Polymeric Components With Integral Snap-Fit Connectors
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Solution Overview
Problem
The complexity, cost, and time associated with assembling automotive vehicle components using multiple fasteners and connectors, as well as the risk of damage to softer components from harder materials, which can degrade their appearance and require repair or replacement.
Innovation Solution
The integration of polymer-based components with flexible and resilient tabs and retainers that form connectors, allowing for secure coupling without additional fasteners, while maintaining visible show surfaces and facilitating easy assembly and potential disassembly for repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple fasteners and connectors are used to connect components, then the connection strength and reliability are improved, but the assembly complexity, cost, and time increase
Solution Approach 1:
The patent combines multiple separate fasteners and connectors into a single integrated connector system. The first connector and second connector are designed to mate together as one unified assembly, eliminating the need for multiple discrete fastening elements. This merging reduces assembly complexity while maintaining connection reliability through the integrated design that incorporates both joining and retaining functions in a single connector pair.
Solution Approach 2:
The connector design incorporates multiple functions within a single component structure. The connector simultaneously provides joining, retaining, and alignment functions through its integrated geometry featuring the retainer, opening, and tab elements. This multi-functionality eliminates the need for separate fasteners for each function, thereby reducing assembly complexity and part count while maintaining reliable connections.
2Strength
If harder materials are used for connectors, then the connector strength and durability are improved, but the softer components become scratched and damaged
Solution Approach 1:
The patent applies homogeneity by forming both the connector and the component body from the same polymer material. This ensures that the connector has comparable strength and hardness to the component it connects, preventing the connector from scratching or damaging the softer component. The uniform material composition throughout the assembly eliminates material incompatibility issues while maintaining adequate connector strength through optimized geometry and molecular weight of the polymer.
3Reliability
If additional fasteners are used to secure components, then the connection reliability is improved, but the number of parts and assembly time increase
Solution Approach 1:
The connector is designed with preliminary action features including the pre-formed retainer structure and tab configuration that automatically engage with the corresponding component features during assembly. The retainer is pre-shaped to snap over the component edge, and the tab is pre-positioned to fit into the opening, enabling automatic alignment and secure engagement without requiring additional fasteners or complex assembly steps. This preliminary structuring ensures reliable connections while minimizing assembly time.
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
This solution simplifies the assembly process, reduces the need for additional fasteners, prevents damage to components during assembly, and maintains the aesthetic appearance of vehicle exterior components by ensuring secure, interference-based connections that are easy to disassemble for maintenance.
Implementation Method 1
a flexible and resilient tab that has an unflexed position in which the tab at least partially overlaps the opening and reduces at least one dimension of the opening
Implementation Method 2
Removal of the first component from the second component is inhibited by interference between the tab and the first component
Implementation Method 3
the retainer at least partially extending through the second opening, the tab being received within the first opening and overlapped by the retainer
Data Source
AI summary
In at least one implementation, a first component includes a first connector and a second component includes a second connector adapted to couple with the first connector to connect together the first component and second component. The first component may be formed from a polymer and have an exterior show surface, and the first connector may have a first opening bounded by a retainer. The second component may also be formed from a polymer and include an exterior show surface, and the second connector may have a second opening and a flexible and resilient tab that has an unflexed position in which the tab at least partially overlaps the opening. In assembly, the first connector is coupled to the second connector with the retainer at least partially extending through the second opening, the tab being received within the first opening and overlapped by the retainer.