Fuel Filler Housing Insert with Segmented Flange
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Solution Overview
Problem
The stamping process for manufacturing vehicle body panels with fuel filler housing openings often results in flange splitting, leading to reduced attachment strength and aesthetic issues due to the need for shorter flange lengths and smaller attachment clips.
Innovation Solution
A fuel filler housing opening insert with a segmented flange and snap-fit retainers is used to attach the fuel filler housing, providing a secure and aesthetically improved solution by capturing the segmented flange and allowing a more robust attachment without excessive installation effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the flange length is reduced to prevent splitting during stamping, then manufacturing reliability improves, but attachment strength deteriorates
Solution Approach 1:
The flange is divided into multiple segments separated by notches, which prevents splitting during stamping while maintaining sufficient attachment length. The segmented structure allows the flange to flex and accommodate stamping forces without failing, while still providing adequate surface area for attachment.
Solution Approach 2:
A fuel filler housing opening insert is introduced as an intermediary component between the segmented flange and the fuel filler housing. This insert provides a continuous mounting surface that spans across the segmented flange, enabling strong attachment while the flange itself remains segmented to prevent splitting.
2Reliability
If the flange length is reduced to prevent splitting during stamping, then manufacturing reliability improves, but aesthetic appearance deteriorates
Solution Approach 1:
The fuel filler housing opening insert acts as a visual intermediary that conceals the segmented flange structure. The insert provides a continuous, aesthetically pleasing mounting surface that hides the notches and segments, eliminating visual defects while the segmented flange behind it prevents manufacturing issues.
3Ease of manufacture
If smaller attachment clips are used due to reduced flange length, then ease of manufacture improves, but attachment strength deteriorates
Solution Approach 1:
The fuel filler housing opening insert serves as a structural intermediary that provides a continuous mounting surface, allowing the use of standard-sized attachment clips rather than smaller ones. This maintains attachment strength while keeping the manufacturing process simple and efficient.
4Reliability
If the flange is segmented to prevent splitting, then manufacturing reliability improves, but device complexity increases
Solution Approach 1:
The flange is segmented by adding notches that are directly formed during the stamping process. This segmentation approach is integrated into the existing manufacturing process rather than requiring additional steps, thereby preventing splitting while minimizing increases in device complexity.
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 solution enhances attachment strength and aesthetics by providing a secure snap-fit connection that overlays the flange notches, improving customer satisfaction and reducing the likelihood of flange splitting during manufacturing.
Implementation Method 1
one or more retainers configured for capturing the segmented flange
Data Source
AI summary
A fuel filler housing opening includes a segmented flange for attachment of a fuel filler housing. A fuel filler housing opening insert is provided, configured for attaching to the segmented flange. The fuel filler housing opening insert includes a body surrounding a central opening dimensioned to receive a fuel filler housing therethrough. The body may be dimensioned to fully overlay the fuel filler housing opening segmented flange. The fuel filler housing opening insert body includes one or more retainers configured for capturing the segmented flange.