Flexible Substrate Connectors with Distributed Fastener Receivers

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional grommets on flexible substrates, such as tarps, are prone to tearing under large loads, leading to increased stress on remaining grommets and potential failure, especially when subjected to wind or heavy use.

Innovation Solution

The use of novel connectors with reinforced designs, including hexagonal first connectors and square second connectors, featuring multiple fastener receivers and a retainer mechanism that distributes force across a larger surface area, reducing the risk of tear-out and enhancing structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If conventional grommets are used on flexible substrates, then the substrate can be attached at discrete points, but the grommets are prone to tearing under large loads

Engineering Contradiction:

Improveattachment capabilityVSAvoidresistance to tear-out

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The connector is divided into multiple components: a base layer, a connector body with recesses, and a cover layer. These segments work together to distribute loads across multiple attachment points (fastener receivers) rather than concentrating stress at a single grommet location, thereby preventing tear-out while maintaining attachment functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connector extends the attachment system from a single-point (0D) or line (1D) attachment to a distributed two-dimensional attachment pattern with multiple fastener receivers arranged in rows and columns. This dimensional expansion allows forces to be distributed across a larger surface area of the flexible substrate, significantly reducing stress concentration and preventing grommet failure.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Strength

If multiple fastener receivers are used to distribute force, then the structural integrity is enhanced, but the device complexity increases

Engineering Contradiction:

Improveforce distribution capabilityVSAvoidnumber of components

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

Multiple functional elements are merged into a single integrated connector assembly: the base layer provides structural support, the connector body contains multiple fastener receivers for force distribution, and the cover layer protects the internal components. This merging achieves enhanced force distribution capability while maintaining relatively simple device complexity through functional integration.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connector assembly serves multiple functions simultaneously: it provides structural reinforcement, distributes forces across multiple attachment points, protects internal components, and enables flexible substrate attachment. This multi-functionality reduces the need for separate components, thereby managing device complexity while achieving enhanced strength and force distribution.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If grommets are used for attachment, then the substrate can be secured, but the grommets are susceptible to failure under wind or heavy use

Engineering Contradiction:

Improveattachment securityVSAvoidvulnerability to wind and heavy use

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The connector assembly provides beforehand cushioning by distributing attachment forces across multiple fastener receivers and a larger surface area of the flexible substrate. This preemptive force distribution prevents stress concentration at any single attachment point, thereby cushioning against the harmful effects of wind loads and heavy use before they can cause grommet failure.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The connector assembly acts as an intermediary between the attachment hardware (fasteners, ropes, cords) and the flexible substrate. It mediates the transmission of forces, distributing them across multiple attachment points and protecting the substrate from direct stress concentration that would otherwise occur at traditional grommet locations, thereby enhancing reliability under adverse conditions.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS10457127B1Flexible substrate connectors

Publication Date: 2019.10.29 TAFCO CORP

AI summary

A connector for a flexible substrate includes a first connector piece including a first plurality of through holes, a second connector piece including a second plurality of through holes, the second connector piece disposable in opposition to the first connector piece to align the first plurality of through holes and the second plurality of through holes to define, via the first plurality of through holes and the second plurality of through holes, a grommet, a plurality of first fastener receivers and a plurality of second fastener receivers and a channel, defined at least in part by the first connector piece, extending across the first connector piece. The plurality of first fastener receivers are disposed on a first side of the channel and the plurality of second fastener receivers are disposed on a second side of the channel, the first side of the channel corresponds to a position at which a flexible substrate is disposable between the first connector piece and the second connector piece, and the second side of the channel corresponds to a position at which a flexible substrate is not disposed between the first connector piece and the second connector piece.