Spring Clip With Three Cantilevered Bars and 4-Way Locator

Solution Overview

Problem

Existing fastening methods for securing plastic parts to sheet metal parts are costly, time-consuming, and prone to squeaks and rattles due to the need for multiple fasteners, which increase part weight, manufacturing costs, and risk of errors during assembly.

Innovation Solution

A new spring clip design featuring three cantilevered bars and an integral 4-way locator that eliminates the need for welding and reduces assembly operations by being molded directly into the plastic part, providing a robust and rattle-free connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If multiple separate fasteners are used to secure plastic parts to sheet metal parts, then the connection strength is improved, but the part weight and manufacturing cost increase

Engineering Contradiction:

Improveconnection strengthVSAvoidpart weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent combines multiple fastener functions into a single integrated spring clip assembly that includes a base, support post, three cantilevered bars, and a 4-way locator. This consolidation provides robust connection strength while eliminating the weight and cost of multiple separate fasteners.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The spring clip assembly performs multiple functions simultaneously: the base and support post provide structural support, the three cantilevered bars provide connection strength and flexibility, and the 4-way locator ensures proper positioning. This multi-functionality replaces what would otherwise require multiple separate components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If multiple separate fasteners are used, then the connection strength is improved, but the manufacturing cost and production time increase

Engineering Contradiction:

Improveconnection strengthVSAvoidproduction time

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The patent combines multiple fastener functions into a single integrated spring clip assembly that includes a base, support post, three cantilevered bars, and a 4-way locator. This consolidation provides robust connection strength while eliminating the weight and cost of multiple separate fasteners.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The spring clip is pre-formed with its resilient cantilevered bars and locator features during molding, allowing it to be inserted as a single unit that automatically locates and secures the plastic part to the sheet metal substrate in one operation, eliminating sequential fastening steps.

Inventive Principle:

Principle #10Preliminary action

3Strength

If multiple separate fasteners are used, then the connection strength is improved, but the risk of squeaks and rattles increases

Engineering Contradiction:

Improveconnection strengthVSAvoidsqueaks and rattles

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The patent combines multiple fastener functions into a single integrated spring clip assembly that includes a base, support post, three cantilevered bars, and a 4-way locator. This consolidation provides robust connection strength while eliminating the weight and cost of multiple separate fasteners.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Instead of using rigid fasteners that create hard contact points prone to squeaking, the patent uses resilient cantilevered bars that flex and conform to the substrate, creating a compliant connection that dampens vibrations and eliminates squeaks and rattles while maintaining connection strength.

Inventive Principle:

Principle #13The other way round (Inversion)

4Productivity

If heat staking process is used to attach plastic parts, then the manufacturing cost and time are reduced, but the requirement for welding process is eliminated

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidmanufacturing process complexity

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The spring clip assembly is designed to be self-installing through a simple snap-in action where the resilient cantilevered bars flex during insertion and then lock into place on the substrate, eliminating the need for external welding equipment or heat staking processes while maintaining strong attachment.

Inventive Principle:

Principle #25Self-service

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 spring clip achieves efficient attachment with reduced manufacturing costs and time, eliminating squeaks and rattles while maintaining pull force requirements similar to heat staking, and simplifying the assembly process.

Implementation Method 1

a first resilient cantilevered bar, a second resilient cantilevered bar and a third resilient cantilevered bar

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

spring clip incorporating three cantilevered bars and an integral 4-way locator

Methodology Applied

Scientific EffectSpring effect: Spring

Data Source

PatentUS10077790B2Spring clip with three cantilevered bars and integral 4-way locator

Publication Date: 2018.09.18 FORD GLOBAL TECH LLC

AI summary

A spring clip includes a body having a base, a support post carried on the base, three cantilevered bars carried on the support post and a 4-way locator fixed to the base.