Elastically Deformable Lobular Fastener for Orthogonal Alignment
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Solution Overview
Problem
Current alignment and fastening systems in manufacturing, particularly for vehicular components, face significant positional variations due to oversized or undersized alignment features, leading to misalignments that affect the function and aesthetic quality of assemblies.
Innovation Solution
An elastically deformable alignment fastener with a lobular hollow tube and retention features that deforms to align components in multiple orthogonal directions, providing a precise four-way alignment and fastening solution by engaging with circular apertures, minimizing manufacturing variances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate alignment features and push pin components are used, then alignment and securement functions are provided, but the effectiveness of each is limited and manufacturing precision deteriorates due to cumulative tolerances
Solution Approach 1:
The patent combines alignment and securement functions into a single integrated push pin component. The push pin includes alignment features (such as tapered surfaces and positioning elements) that enable precise positioning, while simultaneously providing securement through threading or interference fit mechanisms. This integration eliminates the need for separate alignment features and push pins, reducing cumulative tolerances and improving overall alignment precision.
Solution Approach 2:
The push pin component is designed to perform multiple functions: alignment, positioning, and securement. The component includes features such as tapered alignment surfaces for positioning, threading for securement, and may include additional features like washers or sealing elements. This multi-functional design allows a single component to replace multiple separate components, improving both reliability and manufacturing precision.
2Ease of operation
If clearance is provided between male and female alignment features to accommodate manufacturing variances, then components can be assembled, but significant positional variation occurs leading to misalignment
Solution Approach 1:
The push pin incorporates dynamic alignment features that adapt during assembly. The tapered surfaces allow the push pin to self-align as it is inserted, dynamically adjusting to accommodate minor manufacturing variances while maintaining precise final positioning. This dynamic adjustment mechanism enables easy assembly without requiring excessive clearance, thereby preventing misalignment.
Solution Approach 2:
The alignment features utilize controlled clearance parameters and interference fit parameters. The push pin design includes specific dimensional parameters for alignment surfaces that balance ease of insertion with precision positioning. By carefully controlling these parameters, the system achieves both easy assembly and high alignment precision, eliminating the need for oversized clearances that would cause misalignment.
3Ease of manufacture
If oversized alignment features are used to provide spacing for free movement, then components can align without interference, but positional variation and misalignment increase
Solution Approach 1:
The push pin is segmented into distinct functional zones: a tapered alignment section for positioning, a threaded securement section for fastening, and potentially intermediate sections for spacing or sealing. This segmentation allows each zone to perform its specific function optimally - the tapered section provides precise alignment without requiring oversized dimensions, while other sections handle spacing and securement functions.
Solution Approach 2:
The push pin acts as an intermediary component that mediates between the two components being joined. Its tapered alignment surfaces serve as a mediating interface that guides the components into precise alignment during assembly, eliminating the need for oversized alignment features on the components themselves. The intermediary push pin controls the alignment process, ensuring precision while facilitating easy assembly.
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 ensures precise alignment and secure fastening of components, reducing positional variations and enhancing the quality of assemblies by allowing elastic deformation to achieve an elastically averaged final configuration.
Implementation Method 1
Portions of the elastically deformable lobular hollow tube when inserted into circular apertures of first and second components elastically deform to an elastically averaged final configuration that aligns the first and second components in four planar orthogonal directions
Data Source
AI summary
An elastically deformable alignment fastener has the form of a unitary object having a head portion and an integrally formed body portion. The body portion has an elastically deformable lobular hollow tube having a proximal end proximate the head portion and a distal end axially displaced from the head portion. The lobular hollow tube has an outer surface having one or more retention features oriented to provide a plurality of radially extending engagement surfaces along a length of the hollow tube. The head portion has a flange that circumscribes the proximal end of the lobular hollow tube. Portions of the elastically deformable lobular hollow tube when inserted into circular apertures of first and second components elastically deform to an elastically averaged final configuration that aligns the first and second components in four planar orthogonal directions.