Elastic Mating Assembly for Positional Tolerance Compensation
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Solution Overview
Problem
Matable components often experience significant positional variation due to manufacturing variances, leading to poor fit, gaps, and unwanted motion such as squeaking and rattling, as existing mating methods like alignment features and adhesives fail to account for manufacturing tolerances effectively.
Innovation Solution
An elastic mating assembly comprising a rigid first component, an elastically deformable second component with a cutout portion, and a third component that elastically deforms upon contact, providing a snap-fit engagement and elastic averaging to align and secure the components despite positional variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional alignment features with clearance are used to mate components, then assembly is simple and manufacturing tolerances are accommodated, but positional variation between components occurs leading to gaps and poor fit
Solution Approach 1:
The patent changes the physical state of the intermediate component from rigid to elastically deformable. This allows the component to dynamically adjust its shape and position during assembly, accommodating manufacturing tolerances while maintaining tight fit and eliminating gaps between mated components.
Solution Approach 2:
The intermediate component is designed to be elastically deformable rather than static, allowing it to adapt its configuration during the mating process. This dynamic behavior enables the component to absorb positional variations and maintain optimal contact with both the first and third components.
2Ease of operation
If clearance is provided in alignment features to account for manufacturing variances, then assembly is easier, but relative motion between mated components occurs causing squeaking and rattling
Solution Approach 1:
By changing the material property of the intermediate component to be elastically deformable, the patent eliminates clearance gaps that cause relative motion. The elastic deformation allows the component to maintain continuous contact with mating surfaces, preventing squeaking and rattling while preserving ease of assembly.
3Strength
If rigid alignment features are used to mate components, then structural strength is maintained, but positional variation and manufacturing tolerances result in poor fit and gaps
Solution Approach 1:
The patent changes the rigidity parameter of the intermediate component, making it elastically deformable rather than completely rigid. This allows the component to maintain overall structural strength while locally deforming to accommodate manufacturing tolerances, thereby achieving both strength and precise fit.
Solution Approach 2:
The intermediate component transitions from a static rigid structure to a dynamic elastically deformable structure. This enables the component to adapt to manufacturing variations in real-time during assembly, ensuring tight fit and eliminating gaps while maintaining the necessary structural integrity.
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 mating assembly ensures precise alignment and a tight fit by accommodating manufacturing variances, minimizing gaps and motion issues, and allowing for repeatable assembly and disassembly through elastic deformation, thereby enhancing the perceived quality of the mated components.
Implementation Method 1
the elastically deformable second component is configured to elastically deform proximate the cutout portion upon contact with an outer surface of the third component
Data Source
AI summary
An elastic mating assembly includes a first component comprising a substantially rigid material and an aperture defined by an aperture wall. The assembly also includes an elastically deformable second component having a cutout portion. The elastically deformable second component also includes a second component outer wall removably engaged with the aperture wall, wherein the second component is disposed substantially within the aperture. The elastic mating assembly further includes a third component removably engaged with the cutout portion of the elastically deformable second component, wherein the elastically deformable second component is configured to elastically deform proximate the cutout portion upon contact with an outer surface of the third component.