Fastener for Coupling Light-Emitting Device to Composite Panel
Solution Overview
Problem
Conventional methods for coupling electrical components to composite sandwich panels are time-consuming, require significant effort, and often result in unreliable adhesion, making it difficult to securely attach and route wires while managing inventory effectively.
Innovation Solution
A fastener system comprising a composite panel assembly, a printed electronics sheet, and a fastener with an anchor and retainer portion that axially retains a light-emitting device within a bore of the panel, allowing for easy assembly and even pressure distribution, while preventing moisture and debris ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods (soldering and adhesive bonding) are used to couple electrical components to composite panels, then electrical connection and attachment are achieved, but assembly time increases and reliability decreases
Solution Approach 1:
The patent combines mechanical fastening and electrical connection functions into a single integrated fastener assembly. The fastener includes an anchor portion for mechanical attachment to the composite panel and a retainer portion for securing the electrical component, eliminating the need for separate soldering and bonding operations while improving both reliability and reducing assembly time
Solution Approach 2:
The fastener serves multiple functions simultaneously: it provides mechanical anchoring to the composite panel, retains the electrical component in position, and maintains electrical connections. This multi-functional design replaces multiple conventional steps (soldering, adhesive bonding, mechanical fastening) with a single integrated solution
2Ease of operation
If adhesive bonding is used to attach electrical components, then attachment is achieved, but adhesion reliability is insufficient and assembly effort increases
Solution Approach 1:
The patent replaces adhesive bonding (chemical attachment) with a mechanical fastening system consisting of the anchor portion inserted into a bore and the retainer portion that mechanically secures the electrical component. This mechanical system provides both easier operation and higher reliability compared to adhesive bonding alone
3Productivity
If multiple separate operations (soldering, bonding, fastening) are performed, then electrical and mechanical coupling is achieved, but device complexity and assembly time increase
Solution Approach 1:
The patent merges multiple assembly operations into a single integrated fastener component that performs mechanical anchoring, electrical component retention, and connection maintenance simultaneously. This reduces the number of discrete steps and tools required, thereby increasing productivity while simplifying the overall assembly 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
Facilitates rapid and secure coupling of electrical components to composite sandwich panels, reducing assembly time and improving reliability by evenly distributing pressure and inhibiting environmental contaminants.
Implementation Method 1
The plug includes an axial retention structure configured to axially retain the plug in a bore of a composite panel assembly
Implementation Method 2
The retainer portion is configured to press a light-emitting device toward a light-transmission channel of the composite panel assembly when the plug is axially inserted in the bore of the composite panel assembly
Data Source
AI summary
In an example, a fastener for coupling a light-emitting device to a composite panel assembly is described. The fastener includes a fastener head including an anchor portion and a retainer portion. The fastener also includes a plug extending from the anchor portion of the fastener head. The plug includes an axial retention structure configured to axially retain the plug in a bore of a composite panel assembly. The retainer portion extends as a cantilever structure from the anchor portion. The retainer portion is configured to press a light-emitting device toward a light-transmission channel of the composite panel assembly when the plug is axially inserted in the bore of the composite panel assembly.