Weatherstrip Insert Panel Recess Design for Bonding Strength
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Solution Overview
Problem
The adhesion between rubber-like elastic material and metal insert panels in automotive weatherstrips is poor, leading to deformation and increased costs due to the need for resin layers and through holes, which can result in the metal insert panel protruding through openings when external forces are applied.
Innovation Solution
A weatherstrip design featuring a molded part with recesses or protrusions on the side edge of the insert panel near the corner, which engages with the rubber-like elastic material to prevent displacement and deformation, eliminating the need for through holes between the corner and exposed parts, thereby reducing costs and preventing the insert panel from protruding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a resin layer is formed to cover surfaces of the insert panel to improve adhesion, then bonding strength between rubber-like elastic material and metal insert panel is improved, but manufacturing cost increases
Solution Approach 1:
A resin layer is introduced as an intermediary substance between the metal insert panel and rubber-like elastic material to improve adhesion. The resin layer covers the surfaces of the insert panel and bonds the rubber-like elastic material to the metal panel, resolving the poor adhesion problem without requiring structural modifications like through holes or increased panel size.
2Strength
If through holes are formed in the insert panel to achieve anchoring effect, then bonding strength between molded part and insert panel is improved, but manufacturing cost increases
Solution Approach 1:
Through holes are formed in the insert panel to create a porous structure that provides anchoring effect. The rubber-like elastic material enters these through holes during molding, creating mechanical interlocking that strengthens the bonding between the molded part and the insert panel.
3Ease of operation
If corner portion of insert panel is exposed through opening for clip attachment, then ease of operation is improved, but structural stability deteriorates when external force is applied
Solution Approach 1:
The insert panel is designed with non-uniform thickness, featuring a thicker corner portion at the corner and a thinner exposed portion where the clip attachment hole is formed. This local quality variation allows the corner to maintain structural stability and resist deformation under external forces, while the thinner exposed portion facilitates easy attachment operations.
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
This design effectively reduces the displacement and deformation of the molded part, preventing the insert panel from protruding through openings even under external forces, thus maintaining the structural integrity and reducing manufacturing costs.
Implementation Method 1
a molded part made of a rubber-like elastic material... the rubber-like elastic material forming the molded part enters the recesses
Data Source
Figure 1
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AI summary
An insert panel 12 is embedded in a molded part 9 of a weatherstrip. The molded part 9 has an opening 18 formed in its surface. A portion of the insert panel 12 near a corner thereof is exposed through the opening 18. A side edge 15a defining the corner of the insert panel 12 has a recess 25 opening laterally outward and getting engaged with the molded part 9, so as to reduce the displacement of the molded part 9 along the side edge 15a.