T-Bayonet Joint Trim Alignment via Tunable Ribs
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In automotive assembly, aligning and maintaining a proper fit between elongated trim pieces is challenging due to manufacturing variations, and existing solutions like tie plates are costly and prone to fit degradation over time.
Innovation Solution
A flange connector assembly with T-shaped male and female portions that allow for precise engagement and alignment adjustments through tunable ribs, enabling up/down, inboard/outboard, and twist fine-tuning, which can be molded directly into the parts for cost efficiency and improved fitment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional joining methods are used for trim pieces, then assembly is simple, but alignment precision and fit consistency deteriorate due to manufacturing variations
Solution Approach 1:
The bayonet connector incorporates tuning surfaces that allow dynamic adjustment of the joint configuration during assembly. The connector can be rotated and positioned at different angles to compensate for manufacturing variations, enabling the joint to adapt to dimensional tolerances and achieve precise alignment without requiring overly complex fixed structures
Solution Approach 2:
The invention changes the geometric parameters of the connector by providing tuning surfaces at specific angles (e.g., 0 degrees, 45 degrees, 90 degrees) relative to the centerline. These parameter variations allow selective engagement of different surface configurations to optimize alignment and fit for varying manufacturing tolerances
2Reliability
If tie plates are used to force out of specification parts into place, then joint robustness improves, but cost increases due to additional components and fit degrades over time
Solution Approach 1:
The bayonet connector integrates the alignment and securing functions into a single molded component that is formed as part of the trim piece itself. This merging eliminates the need for separate tie plates or additional fastening components, reducing part count and manufacturing cost while maintaining joint robustness through the integrated connector design
Solution Approach 2:
The tuning surfaces on the bayonet connector enable self-alignment and self-adjustment during assembly. The connector automatically finds its optimal position through the geometric interaction of the tuning surfaces, eliminating the need for external adjustment mechanisms or additional components to enforce proper fit
3Manufacturing precision
If assembly line tuning is performed to achieve precise fit, then alignment precision improves, but productivity decreases due to additional tuning time
Solution Approach 1:
The tuning surfaces are pre-configured on the bayonet connector during molding with specific geometric relationships to anticipated manufacturing variations. This preliminary configuration of adjustment capabilities allows the joint to achieve precise alignment through simple rotational adjustment rather than requiring time-consuming assembly line tuning operations
Data Source
AI summary
A flange connector assembly for connecting trim pieces of a vehicle. A first male portion having an end portion connected to a first trim part and a second female portion connected to a trim part end to be attached to the first trim part. The first male portion has a connection portion with a T-shaped cross section and the second portion has a second connecting portion with a T-shaped cavity. The first male connecting portion and the second female connecting portion fit to precisely engage each other and retain the trim portion to be attached. The protruding T-shaped portion includes raised tuning flanges and is capable of adjusting up/down, inboard/outboard or twist fine tuning for providing alignment adjustment to the trim pieces via adjustment of the flange heights in the mold and providing new precisely adjusted T-flanges for providing a tuned butt connection of a trim strip for instance.