Wheel Fastener Cap Retention via Plastic Deformation
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Solution Overview
Problem
Current fasteners used for securing wheels to vehicles face issues with secure fitting due to diameter mismatches between caps and cap receiving portions, leading to potential cap detachment and increased manufacturing costs for tolerance control.
Innovation Solution
A fastener design featuring a cap and cap receiving portion with recesses and protrusions that are plastically deformed to match each other, ensuring a secure fit and alignment, allowing for cost-effective manufacturing and improved cap retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cap is interference fitted to the cap receiving portion, then the cap is securely fastened, but the manufacturing cost increases due to tolerance control requirements
Solution Approach 1:
The cap is pre-formed with a deformation zone that is designed to be plastically deformed during assembly. This preliminary preparation allows the cap to be easily deformed into the cap receiving portion without requiring tight tolerances on the base dimensions, thus reducing manufacturing costs while ensuring secure fastening.
Solution Approach 2:
The invention changes the physical state of the cap material in a specific zone by making it plastically deformable. This parameter change allows the cap to transition from a rigid state during normal operation to a deformable state during assembly, enabling secure fastening without tight tolerance control.
2Ease of operation
If the diameter difference between cap and cap receiving portion is large, then assembly is easier, but the cap may not be securely fastened
Solution Approach 1:
The cap is designed with non-uniform properties: most of the cap maintains its original dimensions for secure retention, while a specific deformation zone is designed to be plastically deformed during assembly. This local quality differentiation allows easy assembly through deformation while maintaining secure fastening through the undeformed portions.
3Manufacturing precision
If tight tolerances are controlled during manufacturing, then the play between cap and cap receiving portion is within specifications, but manufacturing cost increases
Solution Approach 1:
The cap is pre-formed with a deformation zone that is specifically designed to accommodate dimensional variations. This preliminary design allows the cap to compensate for tolerance variations through plastic deformation during assembly, eliminating the need for tight tolerance control and reducing manufacturing costs.
4Manufacturing precision
If the cap is plastically deformed after the cap receiving portion is shaped, then a secure fit is achieved, but additional manufacturing steps are required
Solution Approach 1:
The cap is designed to deform itself into the cap receiving portion through a simple pressing or insertion operation. The plastic deformation zone automatically conforms to the cap receiving portion geometry without requiring complex tooling or multiple manufacturing steps, achieving precise fit through a single self-adjusting action.
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 design provides a secure and cost-efficient fastening solution by ensuring a precise fit between the cap and cap receiving portion, reducing the risk of cap detachment and manufacturing complexities.
Implementation Method 1
said cap can be deformed, or has been deformed, such that said cap forms a mutual matching protrusion or recess
Data Source
AI summary
The present invention relates to a fastener, such as a bolt or a nut, for fastening a wheel to a vehicle, comprising: a body comprising: a cap receiving portion, a threaded portion and a central axis; and a cap, arranged to be received by and cover said cap receiving portion characterized in that said cap receiving portion comprises a recess or a protrusion against which said cap can be deformed, or has been deformed, such that said cap forms a mutual matching protrusion or recess, wherein said recess or protrusion of said cap receiving portion has a longitudinal extension essentially parallel to said central axis. The present invention also relates to a method for assembling a fastener.