Flexible Accordion Clip for Misaligned Rocker Panel Assembly
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Solution Overview
Problem
Existing fasteners used in assembling rocker panels to vehicle frames face difficulties in alignment, making pre-assembly challenging, especially when fasteners are not directly aligned, leading to potential damage during installation.
Innovation Solution
A fastener design featuring a flange with flexible walls and a base connected by a hinge, allowing the post with a retaining member to securely engage with a bore in the substructure, facilitating pre-assembly and alignment regardless of initial fastener alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid fasteners are used for pre-assembly, then structural strength is improved, but alignment flexibility deteriorates making installation difficult when fasteners are misaligned
Solution Approach 1:
The fastener incorporates a flexible hinge connecting the flange to the base, transforming the rigid structure into a dynamic one. The hinge allows the flange to rotate and adjust its angle relative to the base, enabling the fastener to accommodate misaligned holes and achieve proper alignment during installation while maintaining structural integrity
2Productivity
If pre-assembly is performed with rigid fasteners, then assembly efficiency is improved, but risk of damage increases when alignment is poor
Solution Approach 1:
The flexible hinge allows the fastener to adapt to misaligned holes through rotation and adjustment, preventing binding and potential damage to the fastener or panel during pre-assembly operations, while still enabling efficient assembly
Solution Approach 2:
The hinge changes the geometric parameters of the fastener configuration dynamically, allowing the flange angle and position to adjust during insertion, thereby accommodating alignment variations and preventing damage
3Reliability
If multiple fasteners are used on rigid panels, then securing reliability is improved, but installation complexity increases when fasteners are misaligned
Solution Approach 1:
Each fastener with a flexible hinge can independently adjust its alignment, allowing multiple fasteners to be installed on rigid panels without requiring precise pre-alignment, thereby maintaining securing reliability while simplifying installation complexity
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
Enables easy pre-assembly and secure installation of rocker panels to vehicle frames, reducing the risk of damage and simplifying the assembly process by allowing flexible alignment and secure retention within the substructure.
Implementation Method 1
at least one flexible hinge resiliently connecting the base and the flange such that when the base is pushed toward the flange, the post with the retaining member passes through the bore
Implementation Method 2
flexible walls formed around the bore and extending outward from the flange with retaining clips formed at respective leading ends thereof, the flexible walls bending inward towards the bore when pressed into the bore
Data Source
AI summary
A fastener for securing a panel to a substructure includes a flange having a bore, a base disposed under the flange and having a post extending upwardly from the base, the post having a retaining member at an upper portion thereof, and at least one flexible hinge resiliently connecting the base and the flange such that when the base is pushed toward the flange, the post with the retaining member passes through the bore adapted to engage with other member. The flange further includes flexible walls formed around the bore and extending outward with retaining clips formed at respective leading ends thereof. The flexible walls bend towards the bore when pressed into the bore.