Blind Fastening Assembly With Deformable Funnel Alignment
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Solution Overview
Problem
Current fastening systems for large vehicles require skilled alignment and positioning of fastening elements, making blind installation from one side impossible, while also needing thermal decoupling and electrical coupling.
Innovation Solution
A blind fastening system comprising a first fastening element with a base portion and a plastically deformable funnel element, allowing for easy alignment and one-sided installation of a second fastening element, which deforms the funnel element into a disk shape for secure holding and electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fastening elements are used requiring alignment and positioning, then fastening reliability is improved, but ease of operation deteriorates due to skilled alignment being required
Solution Approach 1:
The funnel element acts as an intermediary component between the second fastening element and the base portion. It guides the second fastening element into proper alignment and, when deformed, creates a secure holding structure that ensures reliable fastening without requiring skilled alignment operations.
Solution Approach 2:
The funnel element is designed to be self-aligning and self-adjusting. As the second fastening element is inserted, the funnel element automatically deforms under the collar to create the holding structure, eliminating the need for external alignment tools or skilled positioning operations.
2Ease of operation
If blind installation from one side is implemented, then ease of operation is improved, but manufacturing precision deteriorates due to alignment difficulties
Solution Approach 1:
The funnel element serves as a mediator that compensates for alignment tolerances. Its deformable nature allows it to adapt to slight misalignments while still providing precise positioning of the second fastening element relative to the base portion, enabling blind installation without sacrificing manufacturing precision.
3Reliability
If complex fastening systems with rails are used, then fastening reliability is improved for large articles, but device complexity worsens
Solution Approach 1:
The fastening system is segmented into distinct functional components: the base portion with receiving opening, the deformable funnel element, and the second fastening element with collar. This segmentation allows each component to perform its specific function independently while working together to achieve reliable fastening, avoiding the need for complex rail systems.
4Adaptability or versatility
If thermal decoupling and electrical coupling are both required, then adaptability is improved, but device complexity worsens due to multiple requirements
Solution Approach 1:
The fastening system is designed with universal components that can simultaneously provide thermal decoupling and electrical coupling functions. The base portion and fastening elements can be configured with appropriate materials and structures to achieve both thermal and electrical requirements through a single integrated design rather than separate systems.
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 system enables convenient, flexible, and automated blind fastening of large fixtures in vehicles, allowing for continuous electrical contact and thermal decoupling, while simplifying the installation process.
Implementation Method 1
a plastically deformable funnel element, the funnel element being designed to be deformed from the funnel-like basic shape into a flat, disk-like final shape by the collar of the second fastening element
Data Source
AI summary
A fastening system includes a first fastening element attachable to a structure and which has a base portion for plugging through a structural opening, a second fastening element, and a plastically deformable funnel element. The funnel element has a funnel-like basic shape with a funnel opening. The second fastening element can be introduced through the funnel opening into a receiving opening of the base portion and fastened therein and has a collar which faces away from the receiving opening and which is larger than the funnel opening. The funnel element is designed to be deformed from the funnel-like basic shape into a flat, disk-like final shape by the collar of the second fastening element during the fastening of the second fastening element.