Pre-Captured Push Retainer for Adhesive-Free Panel Assembly
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Solution Overview
Problem
Current fastening techniques for automotive components, such as push retainers, often require adhesives or insert-molding, which increase manufacturing costs and complexity, and are not economical for forming part-in-assembly (PIA) configurations.
Innovation Solution
A push retainer with an annular body, flexible tabs, and legs is pre-attached to a secondary panel, allowing it to be pre-captured as a PIA, featuring angled tabs and legs for engagement with a post and panel, respectively, fabricated through metal stamping and bending, eliminating the need for adhesives and additional manufacturing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesives are used to attach push retainers to the component, then the push retainer can be pre-attached to form a PIA, but manufacturing cost increases and additional manufacturing steps are introduced
Solution Approach 1:
The push retainer and push washer are merged into a single integrated component, eliminating the need for separate attachment steps. The retention member is formed as one piece with the fastening member, allowing direct pre-attachment to the component without adhesives or additional manufacturing steps.
Solution Approach 2:
The retention member serves multiple functions: it provides both the pushing action to install the fastener and the retaining action to hold the fastener in place. This multi-functionality eliminates the need for separate adhesive bonding steps while maintaining pre-attachment capability.
2Ease of manufacture
If insert-molding a push washer into the component is used, then the push retainer can be pre-attached to form a PIA, but additional manufacturing steps are introduced
Solution Approach 1:
The push retainer and push washer are merged into a single integrated component, eliminating the need for separate insert-molding operations. This single-component design can be manufactured more efficiently and attached directly to the component without additional molding steps.
Solution Approach 2:
The fastening system is segmented into distinct functional portions (fastening member and retention member) that are formed as one piece, allowing for simpler manufacturing and direct attachment without complex multi-step processes like insert-molding.
3Reliability
If standard style push retainers are used with adhesives, then attachment to the component is achieved, but material usage increases and cost increases
Solution Approach 1:
The adhesive material is extracted from the system and replaced with a mechanical retention mechanism. The retention member uses its own structural features (flexible tabs and legs) to provide attachment, eliminating the need for additional adhesive materials while maintaining reliable attachment.
Solution Approach 2:
The retention member serves itself by using its own flexible tabs and legs to provide both the attachment mechanism and the retention force. No external adhesive materials are needed as the component itself provides the attachment function through its engineered geometry and material properties.
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 reduces manufacturing costs and complexity by enabling a reliable, efficient fastening system that forms a PIA without additional materials or steps, allowing for easier assembly and improved retention forces while minimizing material usage.
Implementation Method 1
one or more flexible tabs coupled to the annular body and canted upwardly away from a topside surface at a first angle
Implementation Method 2
one or more legs extend downwardly away from an underside surface at a second angle and configured to engage the first panel
Data Source
AI summary
Disclosed are systems and methods for coupling a first panel to a second panel via a push retainer. The push retainer includes an annular body, flexible tabs, and legs. The annular body has a topside surface and an underside surface. The annular body defines an opening. The flexible tabs are coupled to the annular body and canted upwardly away from the topside surface at a first angle. The flexible tabs are configured to engage a post of the second panel. The legs extend downwardly away from the underside surface at a second angle. The legs are configured to engage the first panel to form a part-in-assembly (PIA) component when inserted through the opening.