Retainer and Nut Assembly Structure for Low-Force Centered Installation
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Solution Overview
Problem
Existing retainer and nut assemblies face constraints in production rate, premature failure of bending tooling, high installation force requirements, and inadequate centering with respect to panel apertures.
Innovation Solution
The design includes a retainer with first and second legs extending from a base wall, featuring apertured portions with dimples or shoulders, allowing for efficient production, reduced installation force, and reliable centering with a nut assembly that can be staked, fastened, or coupled to the retainer, using materials like stainless steel and SAE 1035 steel for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional retainer designs are used, then the structure is simple, but the production rate is constrained and tooling fails prematurely
Solution Approach 1:
The retainer is divided into multiple functional segments: a base wall portion and multiple leg portions (first leg, second leg, third leg) with distinct functions. Each segment is optimized independently - the base wall provides mounting surface, while legs provide structural support and aperture positioning. This segmentation allows for optimized manufacturing of each portion while maintaining overall structural integrity, thereby increasing production rate without compromising simplicity.
Solution Approach 2:
Different portions of the retainer are given different geometric qualities suited to their specific functions. The base wall has a first aperture for panel reception, while the legs have second apertures for fastener passage. The leg portions include tabs and flanges with specific geometries for locating and securing the retainer. This local differentiation of qualities allows each portion to be optimized for its function, improving production efficiency while maintaining structural adequacy.
2Duration of action of stationary object
If conventional retainer designs are used, then manufacturing is straightforward, but bending tooling fails prematurely
Solution Approach 1:
The retainer geometry is designed with pre-formed features that reduce the severity of bending operations required during manufacturing. The base wall and leg portions are configured to minimize sharp bends and high-stress concentration points that would cause tooling failure. By incorporating gentle transitions and optimized bend radii in the preliminary design, the manufacturing process requires less aggressive forming operations, thereby extending bending tooling life while maintaining ease of manufacture.
3Force
If conventional retainer designs are used, then installation is straightforward, but high installation force is required
Solution Approach 1:
The retainer incorporates curved and rounded features rather than sharp angles, particularly in the leg portions and at the intersections of structural elements. This curvature distributes installation forces more evenly across the retainer structure, preventing stress concentration at sharp corners that would require excessive installation force. The rounded geometries facilitate easier deformation during installation while reducing the peak forces required, thereby maintaining installation ease with reduced force requirements.
4Manufacturing precision
If conventional retainer designs are used, then the structure is simple, but centering with respect to panel aperture is insufficient
Solution Approach 1:
The retainer employs asymmetric geometry in its leg portions and locating features to achieve precise centering with respect to the panel aperture. The first leg, second leg, and third leg are positioned asymmetrically relative to the base wall, with specific tabs and flanges configured to locate the retainer centrally over the aperture. This asymmetric arrangement provides inherent centering capability without requiring additional centering mechanisms, thereby achieving manufacturing precision while maintaining structural simplicity.
Data Source
AI summary
A retainer comprises first and second legs extending away from a base wall. In one embodiment, the first leg includes a dimple array surrounding an aperture and projecting from an inboard surface of the first leg. In another embodiment, the first leg has a necked portion having a set of first shoulders extending away from a first base, and a first apertured portion extending away from the set of first shoulders. The second leg has a necked and stepped portion having a step extending away from a second base, and a shouldered portion extending away from the step and having a set of second shoulders extending laterally outwardly, and a second apertured portion extending away from the second shoulders. The retainer of either embodiment may be coupled to a nut to produce a retainer and nut assembly.