Adjustable Tower Stud Assembly for Vehicle Roof Rack
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Solution Overview
Problem
Existing fastening systems for attaching accessories to vehicles face issues due to manufacturing tolerances, leading to poor fit, deformation, or water leaks, as they struggle to accommodate variations in the spacing between the external panel and the sub-surface mounting structure.
Innovation Solution
A fastener assembly featuring a dual-stud system with a stop mechanism and prevailing torque nut, allowing for adjustable extension and compression to ensure proper seating and sealing, while preventing over-tightening, using a retention clip and seal to secure the accessory to both panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fixed height fasteners are used to secure the roof rack to the sub-structure mounting plate, then the fastening system is simple and easy to manufacture, but manufacturing tolerances cause variations in spacing that adversely affect product quality
Solution Approach 1:
The fastening system transitions from a fixed-height fastener to an adjustable-height tower stud assembly. The tower stud can be extended or retracted to accommodate variations in spacing between the external panel and sub-structure mounting plate, allowing the system to adapt dynamically to different spacing conditions while maintaining consistent attachment quality.
Solution Approach 2:
The invention changes the height parameter of the fastener from a fixed value to an adjustable value. The tower stud assembly allows modification of its effective length to compensate for spacing variations caused by manufacturing tolerances, thereby maintaining consistent attachment quality across different installation scenarios.
2Strength
If the fastener is tightened when the distance is less than the design height, then the fastener secures the roof rack, but the outer roof panel is dented or deformed
Solution Approach 1:
The tower stud assembly acts as an intermediary between the fastener and the external panel. By adjusting the tower stud height to match the actual spacing, the system ensures that the fastening force is applied at the correct distance from the panel, preventing direct contact and deformation of the panel while still achieving secure attachment.
Solution Approach 2:
The system performs a preliminary measurement or adjustment of the tower stud height before applying the fastening force. This preliminary action ensures that the fastener is positioned at the correct distance from the panel, preventing deformation before the fastening process begins.
3Strength
If the distance between the outer roof panel and the sub-structure mounting plate is greater than the design height, then the fastener can be tightened, but the roof rack is not fully seated to the outer panel
Solution Approach 1:
The tower stud assembly provides dynamic height adjustment to ensure that regardless of the initial spacing distance, the fastener can be tightened to achieve complete seating of the roof rack to the outer panel. The adjustable height compensates for spacing variations, allowing the sealing surface to make full contact.
Solution Approach 2:
The invention changes the effective length parameter of the fastener to match the actual spacing distance. This parameter adjustment ensures that when the fastener is tightened, the roof rack is pulled into complete contact with the outer panel, achieving both secure fastening and complete seating for proper sealing.
4Manufacturing precision
If an adjustable tower stud assembly is used to accommodate spacing variations, then product quality is improved, but the device complexity increases
Solution Approach 1:
The fastening system is segmented into modular components: the tower stud assembly with adjustable height mechanism, the fastener, and the mounting hardware. This segmentation allows for independent optimization of each component and simplifies assembly and adjustment procedures despite the overall system 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
The solution effectively addresses spacing variations, ensuring a secure and watertight attachment by accommodating manufacturing tolerances and preventing deformation, thereby enhancing product quality and reliability.
Implementation Method 1
A seal may be compressed between the object and the external panel when the second stud is rotated in the one direction after the stop engages the slot
Implementation Method 2
A first threaded shaft that extends from the object through an opening in the external panel. A second stud defines a threaded hole in a first end for receiving the first threaded shaft
Data Source
AI summary
An adjustable tower stud assembly is disclosed for securing an object, such as a roof rack, to an external panel such as the roof of a vehicle. The object requires more support than can be provided by the external panel and it is also connected to a sub-surface support. Upper and lower collared studs are connected by a threaded connection that allows the length of the tower stud assembly to be adjusted. Stops on a lower collar ground the tower stud assembly to the sub-surface support after the tower stud assembly is adjusted to the proper length.