Modular Explosive Fastener Assembly for Reusable Bracket Loading
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Solution Overview
Problem
Existing explosively driven fastener systems require a large inventory of power charge/nail/bracket combinations due to variability in applications, leading to high inventory costs and significant waste when malfunctions occur.
Innovation Solution
A modular tool and fastener system that allows for the use of nails of different lengths and interchangeable bracket configurations, with components designed for salvage in case of malfunction, and a safety mechanism to prevent accidental firing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a large inventory of power charge/nail/bracket combinations is maintained to accommodate different applications, then adaptability is improved, but inventory costs and device complexity increase
Solution Approach 1:
The fastener system is divided into separate modular components: power charges, nails of various lengths, and bracket configurations can be individually selected and combined. This segmentation allows the inventory to be stored separately rather than as pre-assembled units, reducing the complexity of managing complete fastener assemblies while maintaining adaptability through component mixing and matching.
2Ease of operation
If pre-assembled power charge/nail/bracket combinations are used, then ease of operation is improved, but waste increases when malfunctions occur
Solution Approach 1:
By separating the power charge from the nail and bracket components, the system enables selective replacement. When a malfunction occurs (misfire, bent nail, spalled penetration), only the affected component needs to be replaced while the power charge and other components can be salvaged and reused, significantly reducing waste while maintaining ease of operation through simple component exchange.
Solution Approach 2:
The system is designed to facilitate recovery and reuse of components after malfunction. The power charge can be recovered and reused with different nails and brackets, and bracket components can be salvaged for reconfiguration with new power charge/nail assemblies, minimizing material waste while keeping the system easy to operate.
3Manufacturing precision
If unitary construction fasteners are used, then manufacturing precision is improved, but adaptability worsens due to inability to salvage components
Solution Approach 1:
The fastener system uses precision-manufactured individual components (power charges, nails, brackets) that are separately engineered to high standards. These precisely manufactured components are designed to work together through standardized interfaces, allowing both high manufacturing precision for each component and adaptability through their modular combination and selective reuse across different applications.
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 modular system reduces inventory costs and waste by allowing the reuse of components, while enhancing safety through improved handling and malfunction management.
Implementation Method 1
an explosive charge positioned in the cup and arranged to explode and drive the metal fastener
Data Source
AI summary
A bracket is formed from metal plate or strap stock having a length, a width and a thickness. The length is greater than the width and the width is greater than the thickness. The metal plate or strap stock forms a first section, a second section, and a third section. The third section is connected to the second section at a “J”-shaped bend for receiving a loop formed in the end of a support wire or cable. The “J”-shaped bend forms a saddle across the width of the metal plate or strap stock having an upwardly-facing convex surface for supporting the loop. In a preferred embodiment, to reduce the risk of accidental disengagement of the wire loop, the metal plate or strap stock further forms a fourth section extending from the third section above the saddle, a gap being left between the first section and the fourth section to permit passage of the loop. The fourth section functions as a hood to reduce the chance of accidental dislodgement of the loop.