Stamped-Metal Panel Retainer for Mixed Thickness Fastening
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional retainers lack flexibility to accommodate a wide range of component thicknesses, necessitating multiple clip types for different materials, increasing manufacturing complexity and assembly errors.
Innovation Solution
A dual-zone retainer design with distinct upper and lower retention zones, accommodating components across a broad thickness spectrum from 0.7 mm to 3.5 mm, using a single retainer with angled engagement surfaces for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional retainers are used for different component thicknesses, then each thickness requires a different retainer type, but this increases manufacturing complexity and assembly errors
Solution Approach 1:
The retainer is designed with a single structure that can accommodate multiple component thicknesses (0.7mm to 3.5mm) through its dual-zone retention system. The first retention zone with first engagement surface handles thicker components, while the second retention zone with second engagement surface handles thinner components, eliminating the need for multiple specialized retainers.
Solution Approach 2:
The retainer body is divided into two distinct retention zones: a first retention zone and a second retention zone. Each zone has its own engagement surface positioned at different distances from the support surface, allowing independent optimization for different thickness ranges while being part of a single unified structure.
2Reliability
If multiple clip types are used for different materials, then material-specific retention is achieved, but supply chain burden increases
Solution Approach 1:
The retainer serves multiple material types (aluminum, steel, composites) and thickness ranges through its dual-zone design. The first retention zone accommodates thicker components while the second retention zone accommodates thinner components, allowing one retainer type to replace multiple material-specific variants.
3Ease of manufacture
If conventional retainers are used for variable cross-sections, then simple design is maintained, but adaptability to mixed materials is limited
Solution Approach 1:
Different regions of the retainer (first retention zone and second retention zone) are optimized for different local requirements: the first engagement surface is positioned for thicker sections while the second engagement surface is positioned for thinner sections. This local differentiation within a unified structure enables adaptability to variable cross-sections and mixed materials.
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
Reduces part count and assembly complexity while maintaining high-performance retention, adapting to both thin and thick components with varying thicknesses.
Implementation Method 1
a pair of retainer legs resiliently coupled to the body portion
Data Source
Figure 1a~1b
Figure 1c~1d
Figure 1e~1f
AI summary
Disclosed is a fastener assembly for coupling a first component (104) to a second component (112). The fastener assembly includes a fastener (108) and a stamped-metal retainer (116). The fastener includes a head (128) and a shank (130). The stamped-metal retainer includes a body portion (142), and a pair of retainer legs (132) resiliently coupled to the body portion. The body portion includes a plate with an internally-threaded collar that defines a retainer opening (138) configured to receive and secure at least a portion of the shank (130). Each of the pair of retainer legs defines a first retention zone between a first angled engagement surface and the plate that is configured to accommodate second components within a first thickness range, and a second retention zone between a second angled engagement surface and the plate that is configured to accommodate second components within a second thickness range. The distance between the first angled engagement surface and the plate is greater than the distance between the second angled engagement surface and the plate.