1. Roof moulding is not able to consistently withstand the required force during pull out test.
“ How to ensure the bonding strength between the surface of roof moulding body and end clip is sufficient
to withstand the pull out standards required by customer ?”
• Meeting customer requirement
• Increased customer satisfaction
• Less defects and wastage
• Increase productivity
• Process become more efficient
• Manufacturing cost is reduced
2.
3. Problem to Resolve
Function Analysis
Cause & Effect Chain Analysis
Trimming
Engineering
Contradiction
Physical
Contradiction
Su-Field Model TESE
Contradiction
Matrix
Separation,
Satisfaction,
Bypass
System of
Standard Inventive
Solutions
Dynamization
Specific Inventive
Principle
Specific Inventive
Principle
Specific Standard
Inventive Solution
4. T = [Funtion2 / (Problem + Cost)]
#40 Composite Material
Not to be considered as material specified by customer
#7 Nested Doll & #8 Anti Weight & #26 Copying
The problems involves two simple components attaching each other during injection
process, additional objects are not to be introduced.
#10 Preliminary Action
It is irrelevant
#17 Another Dimension
Joint surface can be maximized to include the top edge of the body part for additional
contact
#14 Curvature
Combined with principle #17, curvilinear was added into the area. Curve shape needs
less material, it gives better visual appearance
#3 Local Quality & #15 Dynamization
Interlocking can improve the mechanical bonding strength
• Trimmed the glue component as the object is able
to perform the function itself.
• Glue is insufficient function in term of bonding the
body and end clips.
IF contact surface for bonding is small,
THEN less material is needed and the process cycle is short
BUT the bonding strength is weak and defective products are produced.
Improving parameters: Area of stationary object (#6), Speed (#9)
Worsening parameters: Strength (#14), Productivity (#39)
Manipulating variable: Area of contact surface for bonding
Responding variable: Strength of bonding
5. In our problem, the size requirement of contact area at the joint surface is the only parameter
that develops a contradiction at two opposing values.
• Where need to be large?
On the direct contact surface area for sufficient bonding.
• Where need to be small?
Other surrounding surface area for less usage of material.
Inventive Principles : # 4 Asymmetry : (similar to #3 and #15)
provide better inter-locking and improved
mechanical strength at the contact surface
# 24 Use of Intermediary (similar to #10)
this is irrelevant as glue as intermediary
object which has trimmed
#1, #2, #7, #30
not considered as no other parts are to be
introduced to the part assembly
6. • Trend of increasing Dynamization
Inventive Principles
#3 Local Quality
#4 Asymmetry
#15 Dynamization
F1 (Mechanical:
adhesion by glue)
Roof Moulding
Body
End
Clips
Bonds
S1 with S2
Sub Field Model focus on the Zone of conflict where the contact between substance and
field occur the overlapping of either useful or harmful.
F2
(Mechanical: by structural locking)
Roof Moulding
S3 (Modified S1)
End Clips
(S2)
Bonds With
