Reusable Bolt Seal Module Circuit Design

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Solution Overview

Problem

Existing electronic security seals that use bolts for securing containers or cargo doors are costly due to the need to discard the entire assembly when the bolt is severed, and they do not efficiently utilize the bolt as part of the detection circuit, leading to increased costs and potential contamination of the reusable electronic module.

Innovation Solution

An electronic security bolt seal with a reusable electronics module where the bolt forms a secondary portion of the circuit, allowing for continuous communication and tracking, and enabling the seal to be reused without opening the module, which includes a housing with a cavity containing the first portion of the electronics circuit and a bolt with a head and shank that engages with the housing to complete the circuit, allowing the bolt to be severed for unlocking and releasing the module.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the entire seal assembly is discarded when the bolt is severed, then the seal maintains security integrity, but the cost increases and waste is generated

Engineering Contradiction:

Improveseal security integrityVSAvoidelectronic module waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The seal system is divided into two segments: a reusable electronic module and a disposable bolt assembly. The electronic module contains the housing, circuit board, battery, and communication components, while the bolt assembly includes the bolt and locking mechanism. This segmentation allows the electronic module to be recovered and reused after the bolt is severed, resolving the contradiction between maintaining security integrity and reducing waste.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention implements a discard-and-recover strategy where the bolt assembly is designed to be discarded after use (when severed), but the electronic module is recovered and reused. The module housing includes a cavity that receives the bolt, and after the bolt is cut and removed, the housing can be reused with a new bolt, eliminating the need to discard the entire assembly and reducing electronic waste.

Inventive Principle:

Principle #34Discarding and recovering

2Ease of manufacture

If the electronic module is opened for reuse, then the bolt can be replaced, but contamination of the electronic components occurs

Engineering Contradiction:

Improvemodule reusabilityVSAvoidelectronic module contamination

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The seal system is divided into a protected electronic module segment and a sacrificial bolt segment. The bolt is designed to be removed from the outside without opening the module housing, so the electronic components remain sealed and uncontaminated while the bolt can be replaced by simply inserting and removing it through the housing cavity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The bolt acts as an intermediary element that interfaces with the electronic module housing but does not require opening the housing to replace. The bolt can be inserted through the housing cavity and locked in place, allowing replacement without exposing the electronic components to contamination, thus resolving the contradiction between reusability and contamination prevention.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Device complexity

If the bolt is used only as a mechanical component, then the structure is simple, but the detection circuit efficiency is reduced

Engineering Contradiction:

Improvecircuit structureVSAvoiddetection circuit efficiency

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The bolt is merged with the detection circuit by making the bolt itself an integral part of the circuit path. Electrical contacts on the circuit board engage with the bolt, so the bolt serves dual functions: mechanical fastening and electrical circuit completion. This merging eliminates the need for separate detection components, maintaining structural simplicity while improving detection circuit efficiency.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The bolt is designed with multi-functionality, serving both as a mechanical locking component and as an electrical conductor that completes the detection circuit. The bolt's shank acts as a circuit path between contacts, allowing the same component to perform both mechanical and electrical functions, thus resolving the contradiction between device complexity and detection efficiency.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS10497289B2Reusable bolt electronic seal module with GPS/cellular phone communications and tracking system

Publication Date: 2019.12.03 E J BROOKS COMPANY

AI summary

An electronic security bolt seal for locking a hasp includes an electronic module that has a circuit board disposed at an interior cavity of a housing. The housing includes apertures aligned with each other, such that a bolt is configured to be inserted through the apertures and through the interior cavity to engage the circuit board and complete an electronics circuit. When the bolt is inserted through the apertures of the housing, a locking device engages a tip region of the bolt that protrudes from the housing to secure the electronic module to the bolt. Responsive to a determination of breaking the electronics circuit, the circuit board is operable to generate a seal tamper signal. The locking element can be unlocked by a user to disengage the locking device from the bolt to permit the bolt to be removed from the electronic module and disengaged from the hasp.