Angled Vehicle Component Fastening Without Clearance Holes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing one-sided joining methods face challenges in efficiently driving fasteners through components without interference from neighboring parts, especially when the fastener needs to be driven nonperpendicular to the interface plane, as existing methods often require clearance holes and perpendicular alignment.
Innovation Solution
A method involving a first component with a stand-off cavity and a tilted floor, allowing a single-sided fastener, such as a flow drill screw, to be driven through the interface between the components without pre-existing clearance holes, using a torque tool that tilts away from the normal axis to avoid interference and create apertures as it joins the components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a fastener is driven perpendicular to the interface plane using existing one-sided joining methods, then the fastener can be easily aligned and driven, but interference from neighboring parts occurs and pre-formed clearance holes are required
Solution Approach 1:
The cavity floor is designed with an angled surface that is asymmetric relative to the interface plane, causing the fastener to be driven at an angle non-perpendicular to the interface plane. This asymmetric configuration allows the fastener path to clear neighboring parts while maintaining one-sided operation benefits
Solution Approach 2:
The fastener driving direction is changed from the traditional perpendicular dimension to an angled dimension, allowing the fastener to traverse through the interface while avoiding interference zones created by neighboring components
2Ease of operation
If pre-formed clearance holes are used for fastener insertion, then fastener alignment is simplified, but additional manufacturing steps and material removal are required
Solution Approach 1:
The cavity structure with its angled floor is pre-formed in the component, providing built-in fastener guidance and alignment features that eliminate the need for separate clearance hole drilling operations
Solution Approach 2:
The cavity structure serves multiple functions: it houses the fastener, provides alignment guidance through its angled floor, and defines the fastener driving path, replacing what would traditionally require separate clearance holes and alignment features
3Object-affected harmful factors
If a tilted cavity floor is used to drive the fastener nonperpendicular to the interface, then interference from neighboring parts is avoided, but the fastener must be driven at an angled orientation
Solution Approach 1:
The angled cavity floor acts as a self-guiding feature that automatically directs the fastener at the correct angled orientation during insertion, eliminating the need for external alignment devices or complex positioning mechanisms
Data Source
AI summary
A vehicle component joining method includes, among other things, positioning a contact side of a first component adjacent a contact side of a second component, inserting a mechanical fastener into a cavity of the first component, and rotating the mechanical fastener to drive the mechanical fastener through an interface between the contact sides of the first and second components. The interface is disposed along an interface plane and the mechanical fastener is driven through the interface in a direction that is nonperpendicular to the interface plane.