Biased Tab Coupling System for Noise-Free Vehicle Component Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The use of fastener systems in vehicular components leads to increased parts, costs, assembly time, and undesirable noise due to relative motion between components and fasteners, causing issues like squeaking and rattling.
Innovation Solution
A coupling system featuring a first component with biased tabs and a second component with receiving apertures and notches, where the tabs are configured to interferingly engage the notches, facilitating secure coupling and alignment without the need for fasteners, thereby reducing relative movement and noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fastener systems are used to couple vehicular components, then the components can be securely connected, but the number of parts increases, cost increases, assembly time increases, and relative motion between components and fasteners causes noise
Solution Approach 1:
The patent integrates the fastening function directly into the component structures themselves through tabs and receiving apertures with notches. The tab is formed as an integral part of the first component, and the receiving aperture with notch is formed as an integral part of the second component, eliminating the need for separate fasteners and reducing part count while maintaining secure connection.
Solution Approach 2:
The patent extracts the fastening function from separate fastener components and embeds it directly into the component structures. The tab-and-notch configuration removes the need for external fasteners by incorporating the coupling mechanism into the components themselves, thereby reducing the number of parts.
2Reliability
If fastener systems are used to couple vehicular components, then the components can be securely connected, but assembly time increases
Solution Approach 1:
The tab is pre-formed extending from the first component, and the receiving aperture with notch is pre-formed in the second component. This preliminary formation of coupling features allows for rapid assembly by simply inserting the tab into the receiving aperture without requiring additional fastening operations, thereby reducing assembly time while ensuring secure connection.
3Reliability
If fastener systems are used to couple vehicular components, then the components can be connected, but relative motion between components and fasteners causes undesirable noise such as squeaking and rattling
Solution Approach 1:
Instead of using a fastener that clamps or threads onto the component surfaces (which creates relative motion and noise), the patent inverts the approach by having the tab insert into the receiving aperture and lock via the notch. This inversion creates a more rigid, noise-free connection by eliminating the relative motion between separate fastener and component surfaces.
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 provides a secure, noise-free, and efficient coupling method that reduces assembly time, eliminates the need for fasteners, and ensures proper alignment and stability of components, while accommodating thermal expansion and contraction.
Implementation Method 1
The at least one tab is biased in a direction away from the body
Data Source
AI summary
In one aspect, a coupling system is provided. The coupling system includes a first component comprising a body, a second component comprising an inner wall defining at least one receiving aperture, wherein a notch is formed in the inner wall, and at least one tab extending outwardly from the body. The at least one tab is biased in a direction away from the body, and a retention feature is formed on the at least one tab and configured to interferingly engage the notch. When the at least one tab is inserted into a corresponding receiving aperture of the at least one receiving aperture, the at least one tab is biased against the inner wall and the retention feature interferingly engages the notch to facilitate coupling the first component to the second component in a desired orientation.