for additional external fasteners, reducing overall weight while providing sufficient joining strength
3Strength
If tapping screws are used to fix three components, then the joining strength is improved, but the man-hour for assembly increases
Solution Approach 1:
The joining features (projections and claws) are preliminarily formed during the molding process of the components themselves. This preliminary action eliminates the need for separate fastening components and simplifies assembly, reducing man-hour while maintaining joining strength
Solution Approach 2:
The fastening function is merged into the component structure through integrated projection and claw features. This consolidation eliminates multiple separate assembly steps required for tapping screws, thereby improving productivity without sacrificing joining strength
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 design allows for strong, lightweight joining of components with reduced man-hours and improved assembly workability, suppressing backlash and noise, while maintaining excellent recycling properties.
Implementation Method 1
the first projection portion and the second component are welded to each other
Implementation Method 2
a fitting portion projecting to the middle component side, the fitting portion being fitted to an edge portion of the first through hole
Data Source
AI summary
The present invention is to provide a vehicular interior member in which three components can be strongly joined to each other and the weight can be reduced. A vehicular interior member is formed so that first and second components respectively made of thermoplastic resin, and a middle component arranged between the first component and the second component are joined to each other. The first component has a boss projecting to the second component side. The middle component has a through hole through which the boss is inserted. The second component has a through hole through which the boss is inserted, and a fitting portion projecting to the middle component side, the fitting portion being fitted to an edge portion of the through hole. The boss and the second component are welded to each other.