Flexible Base Fastener Bonding for Non-Planar Surfaces
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Solution Overview
Problem
Existing fasteners fail to securely attach to non-planar surfaces without damaging the mounting surface, and current solutions like flexible mounting members suffer from low strength and design constraints, such as the need for apertures and protrusions that can obstruct proper engagement.
Innovation Solution
A fastener design featuring a rigid stud or socket bonded to a flexible base that can conform to non-planar surfaces using adhesive bonding techniques, eliminating the need for mechanical posts and providing increased strength through flexible base materials like silicone or rubber, which can withstand repeated engagement and disengagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a planar base is used to attach the fastener to the mounting surface, then the manufacturing is simple, but the bond strength is insufficient on non-planar surfaces
Solution Approach 1:
The base is designed to be flexible rather than rigid, allowing it to dynamically conform to the non-planar mounting surface. This flexibility enables the base to adapt its shape to match surface irregularities, maximizing contact area and bond strength without requiring complex pre-formed structures.
Solution Approach 2:
The base material properties are changed to provide flexibility, allowing the base to deform and conform to the mounting surface. This parameter change in material rigidity enables the base to adapt to non-planar surfaces while maintaining structural integrity for bonding.
2Strength
If drilling is used to attach the fastener, then the attachment strength is high, but the mounting surface is damaged
Solution Approach 1:
The mechanical drilling system is replaced with an adhesive bonding system. Instead of using mechanical force to create holes and insert fasteners, the invention uses chemical adhesive bonds applied to the flexible base, eliminating damage to the mounting surface while providing sufficient attachment strength.
Solution Approach 2:
An adhesive layer is introduced as an intermediary between the fastener base and the mounting surface. This adhesive mediator transfers and distributes the attachment forces across the flexible base without requiring direct mechanical penetration or damage to the mounting surface.
3Adaptability or versatility
If a flexible mounting member with a post is used, then the adaptability to non-planar surfaces is improved, but the device complexity increases and strength decreases
Solution Approach 1:
The post structure is completely removed from the design. Instead of using a post to mechanically secure the flexible mounting member, the invention relies on adhesive bonding applied to the flexible base itself, eliminating the need for protruding posts and associated apertures while increasing overall strength.
Solution Approach 2:
The flexible mounting member and the bonding interface are merged into a single integrated flexible base structure. The adhesive is applied directly to the flexible base, combining the adaptation function and the attachment function into one unified component rather than separate elements.
4Adaptability or versatility
If a post and aperture structure is used to secure the flexible mounting member, then the attachment to non-planar surfaces is improved, but the engagement of socket and stud is obstructed
Solution Approach 1:
The post and aperture structure is completely extracted from the design. The flexible base secures the socket or stud through adhesive bonding without requiring any protruding posts or corresponding apertures, eliminating obstructions to the engagement of socket and stud components.
Solution Approach 2:
Instead of using a protruding post structure to achieve attachment, the invention inverts the approach by using a bonding interface applied to the flexible base itself. This reversal eliminates the need for mechanical interlocking features that would obstruct engagement.
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 achieves a 62% increase in strength over existing fasteners, ensuring secure attachment to non-planar surfaces without the limitations of previous designs, and avoids leaving components behind on the mounting surface during failure.
Implementation Method 1
A layer of adhesive may be provided on the flexible base to thereby secure the male assembly to a mounting surface
Implementation Method 2
the flexible base may flex to conform to the non-planar mounting surface
Data Source
AI summary
Fasteners including male and female assemblies. At least one of the male or female assembly may have a flexible base that flexes to conform to a non-planar mounting surface. The flexible base is bonded to the stud and/or the socket using techniques that provide a high degree of strength to withstand repeated engagement and disengagement of the fastener. Moreover, in certain embodiments the bonding techniques eliminate the need for mechanical means (for example, threads) to secure the stud to the flexible base. Mechanical tests show that the male assembly according to certain embodiments has 62% more strength than known male assemblies.