Extruded Integrated Fastener Assembly for Custom Length and Retention
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Solution Overview
Problem
Current extruded fasteners, such as push pins and attachment clips, are expensive to manufacture, time-consuming to produce, lack adequate retention, and are not easily customizable in length, making them inefficient for various applications.
Innovation Solution
An integrated fastener system where a continuous strip is extruded with a predetermined profile, featuring a wider upper portion and a lower extending portion with grippers, allowing for fabrication tooling to cut notches and form fasteners that can be linked together and customized to any desired length, reducing manufacturing costs and improving retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional molding methods are used to manufacture individual fasteners, then each fastener can be produced, but manufacturing costs are high and production time is long
Solution Approach 1:
Multiple individual fasteners are merged into a single integrated fastener assembly where multiple fastening elements are combined into one extruded piece. This allows simultaneous production of multiple fastening functions in a single manufacturing cycle, dramatically reducing both cost and time compared to producing individual fasteners separately through conventional molding methods
Solution Approach 2:
The integrated fastener serves multiple functions within a single component - it provides multiple fastening points, can be cut to various lengths, and maintains structural integrity across the entire assembly. This multi-functionality eliminates the need for separate manufacturing processes for each fastening element, improving both ease of manufacture and productivity
2Ease of operation
If fasteners are produced as individual pieces, then each fastener can be independently used, but they become lost easier and are undesirable for certain applications
Solution Approach 1:
Multiple fastening elements are combined into one integrated assembly that cannot become separated or lost. The unified structure ensures all fastening components remain together as a single unit, eliminating the risk of individual fasteners becoming misplaced while maintaining ease of operation through the coordinated design of all elements
3Ease of manufacture
If fixed-length fasteners are manufactured, then production is simplified, but the capability to change fastener length when desired is reduced
Solution Approach 1:
The integrated fastener assembly is designed with inherent flexibility to accommodate various lengths. The continuous extruded structure allows the fastener to be cut to any required length while maintaining structural integrity and fastening functionality, providing adaptability without complicating the manufacturing process
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 manufacturing costs by approximately ¼, enhances retention properties, and eliminates loose pieces by linking fasteners together, enabling efficient customization of length and application in various scenarios.
Implementation Method 1
A continuous strip of predetermined profile is extruded. By way of non-limiting example, the extrusion includes a wider upper portion which is integrally formed with a lower depending portion having a plurality of grippers extending longitudinally along the lower depending portion of the continuous extrusion.
Data Source
AI summary
An extruded integrated fastener assembly comprising a plurality of fasteners cut to length from an extruded length of material. Unwanted areas of material are cut away leaving the individual fasteners, which fasteners are also connected together by an expanse of material that remains. The fastener assembly can be single durometer or double durometer. A profile with retention members and/or leg features are formed in the fasteners for connecting to a predetermined component. The process for manufacturing the extruded integrated fastener assembly includes providing fabrication tooling suitable to cut away the unwanted area between the fasteners. The fasteners are thereby able to be cut to any desired length.