Elastically Deformable Alignment Member for Component Positioning

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Solution Overview

Problem

Matable components, particularly in vehicular applications, face significant positional variations due to manufacturing variances, leading to misalignments, noise issues, and a perception of poor quality, as oversized holes and undersized bosses result in undesirably large variations in spacing and gaps between components.

Innovation Solution

An elastically averaged alignment system utilizing elastically deformable materials in alignment members and apertures, which deform to a final configuration upon insertion, facilitating precise alignment and minimizing manufacturing positional variance, thereby ensuring accurate orientation and reducing noise.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If oversized holes and undersized bosses are used for alignment, then manufacturing tolerance is accommodated, but alignment precision deteriorates due to significant positional variation between mated components

Engineering Contradiction:

Improvemanufacturing tolerance accommodationVSAvoidalignment precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The alignment member is made from an elastically deformable material that changes its physical state during assembly. By transforming the alignment member from a rigid component to an elastically deformable one, the system accommodates manufacturing tolerances while achieving precise alignment through elastic deformation to an averaged final configuration.

Inventive Principle:

Principle #35Parameter changes

2Ease of operation

If clearance between alignment features is increased to accommodate manufacturing variances, then assembly flexibility is improved, but relative motion between components occurs causing noise and quality perception issues

Engineering Contradiction:

Improveassembly flexibilityVSAvoidnoise and quality perception

Core Design Contradiction:

Ease of operationVSObject-generated harmful factors

Solution Approach 1:

The alignment member transitions from a rigid state during insertion to an elastically deformable state upon engagement, allowing initial assembly flexibility followed by stabilization. The elastic deformation creates a stiffened interface that prevents relative motion and eliminates noise while maintaining ease of assembly.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The alignment member utilizes composite material properties combining elastic deformability for assembly with stiffness for final positioning. This composite behavior allows the component to be compliant during insertion but rigid in its final configured state, preventing noise-generating relative motion.

Inventive Principle:

Principle #40Composite materials

3Strength

If rigid alignment features are used, then structural strength is maintained, but positional variation and misalignment occur due to manufacturing tolerances

Engineering Contradiction:

Improvestructural strengthVSAvoidpositional accuracy

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The alignment member changes its mechanical parameters from rigid to elastically deformable during the assembly process. This parameter change allows the component to absorb manufacturing variations through elastic deformation while maintaining sufficient structural strength for the application.

Inventive Principle:

Principle #35Parameter changes

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 elastically averaged alignment system achieves precise alignment of components, minimizes manufacturing positional variance, and reduces noise, enhancing the quality and aesthetic appearance of assemblies by providing a stiffened and robust interface.

Implementation Method 1

The alignment member is an elastically deformable material such that when the alignment member is inserted into the alignment aperture, the alignment member elastically deforms to an elastically averaged final configuration

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS9511802B2Elastically averaged alignment systems and methods

Publication Date: 2016.12.06 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

In one aspect, an elastically averaged alignment system is provided. The alignment system includes a first component including at least one corner region having an alignment member, and a second component including at least one corner region having an inner wall defining an alignment aperture. The alignment aperture is configured to receive at least a portion of the alignment member to couple the first component and the second component. The alignment member is an elastically deformable material such that when the alignment member is inserted into the alignment aperture, the alignment member elastically deforms to an elastically averaged final configuration to facilitate aligning the corner regions of the first and second components in a desired orientation.