Elastically Deformable Alignment Tube for Sealed Compartment Precision
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Solution Overview
Problem
Current alignment systems for mating components, particularly in vehicular applications, face significant positional variations due to manufacturing tolerances, leading to misalignments and poor fitment, which can affect the functionality and aesthetic quality of assemblies, and require complex two-shot molding processes for sealing.
Innovation Solution
An elastically averaging alignment and retention system using an elastically deformable alignment element in the form of an elongated hollow tube that interferingly engages with a blind-end pocket, allowing precise two-way or four-way alignment without through holes, thereby ensuring a sealed compartment without the need for potting compounds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If oversized and/or undersized alignment features are used to provide spacing for free movement of components, then components can be aligned without interference, but significant positional variation occurs between mated components leading to misalignment
Solution Approach 1:
The patent changes the physical state and dimensional parameters of the alignment element by making it elastically deformable. The alignment element is designed to elastically deform during assembly to accommodate manufacturing tolerances, then maintain a precise final position. This elastic deformation capability allows the system to absorb positional variations while achieving precise alignment, resolving the contradiction between ease of assembly and manufacturing precision.
2Ease of manufacture
If clearance is predetermined to match manufacturing tolerances, then components can be assembled, but misalignment occurs affecting function and aesthetic appearance
Solution Approach 1:
The patent introduces dynamic characteristics to the alignment system by using an elastically deformable alignment element that can change its physical state during assembly. The element transitions from a pre-loaded deformable state during insertion to a stable maintained state after assembly, dynamically adapting to manufacturing variations while ensuring precise final alignment and preventing misalignment issues.
3Reliability
If two-shot molding process is used to seal openings with rubber material, then sealing is achieved, but complexity and manufacturing time increase
Solution Approach 1:
The patent merges the alignment function and sealing function into a single integrated alignment element. The elastically deformable alignment element itself provides the sealing capability through its deformation and contact with mating surfaces, eliminating the need for separate rubber sealing components and complex two-shot molding processes. This consolidation maintains reliable sealing while significantly reducing manufacturing complexity.
Solution Approach 2:
The patent extracts the sealing function from the complex two-shot molding process and integrates it directly into the alignment element's deformation mechanism. By taking out the separate sealing component requirement and incorporating sealing capability into the alignment element itself, the system achieves reliable sealing through the element's elastic deformation and contact pressure, simplifying the overall manufacturing process.
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
This solution minimizes manufacturing positional variance, providing a precise and repeatable alignment of components, ensuring a tight seal and improved assembly quality while simplifying the manufacturing process by eliminating the need for complex sealing methods.
Implementation Method 1
the elastically deformable alignment element having an elongated hollow tube... elastically deform to an elastically averaged final configuration that aligns the first component relative to the second component
Data Source
AI summary
An elastically averaging alignment and retention system for a sealable compartment includes a first component and a second component. The first component includes a first alignment member and an elastically deformable alignment element fixedly disposed with respect to the first alignment member, the elastically deformable alignment element having an elongated hollow tube. The second component includes a second alignment member and an alignment feature fixedly disposed with respect to the second alignment member, the alignment feature having a blind-end pocket. The elastically deformable alignment element is configured and disposed to interferingly, deformably and matingly engage the alignment feature. Portions of the elastically deformable alignment element when inserted into the alignment feature elastically deform to an elastically averaged final configuration that aligns the first component relative to the second component in at least two of four planar orthogonal directions.