Window Seal Assembly Molded Bracket Alignment
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Solution Overview
Problem
Conventional methods of manufacturing window seal assemblies face challenges in maintaining precise alignment and secure attachment to vehicles due to tolerance stack-up from dimensional variations and manufacturing processes, which can lead to improper fitment and operation.
Innovation Solution
A method involving a molding apparatus with receptacles and a bracket apparatus to form a window seal assembly, where a first and second strip of material are bonded together with a bracket, ensuring the receiver point is spaced from the molding reference point by a predetermined distance, facilitating secure attachment to the vehicle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If clips, fasteners, locators, and brackets are subsequently installed into holes/formations after the molded seal assembly has been formed, then the seal assembly can be attached to the vehicle, but tolerance stack-up from dimensional variations and manufacturing processes leads to imprecise alignment and improper fitment
Solution Approach 1:
The patent combines the bracket formation process with the molding process into a single integrated operation. The bracket apparatus is positioned within the molding apparatus, allowing the bracket to be formed and bonded to the seal assembly simultaneously with the seal assembly molding, eliminating sequential operations and reducing cumulative tolerances
Solution Approach 2:
The bracket apparatus is pre-positioned within the molding apparatus before the molding process begins. This preliminary positioning ensures that the bracket will be formed at the correct location and orientation, preventing alignment issues that would arise from subsequent installation operations
2Adaptability or versatility
If various types of clips, locators, and brackets are subsequently attached to the molded seal assembly at predetermined locations, then attachment to the vehicle is facilitated, but the multi-step process increases device complexity and manufacturing time
Solution Approach 1:
The patent merges the bracket formation operation with the seal assembly molding operation into a single integrated process. The bracket apparatus is incorporated within the molding apparatus, allowing both components to be formed and bonded simultaneously, thereby reducing the number of manufacturing steps and overall process complexity
Solution Approach 2:
The integrated molding apparatus serves multiple functions: it forms the seal assembly, forms the bracket, and bonds them together in a single operation. This multi-functionality eliminates the need for separate operations for each step, simplifying the manufacturing process
3Ease of manufacture
If holes or other formations are defined in extruded members prior to molding and clips/fasteners are subsequently installed, then attachment features are provided, but the sequential manufacturing process increases production time and reduces productivity
Solution Approach 1:
The bracket apparatus is pre-positioned within the molding apparatus before the molding process begins, ensuring that the bracket will be formed at the correct location and orientation. This preliminary action eliminates the need for subsequent installation operations, thereby increasing productivity
Solution Approach 2:
The integrated process allows for continuous formation and bonding of the bracket and seal assembly in a single uninterrupted operation. Material is directed into the molding cavity and bracket cavity simultaneously, maintaining continuous useful action throughout the process rather than interrupting for separate 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 method enhances the manufacturing process by maintaining precise alignment and secure attachment, reducing tolerance stack-up issues and ensuring proper fitment and operation of the window seal assembly.
Implementation Method 1
directing material into the molding cavity to form a molding bonding the first strip together with the second strip
Implementation Method 2
directing material into the bracket cavity to form a bracket having a flange with a receiver defining a receiver point and having an interface extending from the flange into contact with the first body to bond the bracket to the first body
Data Source
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AI summary
A method of manufacturing a seal assembly for attachment to a vehicle having a securing point spaced from a vehicle point at a distance with an apparatus having first and second receptacles defining a cavity, and a bracket apparatus defining a bracket cavity, including: forming a first strip having a first body with first ends; forming a second strip having a second body with second ends; positioning one first end into the first receptacle with the first body adjacent to the bracket cavity; positioning one second end into the second receptacle; forming a molding bonding the strips together to define a mold point; forming a bracket with a receiver at a receiver point, and an interface bonded to the first body spaced such that a distance between the receiver point of the bonded bracket and the mold point is equal to the distance between the securing and vehicle points.