Bonded Fastener-Washer Assembly for Faster Automated Installation
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Solution Overview
Problem
Existing fastening assemblies are complex, time-consuming to assemble, and require multiple components, making them inefficient for automation and increasing disassembly time, while also risking loose components and tooling requirements.
Innovation Solution
A fastener assembly that uses a first fastener element secured to a second fastener element with bonding material, such as wax, to simplify assembly, reduce component count, and facilitate automation, with configurations including a fastener washer and nut secured with wax, and a spacer with a fastener projecting through its bore, utilizing a truss configuration of wax dots for secure bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fastening assemblies are used, then secure fastening is achieved, but assembly time increases and complexity increases
Solution Approach 1:
The patent combines multiple fastening components (fastener element, washer, and locking mechanism) into a single integrated fastening assembly. The fastener element and washer are bonded together as one unit, eliminating the need for separate assembly steps and reducing overall assembly time while maintaining secure fastening functionality.
Solution Approach 2:
The fastener element and washer are pre-bonded together during manufacturing to form a integrated assembly. This preliminary action of combining components before final installation reduces assembly time at the application site and simplifies the fastening process.
2Reliability
If traditional fastening assemblies with multiple components are used, then secure fastening is achieved, but device complexity increases
Solution Approach 1:
Multiple fastening components are merged into a single integrated assembly where the fastener element and washer are bonded together. This reduces the number of separate parts and simplifies the overall assembly structure while maintaining the secure fastening function.
Solution Approach 2:
The integrated fastening assembly performs multiple functions (fastening, washing/distributing load, and locking) within a single unified structure, reducing device complexity by eliminating the need for separate specialized components.
3Reliability
If traditional multi-component fastening assemblies are used, then secure fastening is achieved, but production part count increases
Solution Approach 1:
The patent merges the fastener element and washer into a single bonded assembly, reducing the production part count from multiple separate components to one integrated unit while maintaining the secure fastening function.
4Reliability
If traditional fastening assemblies are used, then secure fastening is achieved, but disassembly time increases
Solution Approach 1:
The bonding material undergoes a phase transition (melting) when exposed to heat, allowing the integrated fastening assembly to be easily separated during disassembly. This enables quick breakdown of the assembly by applying thermal energy to melt the bonding material and release the components.
5Productivity
If automated assembly is implemented, then productivity increases, but device complexity increases
Solution Approach 1:
The fastener element and washer are pre-bonded during manufacturing to create an integrated assembly that can be easily handled and installed by automated systems. This preliminary combination simplifies the automation process by reducing the number of separate components that need to be manipulated.
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 significantly reduces assembly time, simplifies the assembly process, supports automation, minimizes tooling needs, and lowers disassembly time by using a temporary bonding material that breaks under torque or temperature, ensuring secure fastening without interference in engine operation.
Implementation Method 1
The bonding material secures the second fastener element to the first fastener element
Implementation Method 2
a temporary bonding material that breaks under torque or temperature
Data Source
AI summary
An assembly is provided that includes a first fastener element and a second fastener element. The first fastener element is secured to the second fastener element with bonding material. The first fastener element may be a spacer such as a washer. The second fastener element may be a fastener or a washer.