Push-in Socket Assembly with Retainer Clip for Automotive Lamps
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Solution Overview
Problem
Conventional ball joints for automotive lamp assemblies face challenges in installation, requiring additional assembly time and cost due to the need for screwing sockets into reflectors, and they often lack adequate retention in blind holes, leading to potential pull-out issues.
Innovation Solution
A push-in socket assembly that can be easily installed by hand into a blind hole, featuring a retainer clip with flexible wings that secure the socket in place, allowing for low-force insertion and high resistance to accidental pull-out, compatible with various ball studs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sockets are screwed into reflectors, then secure retention is achieved, but assembly time and cost increase
Solution Approach 1:
The patent replaces the screw-threaded mechanical fastening system with a push-in friction fit system combined with a retainer clip. The socket has a push-in installation feature that allows it to be inserted into the reflector without screws, and the retainer clip provides retention through elastic deformation and friction rather than threading.
Solution Approach 2:
The patent extracts the screw fastening operation from the assembly process. By removing the need for screws and screwing operations, the assembly time is significantly reduced while the retainer clip provides adequate retention through its elastic engagement with the socket's retention features.
2Ease of operation
If sockets are pushed into blind holes, then assembly is simplified, but retention is insufficient leading to pull-out issues
Solution Approach 1:
The retainer clip is designed with elastic flexibility, allowing it to dynamically deform during installation and operation. The clip's elastic properties enable it to flex outward during push-in installation and then spring back to engage with the socket's retention features, providing secure retention while maintaining ease of installation.
Solution Approach 2:
The patent changes the physical state of the retainer clip from rigid to elastic. The clip is made of elastic material that can deform under compression during installation and then recover to provide retention force. This parameter change allows the system to achieve both easy installation (through elastic deformation) and secure retention (through elastic recovery force).
3Force
If retainer clip wings are made flexible for easy installation, then insertion force is reduced, but pull-out resistance may be compromised
Solution Approach 1:
The retainer clip's elastic wings are designed to be dynamic rather than static. During installation, the wings flex outward dynamically to reduce insertion force. During operation, the elastic recovery force of the wings provides the pull-out resistance. The same elastic property serves both functions at different stages.
Solution Approach 2:
The retainer clip is pre-loaded with elastic energy during manufacturing. This preliminary storage of elastic potential energy is released during installation to provide the necessary retention force. The clip is pre-formed with a specific geometry that stores elastic energy, which is then utilized during the push-in installation to secure the socket.
4Adaptability or versatility
If conventional ball joints are used, then pivotable connection is achieved, but manufacturing and assembly costs increase
Solution Approach 1:
The socket is designed as a universal component that can accommodate various types of ball studs (spherical, semi-spherical, disengageable) through a single standardized interface. This multi-functionality reduces the need for multiple specialized socket designs, thereby reducing manufacturing complexity and cost while maintaining pivotable connection capability.
Solution Approach 2:
The ball joint system is segmented into standardized components: a universal socket with push-in installation and a retainer clip, compatible with various ball stud types. This segmentation allows for mass production of standardized sockets and clips, reducing per-unit manufacturing cost while maintaining adaptability to different ball stud configurations.
Data Source
AI summary
A ball socket for connection with a ball stud provides for easy manufacturing and assembly using a flat-stamped flexible retainer clip. The retainer clip is inserted into the socket and flexes to snap-fit within in the socket. The flex of the clip also flexes wings of the clip which engage with a receiving boss or socket. The flexion of the clip allows for easy push-in of the socket and sufficient resistance to accidental pull-out. The push-in socket design eliminates the need for screw-mounting of the socket. The socket assembly may be manufactured for use in connection with disengageable or conventional ball studs.