Injection-Molded Wind Deflector Hoop With Integrated Net Fixing
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Solution Overview
Problem
Existing wind deflector devices for vehicles face challenges in securely attaching the wind deflector net to the hoop without additional assembly steps or joining media, and existing molds do not effectively maintain the net's position during injection molding, leading to potential displacement under internal gas pressure.
Innovation Solution
The wind deflector net is fixedly connected to the injection-molded wind deflector hoop using an injection-molded connection during the molding process, with a positioning unit ensuring accurate placement and attachment, eliminating the need for additional assembly and maintaining the net's position within the mold cavity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the wind deflector net is attached to the wind deflector hoop using additional joining media or separate assembly processes, then the attachment can be achieved, but the manufacturing complexity and production time increase
Solution Approach 1:
The patent combines the attachment of the wind deflector net with the injection molding process of the wind deflector hoop into a single integrated operation. The net is positioned in the mold cavity before injection, and the molten plastic material directly bonds the net to the hoop as it solidifies, eliminating separate attachment steps and joining media while ensuring reliable fixation
Solution Approach 2:
The wind deflector net is pre-positioned in the mold cavity at a defined location before the injection molding process begins. This preliminary positioning ensures the net is correctly placed relative to the hoop geometry, and the subsequent injection molding process secures it in that predetermined position without requiring additional alignment or adjustment steps
2Productivity
If the wind deflector net is attached during injection molding without positioning fixtures, then the process is simpler, but the net may be displaced by internal gas pressure
Solution Approach 1:
The mold cavity acts as an intermediary structure that holds the wind deflector net in a fixed position during the injection molding process. The cavity walls provide physical constraints that prevent the net from being displaced by internal gas pressure, while the mold design integrates positioning features that maintain the net's defined location relative to the hoop geometry throughout manufacturing
3Strength
If additional stiffeners are attached to the wind deflector hoop, then the stiffness and torsional strength increase, but the manufacturing complexity and surface continuity deteriorate
Solution Approach 1:
The patent integrates the stiffening function directly into the wind deflector hoop's injection-molded structure. The hollow profile geometry and wall thickness distribution are designed during molding to provide the required stiffness and torsional strength without requiring separate stiffener components. This integration eliminates additional manufacturing steps for attaching stiffeners and maintains a continuous, smooth surface on the hoop
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 solution provides a securely attached wind deflector net with high stiffness and torsional strength, eliminating the need for additional stiffeners and assembly processes, while ensuring a smooth, continuous surface and easy mold removal.
Implementation Method 1
the closed mold holds a wind deflector net to be connected during injection molding to the wind deflector hoop in a fixing position, in which a fastening edge section of the wind deflector net is held in the mold cavity in an accurate position
Implementation Method 2
the wind deflector hoop is injection molded as a hollow profile by means of a fluid injection technique
Implementation Method 3
the wind deflector net is fixedly connected to the injection molding material forming the wind deflector hoop by means of an injection-molded connection produced during the injection molding process
Data Source
AI summary
The invention relates to a wind deflector device (6) of a vehicle roof (2), having a wind deflector hoop (7), which is injection molded as a hollow profile (17) by means of a fluid injection technique, and having a wind deflector net (13) fastened to the wind deflector hoop (7), whereinthe wind deflector net (13) is fixedly connected to the injection molding material forming the wind deflector hoop (7) by means of an injection-molded connection (23) produced during the injection molding process, and to a mold (24) for producing a wind deflector hoop (7).