Load Carrier Bracket Cold-Formed Pin Attachment
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Solution Overview
Problem
Existing methods for attaching load carrier brackets to vehicles are costly, time-consuming, and do not provide a strong enough attachment to withstand crash forces, as they often require manual work, welding, or roll pining, which can damage materials and result in pins bending or slipping out of fix point holes.
Innovation Solution
A method involving a pin with a groove and flange that is cold-formed into an aperture of the load carrier bracket, allowing for a strong, cost-efficient attachment without welding, using high-strength steel and a flexible head portion to maintain the pin securely in place under deformation, reducing the risk of rupture during collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to attach the pin to the load carrier bracket, then the attachment strength is improved, but the manufacturing cost and time increase due to additional surface treatment steps
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a cold-forming mechanical process. The pin is inserted through the aperture and then cold-formed to deform the bracket material around the aperture, creating a mechanical interlock that secures the pin without requiring welding or subsequent surface treatment
Solution Approach 2:
The patent extracts the problematic welding step and associated surface treatment requirements from the manufacturing process. By using cold-forming instead, the method eliminates the need for post-welding surface treatment while maintaining attachment strength
2Ease of manufacture
If roll pining is used to attach the pin to the load carrier bracket, then the manufacturing process is simplified, but the attachment strength is insufficient and material damage occurs
Solution Approach 1:
The attachment process is segmented into two distinct phases: first, the pin is inserted through the aperture in a simple manner similar to roll pining; second, the pin is cold-formed to create a secure mechanical interlock. This segmentation maintains manufacturing simplicity while achieving high attachment strength
Solution Approach 2:
The patent changes the physical state and properties of the pin during the attachment process. The pin starts in a flexible state for easy insertion, then undergoes cold-forming that permanently deforms it to create a rigid, strong mechanical interlock with the bracket
3Strength
If high strength steel is used for the pin, then the durability and crash resistance are improved, but the material is more difficult to work with during manufacturing
Solution Approach 1:
The patent applies dynamic principles to the manufacturing process by using cold-forming, which allows high strength steel to be shaped and deformed at room temperature through controlled plastic deformation. This dynamic approach enables the use of difficult-to-machine high strength materials without requiring high-temperature processing or complex machining operations
4Device complexity
If the pin is designed without threads, then the design is simplified and manufacturing is easier, but the pin tends to bend and slip out during crash forces
Solution Approach 1:
The patent moves the securing mechanism from a threaded (rotational) dimension to a dimensional interference fit created by cold-forming. The pin's diameter is slightly larger than the aperture, and cold-forming creates radial compression and mechanical interlock in the radial dimension, preventing the pin from slipping out during crash forces without requiring threads
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 provides a sturdy, cost-effective load carrier bracket assembly that securely attaches to vehicles, reducing the risk of detachment during crashes and eliminating the need for manual welding or roll pining, while allowing for the use of high-strength steel for improved durability.
Implementation Method 1
A method involving a pin with a groove and flange that is cold-formed into an aperture of the load carrier bracket
Implementation Method 2
driving, i.e. pushing or pulling the pin with a force so as to deform an area around the aperture of the load carrier bracket and thereby force the area into the groove
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
The present invention relates to a load carrier bracket (61) and a method of manufacturing the load carrier bracket (61), the present invention also relates to a vehicle load carrier foot (60) comprising a load carrier bracket (61) for clamping the vehicle load carrier foot (60) to a vehicle roof (81) or to a vehicle roof rail by imparting a clamping force between a clamping surface (82) of the vehicle load carrier foot (60) and parts of the load carrier bracket (61). The parts of the load carrier bracket (61) comprise at least one pin (10), the at least one pin (10) being cold formed into an aperture (65) of the load carrier bracket (61). The present invention provides for an inexpensive yet sturdy load carrier foot bracket.