Oil Pan Laminate Clinch Nut for Drain Sealing and NVH
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Solution Overview
Problem
Existing oil pan assemblies face challenges with drain attachment design, particularly with laminate materials, including issues with sealing, drainage efficiency, torque resistance, and noise, vibration, and harshness (NVH) properties, due to the limitations of projection welding and machining in aluminum materials.
Innovation Solution
A container assembly with a laminate bottom portion featuring a polymeric layer sandwiched between two aluminum layers, incorporating a clinch nut that provides a primary seal and a secondary seal mechanism, enhancing drainage efficiency and NVH properties while ensuring durability and lightweight construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If projection welding is used to attach a nut to aluminum laminate material, then the nut can be attached to the container, but the thin aluminum layer may fail from applied torques and the welding is not compatible with aluminum laminate materials
Solution Approach 1:
The nut is divided into two functional segments: a clinch portion that mechanically interlocks with the laminate material providing torque resistance, and a threaded portion that receives the drain plug. This segmentation allows each portion to be optimized for its specific function without compromising the other.
Solution Approach 2:
The clinch portion extends beyond what is minimally required for attachment, providing excessive mechanical interlocking capability that ensures sufficient torque resistance even with thin aluminum layers. The extended clinch portion creates multiple engagement points with the laminate material.
2Ease of operation
If a machined threaded opening is provided in cast aluminum, then a drain plug can be received, but the soft nature of aluminum makes the threadings susceptible to stripping
Solution Approach 1:
The nut acts as an intermediary component between the drain plug and the container. The threaded opening is formed in the nut (which can be made of more durable material or with stronger threading) rather than directly in the aluminum container, protecting the container walls from threading damage while still enabling drain plug installation.
3Reliability
If a two-piece cage nut assembly with high stove pipe is used, then the nut can be welded to the bottom portion, but the drainage efficiency is reduced due to flow through channels only when oil level drops below the top of the nut
Solution Approach 1:
The design prioritizes complete drainage over long-term durability of the nut assembly itself. The nut is designed with a short stove pipe that allows the oil pan to be completely drained, accepting that the nut may need replacement rather than compromising drainage efficiency.
4Device complexity
If a single seal at the flange area is used, then the assembly is simpler, but the seal may fail and insufficient drainage may occur
Solution Approach 1:
The sealing function is segmented into two independent seals: a primary seal at the flange area between the bolt and oil pan bottom surface, and a secondary seal at the gasket area. This segmentation ensures that if one seal fails, the other can maintain sealing integrity and prevent oil leakage.
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 achieves improved drainage efficiency, durability, and reduced NVH properties compared to traditional steel or cast aluminum assemblies, with enhanced torque resistance and push-through resistance, while maintaining a lightweight design.
Implementation Method 1
a clinch nut attached to at least the first aluminum layer and position for receiving a drain plug that seals the opening and provides a primary seal to prevent flow of the fluid
Data Source
AI summary
The teachings herein are related to assemblies, such as oil pan assemblies, including a laminate bottom portion and a nut attached to the laminate bottom portion. The nut may provide a sealable opening to a cavity of the assembly. The laminate bottom portion preferably includes a polymeric layer sandwiched between two metallic layers. The nut preferably is a clinch nut.