Moldable Flexible Mount for Curved Surfaces Under Vibration
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Solution Overview
Problem
Existing methods for attaching communication accessories and cameras to curved surfaces, such as helmets and bicycle handlebars, face challenges due to significant vibration and stress, leading to bonding failures, as they are primarily designed for flat surfaces.
Innovation Solution
A mounting assembly comprising a moldable base with a bendable insert and foam adhesive tape, allowing the base to be shaped to match curved surfaces and providing even adhesion using a pressure-sensitive adhesive.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional flat mounting methods are used on curved surfaces, then the mounting structure is simple and easy to manufacture, but the adhesive strength is insufficient and bonding failures occur under vibration and stress
Solution Approach 1:
The mounting base is designed with a curved surface that matches the contour of the helmet or equipment surface. This curvature allows the adhesive to distribute evenly across the bonding interface, maximizing contact area and adhesive strength while accommodating the rounded geometry of the mounting surface.
Solution Approach 2:
The mounting base incorporates a flexible or compliant structure that can conform to the curved surface. This flexibility allows the base to adapt to surface irregularities and maintain consistent adhesive pressure across the bonding area, preventing bonding failures under vibration and stress.
2Adaptability or versatility
If a rigid flat mount is used, then the manufacturing is simple, but the mount cannot conform to curved surfaces and creates stress concentrations
Solution Approach 1:
The mounting base is designed with a curved surface that matches the contour of the helmet or equipment surface. This curvature allows the adhesive to distribute evenly across the bonding interface, maximizing contact area and adhesive strength while accommodating the rounded geometry of the mounting surface.
Solution Approach 2:
The mounting base utilizes materials or structural design that allow it to be molded or shaped into different curved configurations. This enables the same basic mounting structure to adapt to various surface curvatures (helmets, handlebars, etc.) without requiring completely different designs for each application.
3Strength
If adhesive is applied to a flat surface mounted on a curve, then the application is simple, but the adhesive strength is reduced due to poor contact with the curved surface
Solution Approach 1:
The mounting base is designed with a curved surface that matches the contour of the helmet or equipment surface. This curvature allows the adhesive to distribute evenly across the bonding interface, maximizing contact area and adhesive strength while accommodating the rounded geometry of the mounting surface.
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 superior adhesive strength, with the flexible mount demonstrating three times the adhesive strength of traditional flat mounts on smaller diameter pipes, while avoiding stress concentrations and improving overall robustness.
Implementation Method 1
the foam tape utilizes a pressure sensitive adhesive to bond to the curved surface
Data Source
AI summary
The embodied invention is a mounting assembly comprising an attaching bracket, a moldable base with a bending metal insert, and a foam attaching tape. The moldable base is conveniently formed to match the curved surface shape, and the foam tape utilizes a pressure sensitive adhesive to bond to the curved surface.