Blind Fastener with Composite Core for Automotive Panel Assembly
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Solution Overview
Problem
Existing fastening techniques for closely positioned automotive panels face issues such as corrosion, noise (BSR), and increased manufacturing complexity, particularly with metal fasteners, and the limitations of plastic fasteners in achieving secure, close-panel blind connections.
Innovation Solution
A fastening system utilizing a pass-through doghouse-based configuration with a W-type fastener, push pin, or pin and grommet design, featuring a head assembly, neck, and retention features that allow for a blind connection between panels while minimizing protrusion distance and assembly complexity, using ribs and wings to control movement and absorb noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal fasteners are used to make blind connections between panels, then secure fastening is achieved, but the abrasive nature wears through paint or anticorrosive coatings promoting corrosion
Solution Approach 1:
The fastener uses a composite structure with a metal core providing structural strength and a plastic coating providing corrosion protection. The metal core maintains fastening security while the plastic coating prevents direct contact between metal and panel coatings, eliminating abrasion and corrosion risks.
2Strength
If metal fasteners are used to make blind connections, then secure fastening is achieved, but they tend to buzz, squeak, and rattle (BSR)
Solution Approach 1:
The plastic coating on the metal core acts as a damping material that absorbs vibrations and prevents metal-to-metal contact, thereby eliminating buzzing, squeaking, and rattling noises while maintaining the structural integrity and fastening security of the metal core.
3Object-affected harmful factors
If plastic fasteners are used to replace metal fasteners to mitigate abrasion and avoid BSR, then corrosion and noise are reduced, but the distance between panels increases and moderately high insertion forces are required
Solution Approach 1:
The metal core provides high stiffness and strength-to-length ratio, allowing the fastener to maintain short length and minimal panel distance while the plastic coating provides corrosion and noise protection. This composite structure overcomes the limitations of pure plastic fasteners.
4Object-affected harmful factors
If combination metal and plastic fasteners are used to mitigate abrasion and avoid BSR, then corrosion and noise are reduced, but the fasteners are typically larger and more difficult to manufacture
Solution Approach 1:
The fastener is manufactured as a single integrated composite component with metal core and plastic coating formed together, eliminating the need for separate metal and plastic parts and their associated assembly steps. This reduces manufacturing complexity while maintaining the benefits of both materials.
Data Source
AI summary
Disclosed are systems and methods for coupling a first panel to a second panel via a fastening system. The fastening system comprises fastener and a doghouse structure. The fastener includes a head assembly coupled to a collar. The collar is configured to pass through and to retain the second panel via an opening formed in the second panel. The doghouse structure defines a chamber that is configured to receive and secure the head assembly. The doghouse structure is positioned on the first panel and is configured to pass at least partially through the opening.