Elastic Attachment Assembly Reducing Positional Variation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Mated components often experience positional variation due to manufacturing variances, leading to free movement, vibration, and undesirable noise such as squeaking and rattling, as traditional alignment methods like male and female alignment features or adhesives/welding fail to account for manufacturing tolerances effectively.
Innovation Solution
An elastic attachment assembly featuring a first component with elastically deformable protrusions that engage with receiving structures in a second component, allowing for self-alignment and elastic deformation to average positional variations, thereby reducing movement and increasing stiffness through an over-constrained interference fit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional alignment features (male and female features with clearance) are used to mate components, then ease of assembly is improved, but positional variation and free movement increase leading to vibration and noise
Solution Approach 1:
The patent changes the physical state and mechanical properties of the attachment features by making them elastically deformable. The protrusions are designed with elastic material properties that allow them to deform during assembly and maintain constant contact pressure, transforming a rigid clearance-based system into a flexible interference-fit system that accommodates manufacturing variations while eliminating free movement
Solution Approach 2:
The patent introduces dynamic adaptability by using elastically deformable protrusions that can adjust their position and contact pressure in real-time. The elastic deformation allows the attachment features to dynamically compensate for positional variations between mated components, transitioning from a static clearance fit to a dynamic interference fit that maintains optimal contact
2Ease of manufacture
If clearance is provided in alignment features to match manufacturing tolerances, then ease of manufacture is improved, but stiffness and vibration resistance deteriorate
Solution Approach 1:
The patent transforms the attachment mechanism from a clearance-based design to an elastic interference-fit design. The protrusions are designed with elastic properties that enable them to deform and create constant contact pressure, changing the fundamental mechanical parameter from clearance to interference fit, thereby increasing stiffness while remaining manufacturable
Solution Approach 2:
The patent incorporates elastic material properties in advance within the protrusions to cushion and absorb the effects of manufacturing tolerances. The elastic deformation capability is built into the design beforehand, allowing the system to compensate for positional variations without requiring tight manufacturing tolerances, thus maintaining both ease of manufacture and high stiffness
3Manufacturing precision
If elastic deformation is used to account for positional variation, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent achieves high positional precision by changing the material parameter of the attachment features to be elastically deformable. This single parameter change enables the protrusions to automatically compensate for manufacturing variations through elastic deformation, achieving precision without complex adjustment mechanisms or multiple components
Solution Approach 2:
The elastic protrusions are self-adjusting and automatically compensate for positional variations between mated components. The elastic deformation occurs naturally during assembly, and the protrusions self-align and maintain constant contact pressure without requiring external control systems, complex mechanisms, or additional adjustment components
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 elastic attachment assembly effectively reduces positional variation, minimizes free movement, and enhances the stiffness of mated components, resulting in reduced vibration and improved load transfer capabilities while allowing for repeatable assembly and disassembly.
Implementation Method 1
a plurality of elastically deformable protrusions extending from the base outer surface of the first component... configured to elastically deform upon insertion to the plurality of receiving structures
Data Source
AI summary
Included is a first component having a base outer surface. Also included is a plurality of elastically deformable protrusions extending from the base outer surface of the first component. Further included is a second component having a pocket portion configured to receive the first component therein, the pocket portion defined by a base wall and at least one sidewall extending from the base wall. Yet further included is a plurality of receiving structures defined by the base wall of the pocket portion and configured to receive the plurality of elastically deformable protrusions, wherein the plurality of elastically deformable protrusions is configured to elastically deform upon insertion to the plurality of receiving structures.