Tolerance Compensation Element With Adjustable Overmolded Thread Bolt
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Solution Overview
Problem
Existing tolerance compensation elements in the automotive industry are laborious and cost-intensive due to their complex composition of multiple components, requiring numerous production and assembly steps.
Innovation Solution
A tolerance compensation element featuring a metal thread bolt with a first and second external thread, where a protrusion extends radially, and is overmolded with plastic to provide a fastening structure that can be adjusted by overcoming a start-up torque, allowing for manual or machine-driven rotation to compensate for tolerances between components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tolerance compensation elements are composed of multiple components, then reliable connection properties are achieved, but production and assembly become laborious and cost-intensive
Solution Approach 1:
The patent combines multiple separate components (thread bolt, plastic retention element, adjustment mechanism) into a single integrated tolerance compensation element. The thread bolt and plastic overmold are formed as one piece through overmolding, eliminating the need for separate assembly steps and reducing component count while maintaining the functional integrity of the connection system.
Solution Approach 2:
The integrated tolerance compensation element performs multiple functions simultaneously: it provides mechanical fastening through the thread bolt, retention through the plastic overmold, and tolerance adjustment through the integrated adjustment mechanism. This multi-functionality in a single component reduces the overall system complexity while maintaining reliable connection properties.
2Reliability
If multiple production and assembly steps are used, then reliable connection is achieved, but productivity decreases and costs increase
Solution Approach 1:
The thread bolt and plastic overmold are pre-integrated into a single component through overmolding during manufacturing. This preliminary integration eliminates the need for separate assembly steps during production, allowing the tolerance compensation element to be installed as one unit, thereby increasing productivity without compromising connection reliability.
3Adaptability or versatility
If complex adjustment mechanisms are implemented, then tolerance compensation capability is improved, but device complexity increases
Solution Approach 1:
The tolerance compensation element incorporates a dynamic adjustment mechanism that allows the distance between the first and second components to be modified after assembly. The adjustment mechanism enables the plastic overmold to move relative to the thread bolt along the longitudinal axis, providing adaptability for tolerance compensation while maintaining a relatively simple integrated structure.
Data Source
AI summary
A tolerance compensation element that compensates for tolerances in the distance between first and second components, includes a thread bolt having a first drive feature, a first thread of a first thread direction and a second thread of a second thread direction. Between the first and the second thread, a protrusion extends from the thread bolt radially to the outside. The element includes a first plastic overmold in the portion of the first thread, which provides a fastening structure for the fastening to the first component, and a second plastic overmold around the protrusion which extends radially to the outside, to provide an abutment portion abutting the second component when in use. A distance of the second plastic overmold to the first plastic overmold is changeable after overcoming a start-up torque between the first plastic overmold and the first thread in longitudinal direction of the thread bolt.