Push-Nut Fastener Clip for Self-Aligning Chassis Attachment
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Solution Overview
Problem
Conventional fasteners for attaching vehicle body panels to a chassis face issues with unequal force distribution, wing breakage, misalignment, and inability to self-align, leading to rattling, corrosion, and inadequate security under varying environmental conditions and production tolerances.
Innovation Solution
A fastener clip with four legs and wings, featuring threaded barrels, thread stops, and angled wings with ledges, designed to self-align and securely attach to chassis slots, allowing for easy insertion and removal while preventing wing breakage, using a single piece of metal stamped and shaped for durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional single piece fasteners are used, then manufacturing cost is reduced, but wing breakage occurs due to unequal force distribution during misalignment
Solution Approach 1:
The fastener is divided into two separate pieces: a clip portion with wings and a base portion with a post. This segmentation allows the clip to be inserted independently through the panel, eliminating the risk of wing breakage during misalignment since the wings are not subjected to excessive insertion forces. The two pieces are then secured together using a push nut and threaded barrel assembly.
2Device complexity
If conventional single piece fasteners are used, then device complexity is reduced, but self-alignment capability is lost leading to misalignment issues
Solution Approach 1:
The clip portion is designed with flexible wings that can dynamically adjust their position during insertion. The wings are spring-loaded to engage with the slot edges, allowing the clip to self-align with the slot even when there are tolerance variations. This dynamic adjustment capability enables automatic correction of misalignment without requiring complex alignment mechanisms.
3Ease of operation
If conventional single piece fasteners are used, then ease of operation is improved, but extraction force becomes too low providing inadequate security
Solution Approach 1:
By separating the fastener into a clip portion and a base portion secured with a push nut, the design achieves both easy insertion (clip passes through panel) and high extraction force (threaded connection with push nut requires significant force to remove). The two-piece construction with threaded fastening provides secure attachment while maintaining operational simplicity.
4Manufacturing precision
If conventional single piece fasteners are used, then manufacturing precision requirements are reduced, but production tolerances cause misalignment and rattling
Solution Approach 1:
The clip design incorporates parameter changes in the form of spring-loaded wings with adjustable engagement forces. The wings can accommodate variations in slot dimensions and panel thickness within tolerance ranges by adjusting their engagement depth and force. This flexibility eliminates rattling and noise by ensuring consistent contact between the clip and the slot edges despite manufacturing variations.
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 fastener clip provides secure attachment with reduced wing breakage, self-alignment, and improved durability, minimizing noise and corrosion, and accommodating various production tolerances and environmental conditions, ensuring long-term reliability.
Implementation Method 1
engagement of one portion of the hole in the chassis with one of the wings may not provide suitable frictional engagement
Implementation Method 2
The wings of conventional fasteners have a sharp, unsmooth groove to engage the edge of the frame slot
Data Source
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AI summary
A system and method including a fastener clip (100), including one or more legs (10), one or more wings (30) attached to the legs, and threads (50) between the one or more legs. The fastener clip is configured to be inserted into and to attach to a slot in a chassis. The wings include ledges (35). The fastener clip is configured to attach to the slot based at least upon the ledges being configured to engage the slot. The threads form a barrel configured to receive a screw. The fastener clip is configured to couple a component to the chassis based at least upon the screw being configured to be coupled to the component and to be screwed into the threads.