Curved-Flange Weather Strip Structure for Stable Sensor Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing weather strips struggle to couple effectively alongside the curved parts of automobile flanges, leading to misalignment and compromised sensor functionality for detecting objects.
Innovation Solution
A weather strip design that incorporates an installation base member formed by extrusion molding, with a cut-out portion subjected to die molding, and an insert shaped to conform with the curved parts, ensuring stable coupling and precise object detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the weather strip is formed by extrusion molding, then the manufacturing process is simple and production efficiency is high, but the weather strip cannot couple effectively alongside curved parts of the flange
Solution Approach 1:
The weather strip is divided into two distinct parts: an installation base member formed by extrusion molding and a die-molded part formed by die molding. The extrusion-molded base member provides manufacturing efficiency, while the separately formed die-molded part provides the curved shape needed to couple with the flange's curved parts. This segmentation allows each part to be optimized for its specific function.
Solution Approach 2:
The die-molded part is integrated with the extrusion-molded installation base member to form a complete weather strip assembly. The die-molded part includes a curved outer-cabin side wall that couples to the curved parts of the flange, while the base member provides the structural foundation. This merging combines the advantages of both manufacturing methods.
2Adaptability or versatility
If the curved part is cut out and subjected to die molding to improve followability, then the weather strip can couple to curved parts, but the coupling strength may be insufficient
Solution Approach 1:
The weather strip uses a composite structure combining the extrusion-molded installation base member (typically rubber or elastomer material) with the die-molded part (which may include different materials optimized for curved coupling). This composite construction allows the die-molded part to provide superior followability to curved surfaces while the base member provides overall structural integrity and coupling strength.
3Strength
If an insert is embedded in the curved part to increase strength, then the coupling strength is improved, but the insert may misalign during die molding, spoiling appearance and affecting sensor detection
Solution Approach 1:
The sensor is pre-installed within the installation base member before the die molding process. The die-molded part is then formed to couple with this pre-assembled base member, ensuring that the sensor is already in its correct position and orientation. This preliminary action prevents misalignment issues that would occur if the sensor were installed after die molding.
Solution Approach 2:
The installation base member acts as an intermediary between the sensor and the die-molded curved part. The sensor is embedded in the base member, which then couples to the die-molded part. This intermediary structure provides a stable mounting platform for the sensor that is not affected by the die molding process, ensuring precise sensor positioning while still achieving strong coupling to curved surfaces.
Data Source
AI summary
A weather strip couples to a flange with curved parts of a sliding door of an automobile. The weather strip includes an installation base member, a hollow part, and an insert. The installation base member couples to the flange and includes an inner-cabin side wall, a first outer-cabin side wall, and a connecting wall. A part of the installation base member which couples to the curved parts is cut out, to provide a cut-out portion. The cut-out portion is subjected to die molding, to provide a die-molded part. The hollow part is integrally formed with the installation base member by extrusion molding. The insert is shaped in conformance with the curved parts and is embedded in the die-molded part with a plurality of concave shaped parts of the insert abutted with a plurality of pins of a die under the die molding.