Vehicle Joining Stand-Off for Angled Fastener Access
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for joining vehicle components using one-sided fasteners face challenges in driving the fastener without interference from neighboring components, especially when the fastener needs to be driven nonperpendicular to the interface plane, as it often results in stripped drive features and loss of contact between the tool and the fastener.
Innovation Solution
The method involves using a first component with a stand-off that provides a cavity with a tilted floor, allowing the fastener to be driven nonperpendicular to the interface plane without requiring throughbores in the components, using a single-sided fastener like a flow drill screw that creates its own holes and threads, and is driven by a torque tool tilted away from the normal axis to avoid interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the fastener is driven perpendicular to the interface plane, then the driving operation is straightforward, but the tool and fastener interfere with neighboring components
Solution Approach 1:
The cavity floor is designed with an angled surface that is asymmetric relative to the interface plane, causing the fastener to be driven at an angle non-perpendicular to the interface. This asymmetric configuration allows the fastener shaft to clear neighboring components while maintaining secure joining of the first and second components.
Solution Approach 2:
The solution transitions from a conventional perpendicular driving direction to a non-perpendicular angled direction by utilizing the angled cavity floor. This dimensional change in the driving angle enables the fastener to avoid interference with neighboring components while still achieving effective joining.
2Object-affected harmful factors
If the fastener is driven nonperpendicular to the interface plane, then interference with neighboring components is avoided, but the drive feature may be stripped and contact between tool and fastener may be lost
Solution Approach 1:
The cavity with its angled floor is pre-configured in the first component before the joining operation. This preliminary structural preparation ensures that when the fastener is driven at an angle, the drive feature remains properly aligned and engaged throughout the driving process, preventing stripping and maintaining reliable tool-to-fastener contact.
Solution Approach 2:
The driving angle parameter is changed from the conventional perpendicular orientation to a non-perpendicular angle determined by the cavity floor geometry. This parameter change is carefully controlled within optimal ranges to simultaneously avoid interference with neighboring components and maintain sufficient engagement between the drive feature and driving tool for reliable operation.
3Productivity
If throughbores are created in the components, then the fastener can be driven through, but additional manufacturing steps and material removal are required
Solution Approach 1:
The mechanical fastener is designed to create its own apertures and threaded holes as it is driven through the interface between the first and second components. This self-service capability eliminates the need for separate throughbore creation steps, reducing manufacturing complexity while maintaining joining productivity.
Solution Approach 2:
The cavity structure is pre-formed in the first component to receive and guide the self-drilling fastener. This preliminary preparation provides proper alignment and support for the fastener as it creates its own path through the components, enabling efficient one-sided joining without requiring pre-drilled throughbores.
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 enables efficient joining of vehicle components without interference from neighboring components, reduces material penetration, and ensures secure fastening by maintaining contact between the tool and the fastener, preventing stripping and ensuring a seated position with the fastener's longitudinal axis tilted away from the normal axis.
Implementation Method 1
When flow drill screwing, a fastener can be rotated and driven through the components to be joined. The fastener can both create its own hole and form threads.
Data Source
AI summary
A vehicle assembly includes a first component having a stand-off that provides a cavity. The stand-off protrudes from an insertion side of the first component. The stand-off includes at least one side wall that extends from a floor of the cavity to at least one outer surface of the stand-off. The assembly further includes a second component that contacts the first component at an interface. The cavity is configured to receive a mechanical fastener that joins the first component to the second component. A distance between the floor of the cavity and the interface is greater in some areas than in other areas such that a cross-sectional thickness at a bottom of the cavity is varied.