Overmolded Isolating Fastener Assembly for Automotive BSR Sealing
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Solution Overview
Problem
Existing fastening techniques in automotive components fail to effectively mitigate buzz, squeak, and rattle (BSR) while being simple to manufacture and assemble, particularly when using fasteners with integral isolators.
Innovation Solution
A multi-material fastener assembly is developed, comprising a rigid fastener portion and a pliable isolator portion integrated via a two-shot injection or over-molding process, which forms a sealed connection to reduce BSR.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fastener assembly with an integral isolator is used, then the sealing and isolating capabilities are enhanced to mitigate BSR, but the manufacturing complexity increases due to multi-material integration
Solution Approach 1:
The isolator and fastener are merged into a single integral component through overmolding, combining two previously separate parts (rigid fastener and pliable isolator) into one unified assembly that provides both structural and sealing functions simultaneously
Solution Approach 2:
The fastener assembly utilizes composite construction by integrating two different materials with distinct properties: a rigid fastener material providing structural strength and a pliable isolator material providing sealing capability, creating a multi-material component that leverages the advantages of each material
2Ease of manufacture
If separate isolator and fastener components are used, then manufacturing is simpler, but the sealing effectiveness is reduced
Solution Approach 1:
The isolator and fastener are merged into a single integral component through overmolding, combining two previously separate parts (rigid fastener and pliable isolator) into one unified assembly that provides both structural and sealing functions simultaneously
Solution Approach 2:
The pliable isolator material acts as an intermediary between the rigid fastener and the panels, providing a compliant sealing interface that accommodates surface irregularities and enhances contact sealing while the rigid fastener provides structural attachment
Data Source
AI summary
Disclosed is fastener assembly to couple a first component to a second component via a post associated with the second component. The fastener assembly includes a fastener portion and an isolator portion. The fastener portion has a body with a collar at a first end and a base at a second end. The base couples with the first component, and the body defines one of more channels. The isolator portion is formed on the collar and at least a portion of the isolator portion extends into the one of more channels. The fastener assembly defines a passageway therethrough to receive and engage the post via, for example, one or more retainers. The one or more retainers can be resiliently connected to an inner sidewall of the passageway.