Stamped Metal Trim Retainer for Quiet Corrosion-Resistant Panel Joining
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Solution Overview
Problem
Existing metal retainers for forming blind connections between panels, such as automotive panels, cause corrosion due to abrasion and produce noise (BSR), while plastic retainers are complex and difficult to manufacture, and larger metal-plastic combinations are cumbersome.
Innovation Solution
A stamped metal retainer with a U-shaped body, flanges, and retaining tabs that form a blind connection by being installed into the secondary panel first, allowing for a smaller size and reduced noise through flexible flanges and angled wings, which engage the primary panel's bezel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal retainers are used to form blind connections between panels, then structural strength and manufacturing simplicity are improved, but corrosion resistance deteriorates due to abrasion of paint or anticorrosive coatings
Solution Approach 1:
A plastic coating layer is applied to the metal retainer, serving as an intermediary between the metal structure and the panel surfaces. This coating layer prevents direct contact between the metal retainer and the paint or anticorrosive coatings on the panels, thereby eliminating abrasion and corrosion while maintaining the structural strength benefits of metal retainers.
2Ease of manufacture
If metal retainers are used to form blind connections, then manufacturing simplicity is improved, but noise reduction deteriorates due to buzzing, squeaking, and rattling
Solution Approach 1:
The retainer is constructed as a composite structure with a metal core providing structural strength and a plastic coating layer providing noise reduction. The plastic material absorbs vibrations and prevents metal-to-metal contact, thereby eliminating buzzing, squeaking, and rattling while maintaining manufacturing simplicity through a single integrated component.
3Object-affected harmful factors
If plastic retainers are used to replace metal retainers, then corrosion resistance and noise reduction are improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The retainer design utilizes parameter changes in material properties by combining metal structural parameters (for strength) with plastic surface parameters (for corrosion and noise resistance). The plastic coating is applied directly to the metal retainer in a single manufacturing process, avoiding the complexity of assembling separate metal and plastic components while achieving both corrosion resistance and noise reduction.
4Object-affected harmful factors
If metal and plastic combination retainers are used, then corrosion resistance and noise reduction are improved, but size increases and manufacturing difficulty increases
Solution Approach 1:
The metal retainer and plastic coating are merged into a single integrated component where the plastic layer is applied directly to the metal structure. This merging eliminates the need for separate assembly of metal and plastic parts, maintaining compact size while achieving both corrosion resistance and noise reduction through the combined material properties.
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 solution provides a compact, noise-reducing, and corrosion-resistant connection suitable for space-constrained areas, with simplified manufacturing and reduced BSR, while maintaining structural integrity.
Implementation Method 1
a pair of flanges spaced apart and flexibly connected to one another at a second end of each of the pair of legs
Data Source
AI summary
Disclosed are systems and methods for retaining system coupling a first panel to a second panel via a retainer. The retainer comprises a body portion, a pair of flanges, a plurality of wings, and one or more retaining tabs. The body portion may employed a pair of legs that are spaced apart and flexibly connected to one another at a first end to define a channel. The channel is configured to receive and/or engage a bezel associated with the first panel. The pair of flanges are connected to and extends outwardly from a second end of its respective leg. The plurality of wings are coupled to the pair of legs and canted outwardly from the body portion. The plurality of wings are configured to engaged, for example, a retaining ledge of the second panel when the bezel is inserted in the channel. The one or more retaining tabs extending inwardly from one of the pair of legs and engage the bezel.