Deformable Coupling Device for Vehicle Assembly Tolerance Compensation

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Solution Overview

Problem

Manufacturing tolerances in vehicle components lead to misalignment and forced fits during assembly, causing vibrations and potential damage in vehicle accessories like indicator lights.

Innovation Solution

A coupling device with a deformable plastic or rubber main body featuring tolerance compensating means, such as accordion-like folds, to absorb dimensional variations, ensuring correct alignment and retention of fastening pins to structural elements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional fastening methods with rigid pins and holes are used, then assembly is simple and direct, but manufacturing tolerances cause misalignment and forced fits leading to vibrations and potential damage

Engineering Contradiction:

Improveassembly reliabilityVSAvoidvibrations and damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the physical state and geometric parameters of the coupling device by introducing deformable material (rubber or plastic) and accordion-like folds, allowing the device to change shape and absorb dimensional variations, thereby preventing vibrations and damage while maintaining reliable assembly

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The coupling device transitions from a rigid static structure to a dynamic flexible structure that can deform and adapt during assembly, enabling it to accommodate misalignment and tolerances while maintaining connection reliability and reducing harmful vibrations

Inventive Principle:

Principle #15Dynamics

2Manufacturing precision

If rigid coupling devices are used to ensure precise alignment, then manufacturing precision is maintained, but the device cannot absorb dimensional variations and tolerances

Engineering Contradiction:

Improvealignment precisionVSAvoidtolerance absorption

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The patent employs a flexible shell structure made of rubber or plastic material with accordion-like folds that can deform to absorb dimensional variations and tolerances while maintaining precise alignment through controlled elasticity, thus achieving both manufacturing precision and adaptability

Inventive Principle:

Principle #30Flexible shells and thin films

3Adaptability or versatility

If deformable materials are used to absorb tolerances, then adaptability and tolerance absorption improve, but device complexity increases

Engineering Contradiction:

Improvetolerance compensationVSAvoidstructure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The coupling device is segmented into distinct functional zones: the cap for receiving the pin, the accordion-like folds for tolerance absorption, and the base for fastening. This segmentation allows each part to perform its specific function efficiently while keeping the overall design relatively simple

Inventive Principle:

Principle #1Segmentation

4Device complexity

If conventional fastening methods are used, then device complexity is low, but the assembly cannot compensate for manufacturing tolerances causing forced fits

Engineering Contradiction:

Improveassembly simplicityVSAvoidfit accuracy

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The coupling device acts as an intermediary element between the pin and the structural element, using its deformable accordion-like structure to mediate the connection and absorb dimensional variations, thereby achieving accurate fit without increasing overall assembly complexity

Inventive Principle:

Principle #24Intermediary (Mediator)

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 coupling device effectively compensates for manufacturing tolerances, ensuring proper fit and preventing damage by allowing controlled deformation to align pins with structural elements, providing a secure and vibration-resistant assembly.

Implementation Method 1

The main body is formed of plastic material and comprises tolerance compensating means, said means being substantially deformable

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

allowing controlled deformation to align pins with structural elements

Methodology Applied

Scientific EffectDeformation: Deformation

Data Source

PatentEP3832148B1Coupling device

Publication Date: 2023.08.16 SEAT SA

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AI summary

The invention relates to a coupling device (100) for coupling to a structural element (300), wherein the device (100) comprises a main body comprising: a cap (101) that creates a hollow space, with at least one side wall (104), wherein the hollow space is suitable for receiving a fastening pin (200); a base (105) located at a first end (106) of the cap (101), wherein the base (105) defines an opening (108) suitable for receiving the fastening pin (200) in the hollow space of the main body; fastening means (102) suitable for fastening the coupling device (100) to the structural element (300); and retaining means (109), arranged on the inner surface of the side wall (104), wherein the retaining means (109) are suitable for retaining the fastening pin (200) in the cap (101). The main body is formed of plastic material and comprises substantially deformable tolerance compensating means (110) such that they enable at least one dimension to be adjusted in the assembly of the fastening pin (200) with respect to the structural element (300).