Capped Wheel Fastener with Deflected Projections for Weight Reduction
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Solution Overview
Problem
Automotive wheel nuts are prone to corrosion due to their exposure to wet and salty environments, affecting their aesthetic appearance, and there is a need to reduce their weight while maintaining durability and aesthetics to improve energy efficiency.
Innovation Solution
A fastener design featuring a threaded body with a top portion and a bottom portion forming a horizontal shelf, where projections on the shelf extend radially outward to axially retain a cap with a double wall section, eliminating the need for a radial flange, thus reducing weight and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a radial flange is used to secure the cap, then the cap retention is improved, but the weight and material cost increase
Solution Approach 1:
The patent removes the radial flange from the fastener body, extracting the unnecessary component that added weight. Instead, projections on the shelf engage with the cap wall to provide cap retention, achieving the same function with less material.
Solution Approach 2:
The patent concentrates the retention function at specific locations (projections on the shelf engaging with the cap wall) rather than using a comprehensive radial flange structure. This localized approach reduces material while maintaining effectiveness.
2Reliability
If a complex assembly process is used to secure the cap, then the cap retention is improved, but the manufacturing complexity increases
Solution Approach 1:
The projections on the shelf automatically engage with the cap wall during assembly through elastic deformation, creating a self-retaining mechanism that eliminates complex assembly steps while ensuring reliable cap retention.
3Strength
If more material is used to reinforce the fastener body, then the strength is improved, but the weight increases
Solution Approach 1:
The patent segments the reinforcement function into discrete projections on the shelf rather than adding material throughout the entire fastener body. This targeted reinforcement provides necessary strength while minimizing weight increase.
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 design reduces the weight of wheel nuts, improves handling performance, and maintains durability and aesthetics by using an interference fit and projections to secure the cap, which also simplifies the assembly process and reduces material costs.
Implementation Method 1
the plurality of projections are deflecting the plurality of projections radially outward beyond the circular cross-section of the bottom portion of the fastener body
Data Source
Figure 1A~1B
Figure 2A~2C
Figure 3A~3C
AI summary
A capped fastener is provided with deflected projections on the nut body for securing a cap on the nut body. The deflected projections fit within a double walled edge of the cap. The projections are deflected through a simple method during the assembly process.