Serrated Washer Acoustical Absorber Mounting

Solution Overview

Problem

Existing acoustical absorbers, such as shock tower insulators, require separate fasteners and tool clearance for installation, which complicates vehicle design and limits space utilization in the engine compartment.

Innovation Solution

The use of serrated washers made from composite materials with higher density than the body, fixed to the acoustical absorber or shock tower insulator, provides a retention mechanism that eliminates the need for separate fasteners by engaging with mounting studs, offering a positive retention force of at least 44 Newtons.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate fasteners (nuts or tinnerman clips) are used to secure the acoustical absorber, then the mounting connection is reliable, but tool clearance is required which complicates vehicle design and limits space utilization

Engineering Contradiction:

Improvemounting connection reliabilityVSAvoidvehicle design complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The serrated washer integrates the fastening function directly into the mounting component that attaches to the stud. The serrated edges provide gripping action while the central aperture accommodates the stud, combining what were previously separate elements (washer and fastener) into a single integrated component that eliminates the need for additional nuts or clips

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The serrated washer serves multiple functions simultaneously: it provides structural support through its washer body, creates secure fastening through serrated gripping edges, and enables tool-free installation by integrating the fastening mechanism directly into the mounting component

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If separate fasteners are used to secure the acoustical absorber, then the mounting connection is reliable, but tool clearance space is consumed which reduces available space in the engine compartment

Engineering Contradiction:

Improvemounting connection reliabilityVSAvoidavailable space in engine compartment

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The serrated washer integrates the fastening function directly into the mounting component that attaches to the stud. The serrated edges provide gripping action while the central aperture accommodates the stud, combining what were previously separate elements (washer and fastener) into a single integrated component that eliminates the need for additional nuts or clips

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention extracts and eliminates the separate fastener (nut or tinnerman clip) from the mounting assembly, retaining only the essential serrated washer component that provides both support and fastening functions, thereby removing the need for tool clearance space

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If separate fasteners are used, then the acoustical absorber can be securely mounted, but assembly time and material usage increase

Engineering Contradiction:

Improvemounting securityVSAvoidassembly speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The serrated washer integrates the fastening function directly into the mounting component that attaches to the stud. The serrated edges provide gripping action while the central aperture accommodates the stud, combining what were previously separate elements (washer and fastener) into a single integrated component that eliminates the need for additional nuts or clips

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The serrated washer is pre-configured with gripping edges that automatically engage with the stud surface upon installation, eliminating the need for separate fastening operations. The mounting component is designed beforehand to include the fastening function, allowing direct attachment without additional assembly steps

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS10457226B2Acoustical absorber having a body and at least one serrated washer

Publication Date: 2019.10.29 FORD GLOBAL TECH LLC

AI summary

An acoustical absorber, which may take the form of a shock tower insulator, includes a body made from a sound insulating material and one or more serrated washers fixed to the body. The washers function to retain the body to mounting studs without the need for using a separate fastener.