Push-in Connector Retainer Clip for Blind Hole Assembly
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Solution Overview
Problem
Conventional connectors require additional assembly time and cost due to the need for screwing or snap-fit mechanisms, and they often fail to securely retain objects in blind holes, which are preferred for manufacturing simplicity but pose challenges with retention and installation force.
Innovation Solution
A push-in connector assembly featuring a retainer clip with molded ledges and legs that securely fit into a boss, allowing easy hand assembly and high pull-out resistance, suitable for use in blind holes with various types of ball studs, shafts, or wiring, using a flexible metal clip that bends into place without requiring specific orientation or high installation force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional connectors use screwing or snap-fit mechanisms, then they can secure objects in place, but they require additional assembly time and cost
Solution Approach 1:
The connector is divided into two functional parts: a push-in body for insertion and a separate retainer clip for securing. This segmentation allows the push-in body to be quickly inserted while the retainer clip provides reliable retention, resolving the contradiction between assembly speed and retention security.
Solution Approach 2:
The retainer clip is designed to automatically engage with the push-in body and secure it within the blind hole without requiring additional fastening operations. The clip's spring-loaded tabs self-engage with grooves on the push-in body, providing secure retention immediately upon insertion, thus eliminating the need for separate screwing or snap-fit operations.
2Ease of manufacture
If blind holes are used for manufacturing simplicity, then manufacturing is easier, but retention and installation force become problematic
Solution Approach 1:
The retainer clip extends radially outward from the push-in body, utilizing the radial dimension within the blind hole to create retention points on the hole's inner surface. This radial extension allows the clip to anchor securely against the blind hole wall without requiring the connector to protrude axially, thus maintaining manufacturing simplicity while achieving reliable retention.
Solution Approach 2:
The retainer clip acts as an intermediary element between the push-in body and the blind hole wall. Instead of the push-in body directly engaging the blind hole wall (which would require high installation force), the flexible clip mediates the connection, allowing easy insertion while providing secure retention through its spring-loaded engagement with the hole surface.
3Reliability
If retainer clips are designed for secure retention, then pull-out resistance increases, but installation force may increase
Solution Approach 1:
The retainer clip's material properties and geometric parameters are optimized to provide high pull-out resistance during installation that automatically transitions to high retention after installation. The spring rate and tab geometry are designed so that during insertion, the clip flexes easily to accommodate the push-in body, but once engaged, the spring force provides strong retention against pull-out loads.
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 push-in connector assembly reduces manufacturing and installation costs, allows easy hand assembly, and provides secure retention with high pull-out resistance, making it suitable for diverse applications including headlamp assemblies and other fields where blind holes are used.
Implementation Method 1
using a flexible metal clip that bends into place without requiring specific orientation or high installation force
Data Source
AI summary
A push-in connector provides for easy manufacturing and assembly using a flat-stamped flexible retainer clip. The retainer clip is inserted into the connector and flexes to snap-fit within in the connector. The flex of the clip also flexes wings of the clip which engage with a receiving boss. The flexion of the clip allows for easy push-in of the connector and sufficient resistance to accidental pull-out. The push-in connector design eliminates the need for screw-mounting of the connector. The connector assembly may be manufactured for use in connection with a variety of ball studs, as well as other items such as shafts of various objects and wires, or may be used a fastener.