Unitized Fastener Assembly with Deformable Projections
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Solution Overview
Problem
The existing method of securing components with fasteners requires multiple steps and time, as fasteners are typically provided separately and must be manually or automatically assembled with the components, which can lead to inefficiencies and increased assembly time.
Innovation Solution
A unitized component assembly is created by integrating fasteners with components, featuring a fastener with a necked and threaded shank that deforms discrete projections on the component to provide an axial stop, allowing for secure attachment and easy handling as a single unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fasteners are provided separately from components, then the components can be manufactured independently, but the assembly process requires multiple steps and increased time
Solution Approach 1:
The patent combines the fastener and component into a single unitized assembly where the fastener is permanently attached to the component during manufacturing. This merging eliminates the need for separate fastener installation steps during assembly, directly resolving the contradiction by maintaining independent manufacturability while dramatically improving assembly productivity.
Solution Approach 2:
The fastener is pre-installed and secured to the component during the component manufacturing process itself. This preliminary action of attaching the fastener beforehand eliminates the need for separate assembly steps, allowing the unitized component to be installed as a single piece and thereby increasing assembly speed without compromising manufacturing independence.
2Productivity
If fasteners are integrated with components, then the number of assembly steps is reduced, but the component structure becomes more complex
Solution Approach 1:
The patent integrates the fastener with the component to form a unitized assembly, merging two previously separate elements into one. This reduces assembly steps and improves productivity while the complexity is managed through standardized fastener designs and efficient attachment methods during component manufacturing.
Solution Approach 2:
The unitized component design allows the same component structure to serve multiple functions: both as the structural component itself and as a pre-assembled fastening system. This multi-functionality reduces the need for additional parts and assembly steps, improving efficiency without proportionally increasing complexity.
3Reliability
If discrete projections are deformed during fastener insertion, then secure retention is achieved, but the insertion process requires precise control
Solution Approach 1:
The discrete projections are pre-formed on the component before fastener installation. This preliminary preparation of the retention features ensures that when the fastener is inserted, the deformation process is controlled and predictable, achieving reliable retention without requiring excessive precision during the insertion operation itself.
Solution Approach 2:
The deformation of the discrete projections during fastener insertion serves a dual purpose: it provides the mechanical interlock for secure retention while simultaneously indicating proper installation. The self-deforming nature of the projections during insertion eliminates the need for separate retention verification steps, reducing the precision burden on the insertion process.
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 approach reduces the number of assembly steps and time by integrating the fastener with the component, enabling secure attachment and easy handling without the need for pre-threading, thus enhancing efficiency and reducing manufacturing costs.
Implementation Method 1
at least partially deforming each of the projections during insertion of the threaded portion of the shank into the aperture
Data Source
AI summary
A unitized component assembly includes an component having an aperture, and a plurality of discrete projections extending into the aperture and spaced apart from one another about the perimeter of the aperture, and a fastener having a head and a shank extending from the head. The shank includes a necked portion and a threaded portion adjacent the necked portion. The shank is positioned in the aperture such that the necked portion is in facing relationship with the projections. The threaded portion is engageable with the projections to provide an axial stop for limiting movement of the fastener relative to the component.