Hybrid Fastener Assembly With Metal Insert for Low-Weight Strength
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional fasteners, such as grommet-type fasteners, face issues with high weight, complex design, and material brittleness, leading to increased manufacturing costs and potential damage to sheet metal components due to rusting, while polymeric alternatives lack strength and require larger sizes to match metal components, resulting in increased overall costs and sizes.
Innovation Solution
A hybrid fastener assembly comprising a body made of low-cost polymer and a removable insert made of strong, lightweight stainless steel, with internally threaded circular holes and snap locks for secure attachment, allowing for easy assembly and high serviceability without the need for specialized tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal fasteners are used, then strength and durability are improved, but weight increases and manufacturing costs increase
Solution Approach 1:
The fastener combines polymer body with metal insert to create a composite structure that achieves both light weight and high strength. The polymer provides low weight while the metal insert provides the necessary strength and threading capability.
Solution Approach 2:
The fastener is divided into separate components: a polymer body and a metal insert. This segmentation allows each component to be optimized for its specific function - the polymer for weight reduction and the metal for strength.
2Strength
If metal fasteners are used, then strength is improved, but susceptibility to rusting increases
Solution Approach 1:
The polymer body acts as an intermediary between the metal insert and the external environment. It protects the metal insert from direct exposure to moisture and corrosive elements while allowing the metal to provide structural strength.
Solution Approach 2:
The composite structure of polymer and metal creates a system where the polymer shields the metal from rusting environments while maintaining the mechanical advantages of metal.
3Weight of moving object
If polymeric fasteners are used, then weight is reduced and cost is reduced, but strength decreases
Solution Approach 1:
The hybrid fastener uses a polymer body for weight reduction and cost savings, while incorporating a metal insert to restore the necessary strength and threading functionality that pure polymer fasteners lack.
Solution Approach 2:
By segmenting the fastener into polymer and metal portions, the design allows the polymer to handle weight and cost requirements while the metal insert handles strength and structural requirements.
4Adaptability or versatility
If conventional grommet-type fasteners are used, then mounting capability is achieved, but design complexity increases
Solution Approach 1:
Separating the fastener into modular components (polymer body and metal insert) simplifies the overall design while maintaining mounting capabilities. Each component can be independently optimized and manufactured.
Data Source
AI summary
A hybrid fastener assembly includes a body and a removable insert. The removable insert includes a first flange having a first circular hole. The body includes a receptacle, a second circular hole, a retention mechanism, and a plurality of lateral walls. The removable insert is accommodated in the receptacle and is inserted in a lateral direction perpendicular to a central longitudinal axis of the body. The second circular hole aligns with the first circular hole to form a channel for receiving the threaded fastener. The retention mechanism secures the removable insert inside the receptacle. At least two lateral walls include a snap lock for mounting the hybrid fastener assembly to a first component.