Clinching Fastener for Flush Magnet Mounting
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Solution Overview
Problem
Existing methods for attaching magnets to host objects, such as adhesives and mechanical fasteners, face limitations in strength and alignment, with gaps between the magnet and host object weakening the magnetic connection and adhesives not providing sufficient attachment strength, especially for plated magnets.
Innovation Solution
A clinching or swaging fastener with a center knob and radial flange that holds the magnet flush to the surface, using an undercut for secure attachment and alignment features to ensure consistent orientation, combining deformation of the lip and knob for a strong interference fit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesives are used to attach magnets to host objects, then the attachment process is simple, but the attachment strength is insufficient
Solution Approach 1:
The patent replaces the chemical bonding mechanism of adhesives with a mechanical clinching system. The fastener includes a body with an undercut that mechanically interlocks with the magnet and host object, providing superior attachment strength through mechanical engagement rather than chemical adhesion.
Solution Approach 2:
The fastener system combines multiple materials and mechanisms: the fastener body material, the magnet material, and the host object material work together in a composite assembly. The mechanical fastener integrates with both the magnet and host object to create a unified strong attachment system that overcomes the limitations of single-material adhesive bonding.
2Strength
If magnets are arranged countersunk relative to the host target, then mechanical fastening is achieved, but the magnetic connection is weakened due to gap creation
Solution Approach 1:
The fastener body extends beyond the magnet in certain regions (the flange and undercut portions) to provide mechanical anchoring, while the magnet's active surface remains flush with or slightly protrudes from the host object surface. This partial extension provides the necessary mechanical fastening without creating gaps that would weaken the magnetic field.
Solution Approach 2:
The patent separates the mechanical fastening function from the magnetic connection function in different spatial dimensions. The mechanical interlocking occurs in the radial and axial dimensions through the undercut and flange, while the magnetic connection operates optimally in the axial dimension with flush surfaces, allowing both functions to perform without compromising each other.
3Strength
If magnets are shaped to include clinch undercut, then mechanical attachment is possible, but the magnet structure is compromised
Solution Approach 1:
The patent divides the attachment system into separate functional components: the magnet retains its intact active surface for optimal magnetic performance, while the fastener body provides the mechanical clinching function through its own undercut structure. This segmentation allows each component to optimize its shape for its specific function without compromising the other.
Solution Approach 2:
The fastener body acts as an intermediary element between the magnet and the host object. Instead of modifying the magnet's shape, the intermediary fastener provides the mechanical interlocking feature, allowing the magnet to maintain its original intact shape and optimal magnetic properties while still achieving strong mechanical attachment.
4Manufacturing precision
If alignment features are added to the fastener, then orientation consistency is achieved, but the device complexity increases
Solution Approach 1:
The fastener incorporates asymmetric alignment features such as non-circular cross-sections, keyed portions, or positioned protrusions that prevent rotational misalignment during assembly. These asymmetric geometric features provide inherent orientation guidance, ensuring consistent magnet positioning without requiring complex external alignment mechanisms or multiple component systems.
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 stronger and more reliable attachment of magnets to host objects by ensuring the magnet's active surface is flush, enhancing the magnetic connection and resisting rotation, while reducing installation force and damage.
Implementation Method 1
an article is rigidly held between the lip and the knob after they are simultaneously deformed against opposite ends of the article
Implementation Method 2
the magnetic field, and hence magnetic connection, between a magnet and its target is inversely proportional to the distance between the magnet and the target
Data Source
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AI summary
A clinching or swaging fastener for securely mounting a secondary article, such as a magnet, flush to a surrounding surface. An interference fit fastening feature holds the secondary article flush by using a deformable center knob on the end wall at the bottom of the retainer. Alignment features on the outer portion of the retainer body can fixture the magnet in a desired orientation. A radial flange surrounds the mouth of the bore which has a peripheral lip that extends upwardly. Clinch attachment means comprising a circular peripheral undercut is located on the outside of the body just below the flange for attaching the body to a host object. The article may have a peripheral chamfer at the top which receives the lip as it is deformed against the article to provide a flush alignment to the host object.