Flow Drill Screw Grounding Block for Chassis Repair
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Solution Overview
Problem
Conventional grounding blocks in vehicles require permanent welding to the chassis, making replacement difficult and causing damage, and are not designed for easy connection or disconnection, which complicates maintenance and repair in wet environments prone to corrosion.
Innovation Solution
A modular, ergonomic grounding block with reversible fastening means, such as flow drill screws, and weight-reduced design with clearance to prevent rattling, allowing for secure and easy installation and removal without damaging the chassis, and accommodating various bolt sizes for flexible wire attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to attach grounding blocks to chassis/body, then secure electrical connection is achieved, but replacement requires considerable effort and causes damage to chassis/body
Solution Approach 1:
The grounding block system is divided into separate components: the grounding block itself and the fastening means (flow drill screws). This segmentation allows the grounding block to be easily removed and replaced without damaging the chassis/body, while still maintaining a secure electrical connection during use.
Solution Approach 2:
The fastening system transitions from a permanent state (welding) to a dynamic, reversible state using flow drill screws. These screws can be easily inserted and removed, enabling the grounding block to be securely attached during operation but easily replaced when needed, eliminating the need for damaging grinding operations.
2Ease of manufacture
If conventional grounding blocks are designed for single use with basic attachment points, then manufacturing cost is reduced, but connection and disconnection time increases
Solution Approach 1:
The grounding block incorporates multiple flanges with multiple attachment points, making it a multi-functional component. This universal design allows the same grounding block to be quickly attached at different locations on the chassis/body using standard flow drill screws, reducing both manufacturing complexity and installation time compared to custom-designed single-use blocks.
3Weight of moving object
If material weight is reduced in grounding blocks, then overall vehicle weight decreases, but structural integrity and electrical connection strength may be compromised
Solution Approach 1:
The grounding block utilizes composite construction with a aluminum alloy body that provides adequate strength and electrical conductivity while reducing weight. The flanges are strategically designed and positioned to concentrate structural strength where needed for fastening, allowing weight reduction in non-critical areas while maintaining overall structural integrity and electrical connection strength.
Data Source
AI summary
A grounding block is provided. The grounding block includes a means for fastening and a formed metallic block. The formed metallic block further comprises two or more flanges, where each flange is configured to accept the means for fastening. The formed metal block further comprises a uniform clearance formed into the underside of the grounding block between the flanges and a hole formed through the grounding block configured to accept a bolt. Various embodiments include angled surfaces to optimize assembly ergonomics and variable depth to optimize the mass of the blocks.