Single Cantilevered Leg Spring Clip for Sheet Metal Assembly
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Solution Overview
Problem
Conventional fastening methods require additional separate fasteners, increasing assembly costs, weight, and the risk of squeaks and rattles, while also complicating the assembly process and potentially leading to mismatches or omissions.
Innovation Solution
A V-shaped spring clip with a post and a single resilient cantilevered leg, featuring a double blocked notch and S-curve segment, which eliminates the need for separate fasteners by providing a robust and durable joint that secures a plastic part to a sheet metal part with a single snapping action, reducing weight and cost while minimizing noise and misalignment risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fasteners (bolts/nuts, metal clips, plastic clips) are used to secure plastic parts to sheet metal parts, then the joint strength and reliability are improved, but the assembly weight, cost, and complexity increase
Solution Approach 1:
The patent combines the functions of the fastener and the plastic part into a single integrated spring clip structure. The spring clip is molded as part of the plastic component, eliminating the need for separate fasteners. This merging reduces assembly complexity while maintaining joint reliability through the resilient cantilevered leg that provides secure attachment to sheet metal parts.
Solution Approach 2:
The spring clip serves multiple functions: it acts as both a structural component of the plastic part and a fastening mechanism for securing to sheet metal parts. The resilient cantilevered leg provides both positioning and locking functions, while the guide rib ensures proper alignment. This multi-functionality reduces the number of components needed while maintaining reliable joints.
2Strength
If additional separate fasteners are added to secure plastic parts, then the joint strength is improved, but the assembly weight and cost increase
Solution Approach 1:
The fastening function is merged into the plastic part itself through the integrated spring clip structure. By eliminating separate fasteners, the overall assembly weight is reduced while the joint strength is maintained through the resilient cantilevered leg design that provides secure mechanical attachment to sheet metal parts.
3Reliability
If multiple separate fasteners are used, then the joint reliability is improved, but the risk of squeaks and rattles increases
Solution Approach 1:
The integration of the spring clip into the plastic part creates a unified structure with fewer interfaces between separate components. This reduces the number of potential sources of squeaks and rattles while maintaining joint reliability through the resilient cantilevered leg that provides secure, vibration-dampening attachment.
4Duration of action of stationary object
If conventional fasteners are used, then the joint durability is improved, but the production time and manufacturing cost increase
Solution Approach 1:
The spring clip is molded as an integral part of the plastic component during the molding process, eliminating the need for separate fastener installation steps. This integration maintains joint durability through the resilient cantilevered leg design while significantly reducing production time and manufacturing cost by eliminating additional assembly operations.
Solution Approach 2:
The spring clip is pre-formed as part of the plastic molding process, with the resilient cantilevered leg and guide rib already in place. This preliminary formation during molding eliminates the need for subsequent fastener installation steps, improving productivity while ensuring the joint durability is built into the structure from the beginning.
5Reliability
If multiple separate fasteners are used, then the joint reliability is improved, but the risk of missing or mismatched fasteners increases
Solution Approach 1:
The spring clip is integrated into the plastic part as a single molded structure, eliminating the risk of missing or mismatched fasteners. The guide rib on the spring clip ensures proper alignment with the sheet metal part, while the resilient cantilevered leg provides secure attachment, maintaining joint reliability without the precision issues associated with multiple separate fasteners.
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 spring clip effectively secures plastic parts to sheet metal components with reduced weight and cost, minimizing noise and misalignment risks, and simplifying the assembly process by eliminating the need for additional fasteners, while maintaining robustness and durability.
Implementation Method 1
a single resilient cantilevered leg depending from the post
Implementation Method 2
The spring clip also includes a double blocked notch on the end of the single resilient cantilevered leg to dissipate stress concentrations
Data Source
AI summary
A spring clip includes a base, a post carried on the base and a single resilient cantilevered leg depending from the post. That resilient cantilevered leg includes an S-curve segment and a distal end having a double blocked notch.