Trim Panel Mounting via Keyhole Push Pin Holder

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The traditional trim panel mounting system requiring a 'lifter' in the mold for the doghouse feature increases capital investment and necessitates a significant clearance of 16 mm between the trim panel and the sheet metal panel, limiting vehicle design flexibility.

Innovation Solution

A trim panel mounting system that eliminates the need for a lifter by using a push pin holder with a keyhole opening and a resilient retention finger, reducing the clearance requirement to 12 mm or less by capturing the push pin between the trim panel and the holder, and heat staking the holder in position.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a traditional doghouse feature with lifter is used in the mold, then the push pin connection is achieved, but the capital investment increases by 10% to 15% and the clearance distance increases to 16 mm

Engineering Contradiction:

Improvepush pin connection reliabilityVSAvoidmold complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts the push pin retention function from the traditional doghouse feature by introducing a separate push pin holder component. This holder includes a keyhole opening that receives and retains the push pin, eliminating the need for the complex lifter mechanism in the mold while maintaining reliable push pin connection.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent segments the trim panel mounting system into distinct components: the trim panel with mounting posts, the push pin holder with keyhole opening, and the push pin itself. This segmentation allows each component to be optimized independently, reducing overall system complexity while maintaining functionality.

Inventive Principle:

Principle #1Segmentation

2Reliability

If a traditional doghouse feature is used, then the push pin can be held in position, but the clearance distance from flange to sheet metal must be 16 mm or more

Engineering Contradiction:

Improvepush pin retentionVSAvoidclearance distance

Core Design Contradiction:

ReliabilityVSLength of stationary object

Solution Approach 1:

The patent changes the retention mechanism from a depth-dependent doghouse feature to a lateral keyhole opening configuration. The keyhole opening's entry portion provides lateral retention of the push pin, allowing the system to function with reduced clearance distance of 12 mm or less.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Ease of manufacture

If a lifter is incorporated in the mold, then the doghouse feature can be molded, but the investment capital increases substantially

Engineering Contradiction:

Improvedoghouse feature moldingVSAvoidcapital investment

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

The patent replaces the expensive, complex lifter mechanism with a simpler, more economical push pin holder component that can be molded using standard mold technology without requiring additional lifter hardware, thereby reducing capital investment.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Adaptability or versatility

If the clearance distance is reduced to 12 mm or less, then more design flexibility is achieved, but the traditional doghouse feature cannot accommodate the reduced space

Engineering Contradiction:

Improvevehicle design flexibilityVSAvoidmounting system structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent changes the geometric parameters of the retention mechanism by using a keyhole opening with specific dimensions (entry width W1 greater than retention slot width W2) that allows effective push pin retention in the reduced 12 mm clearance space, providing design flexibility while maintaining structural efficiency.

Inventive Principle:

Principle #35Parameter changes

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

This solution reduces capital investment in mold production and minimizes the clearance between the trim panel and sheet metal panel, providing more design flexibility and reducing unnecessary space for other uses.

Implementation Method 1

a resilient retention finger capturing the push pin between the trim panel and the push pin holder

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

heat staking the holder in position

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS9802552B2Trim panel mounting system for securing a trim panel to a substrate

Publication Date: 2017.10.31 FORD GLOBAL TECH LLC

AI summary

A trim panel mounting system is provided for securing a trim panel to a substrate. That trim panel mounting system includes a push pin, a push pin holder and a trim panel. That trim panel includes at least one mounting post engaging the push pin holder and a resilient retention finger capturing the push pin between the trim panel and the push pin holder.