Wind Deflector Fastening Device for Crease-Free Fabric Deployment
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Solution Overview
Problem
Conventional wind deflector connection methods lead to creases and folds in flexible deflector elements, and the production of differently sized wind deflectors is costly due to the need for multiple injection molding tools, with high transportation costs and inefficiencies in assembly and logistics.
Innovation Solution
A fastening device with clamping strips and connecting elements that penetrate the fabric, providing a homogeneous surface pressure and allowing for easy assembly and adaptation to various geometries, with the option to pre-fix the fabric using through-openings and reinforcement structures for added stability and reduced tooling costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional clamping methods (insertion pins and openings) are used to connect the deflector element to the deployment bracket, then the deflector element can be securely fastened, but creases and folds form in the flexible deflector element material
Solution Approach 1:
An intermediate fastening structure consisting of a first and second fastening element is introduced between the deployment bracket and the deflector element. These fastening elements distribute the clamping force along the edge of the deflector element, preventing localized stress concentrations that cause creases and folds while maintaining secure fastening.
Solution Approach 2:
The fastening system changes the distribution parameter of clamping force from concentrated (at insertion pin points) to distributed (along the edge through multiple fastening elements). This parameter change eliminates the formation of creases and folds by avoiding localized stress concentrations.
2Adaptability or versatility
If multiple injection molding tools are used to produce differently sized wind deflectors, then various geometries can be manufactured, but procurement and investment costs increase significantly
Solution Approach 1:
The wind deflector system is segmented into modular components: a standardized deployment bracket and customizable deflector elements. This segmentation allows the use of a single injection molding tool for the bracket while enabling cost-effective production of different deflector element sizes and geometries through alternative manufacturing methods.
Solution Approach 2:
The deployment bracket is designed as a universal component that can accommodate different deflector element sizes and geometries through standardized connection interfaces. This universality eliminates the need for multiple specialized injection molding tools, reducing procurement and investment costs while maintaining adaptability to various geometries.
3Quantity of substance
If the deflector element is prefabricated separately and then assembled to the deployment bracket, then transportation costs and volumes are reduced, but assembly complexity increases
Solution Approach 1:
The system is divided into separable components (deployment bracket and deflector element) that can be prefabricated independently. This segmentation enables reduced transportation costs and volumes by allowing compact packaging of individual components before final assembly at the installation location.
Solution Approach 2:
The fastening elements serve as intermediaries that simplify the assembly process between the prefabricated deflector element and the deployment bracket. Despite the separation of components, the standardized fastening mechanism maintains assembly simplicity by providing clear, tool-free connection interfaces.
Data Source
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AI summary
A deflection element for a wind deflector of a motor vehicle includes a flexible fabric configured to be transferred by a deployment element of the wind deflector into a raised or spread out use position in relation to a basic position. The deflection element has a fastening device along at least one upper or lower side edge of the fabric for fixing the deployment element on a base element of the wind deflector, or on a motor vehicle chassis. The fastening device has at least one first clamping strip and at least one second clamping strip connected to one another by connecting elements which correspond to one another and penetrate through the fabric to thereby clamp the side edge of the fabric between the first clamping strip and the second clamping strip.