Press-In Alignment Element With Lateral Float and Axial Retention
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Solution Overview
Problem
Existing component assemblies in sheet metal parts face challenges in ensuring proper alignment of press-in elements without the need for a sheet metal cage and welding, which is not feasible for all components, such as composite sheet metal parts.
Innovation Solution
A component assembly design where a non-circular collar with acute angled outer surfaces is inserted with clearance into a complementary aperture, allowing lateral alignment movement while preventing axial separation through material overlap, eliminating the need for a sheet metal cage and welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a sheet metal cage with welding is used to ensure alignment, then alignment precision is improved, but device complexity and manufacturing feasibility worsen due to additional components and welding processes that are not possible for all components such as composite sheet metal parts
Solution Approach 1:
The invention extracts and eliminates the sheet metal cage and welding process from the alignment mechanism. Instead of using a separate cage structure with welded alignment elements, the alignment function is integrated directly into the press-in element through its geometric features (non-circular cross-section, collar, and interaction with the aperture), simplifying the overall device structure while maintaining alignment precision.
Solution Approach 2:
The invention introduces a geometric intermediary mechanism where the non-circular collar and complementary aperture serve as the alignment mediators. The specific geometric shapes (rectangular, square, or polygonal cross-sections) act as intermediaries that enable precise alignment without requiring additional components or welding processes, resolving the contradiction between alignment precision and device complexity.
2Manufacturing precision
If a sheet metal cage with welding is used to ensure alignment, then alignment precision is improved, but ease of manufacture worsens due to the additional welding process and component assembly steps
Solution Approach 1:
The invention removes the welding process and sheet metal cage from the manufacturing sequence. The alignment function is achieved through the inherent geometry of the press-in element and aperture, eliminating the need for separate welding operations and component assembly, thereby significantly improving ease of manufacture while maintaining alignment precision.
Solution Approach 2:
The press-in element performs self-alignment through its non-circular collar geometry that complements the aperture shape. During the pressing operation, the element automatically orients itself correctly without requiring external alignment fixtures, welding, or additional assembly steps, making the manufacturing process simpler and more versatile.
3Stability of the object's composition
If the collar is tightly fitted in the aperture, then axial separation is prevented, but lateral alignment movement is restricted
Solution Approach 1:
The invention applies different fit characteristics to different regions of the collar-aperture interface. The collar is designed with a non-circular cross-section (rectangular, square, or polygonal) that provides clearance for lateral alignment movement in radial directions, while the convergence of outer surfaces toward the end face and material overlap in recesses provide axial stability. This local differentiation of fit quality resolves the contradiction between axial stability and lateral alignment movement.
Solution Approach 2:
The invention creates a dynamic fit where the clearance between the collar and aperture allows the element to move laterally for alignment during insertion, while the converging surfaces and material overlap mechanisms engage to prevent axial separation once positioned. The system transitions from a loose fit enabling movement to a constrained fit preventing separation, resolving the contradiction between lateral alignment movement and axial stability.
4Ease of manufacture
If the collar has parallel outer surfaces, then manufacturing is simplified, but rotation prevention is insufficient
Solution Approach 1:
The invention employs asymmetric (non-circular) cross-sectional shapes for the collar and complementary aperture, such as rectangular, square, or polygonal sections. This asymmetry inherently prevents rotation by ensuring that only one orientation allows the collar to fit within the aperture, providing reliable rotation prevention while maintaining manufacturing simplicity through standard forming processes.
Data Source
AI summary
A component assembly is described which consists of a component and an element attached to the component and formed as an alignment element. The element has a head part, a component contact surface provided at an end face of the head part and a collar arranged inside the component contact surface and projecting away from it. The collar has a cross-sectional shape which is non-circular. The collar is inserted with clearance into an aperture of the component formed complimentary to the cross-sectional shape of the collar and has outer surfaces which converge in the direction of the said end face of the head part and with respect to the central longitudinal axis of the element and form an acute angle with the latter. The marginal region of the aperture of the component adjacent to the component contact surface extends into recesses formed between the collar and the end face of the head part but does not reach the base of the recesses, with a free space arising which ensures a lateral alignment movement of the element relative to the component. An axial separation of the element from the component is prevented as a result of material overlap of the component material with the collar within the recesses. Elements and methods for manufacture of the component assembly are also claimed.