Breakout Fastener Adapter With Stepped Arms for Reverse Burr Openings

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Solution Overview

Problem

Conventional fastening systems struggle to securely attach traditional fasteners to components with breakout openings, particularly those with reverse burrs, without requiring rework or excessive force.

Innovation Solution

An adapter with a discorectangular annular body and resilient retention arms, featuring a stepped profile and living hinges, allows secure engagement with breakout openings by inserting from the reverse side, accommodating various fastener sizes and panel thicknesses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional fasteners are used with breakout openings, then assembly is simple, but reliable attachment cannot be achieved especially with reverse burrs

Engineering Contradiction:

Improveattachment reliabilityVSAvoidassembly difficulty

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The adapter serves as an intermediary component between the breakout opening and the traditional fastener. It features retention arms with stepped profiles that engage the breakout opening (including reverse burrs) and a central opening that receives the fastener, thereby enabling reliable attachment without requiring modification to the fastener or opening.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The adapter is divided into functional segments: retention arms for engaging the breakout opening, a central body for receiving the fastener, and a flange for positioning. This segmentation allows each part to perform its specific function optimally, resolving the contradiction between reliability and ease of assembly.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If breakout openings are used to accommodate fasteners, then manufacturing is simplified, but compatibility with traditional fasteners is limited

Engineering Contradiction:

Improvefastener compatibilityVSAvoidadapter structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The adapter provides universal compatibility with traditional fasteners (bolts, screws, nuts) while adapting to breakout openings of various sizes and configurations. The stepped profile on retention arms and adjustable central opening size enable one adapter design to serve multiple fastener types and opening geometries.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

Different portions of the adapter have specialized features: retention arms with stepped profiles for engaging breakout openings, a central opening sized for specific fasteners, and a flange for positioning. This local quality optimization enables broad compatibility without excessive overall complexity.

Inventive Principle:

Principle #3Local quality

3Reliability

If excessive force is applied to attach fasteners to breakout openings, then attachment is achieved, but damage occurs to the component

Engineering Contradiction:

Improveattachment securityVSAvoidcomponent damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The retention arms are designed with resilient properties, allowing them to flex during insertion and then spring back to engage the breakout opening securely. This dynamic behavior enables reliable attachment without requiring excessive insertion force, thereby preventing damage to the component.

Inventive Principle:

Principle #15Dynamics

4Reliability

If rework is performed on breakout openings to accommodate fasteners, then secure attachment is achieved, but manufacturing time and cost increase

Engineering Contradiction:

Improveattachment securityVSAvoidassembly efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The adapter is pre-configured with retention arms and stepped profiles that are designed to engage breakout openings as-manufactured, including any reverse burrs. This preliminary design eliminates the need for rework operations such as deburring or modifying the opening, thereby maintaining assembly efficiency while achieving secure attachment.

Inventive Principle:

Principle #10Preliminary 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

Enables reliable and efficient attachment of fasteners to components with breakout openings, minimizing damage and ensuring compatibility with legacy and new fastener types, while reducing manufacturing costs and enhancing versatility.

Implementation Method 1

a plurality of retention arms resiliently coupled to the annular body and extending from an underside surface of the annular body

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS20260016039A1Breakout Adapter

Publication Date: 2026.01.15 ILLINOIS TOOL WORKS INC

AI summary

An adapter to attach a fastener assembly to a component that has a breakout opening. The adapter includes an annular body with a central opening, both of which can have a discorectangular shape (a rectangular shape with rounded ends). Attached to the underside of the annular body are several flexible retention arms. Each arm has a stepped outer surface with at least three levels that help it grip the side of the breakout opening. Among these arms, one can have a straight surface, and another can have a curved surface. The arms are designed to fit at least partly through the breakout opening to hold the adapter securely to the component.