UV-Transmissive Fastener Flange for Automated Panel Bonding
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Solution Overview
Problem
Existing potted fasteners in vehicle interiors face challenges such as inconsistent manual installation, long adhesive curing times, and difficulties in automating the installation process, leading to quality control issues and increased cycle times.
Innovation Solution
A fastener design featuring a body made from a high-strength, high-melting-point material and a flange made from a translucent, lower-melting-point material, allowing for UV light curing of adhesives and improved installation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional potted fasteners are used with manual installation, then installation flexibility is maintained, but installation consistency deteriorates and quality control becomes difficult
Solution Approach 1:
The patent replaces the traditional mechanical potting process with UV light curing. The flange is made of UV-transmissive material that allows UV light to pass through and cure the adhesive quickly and consistently, eliminating manual potting operations and enabling automated installation while ensuring uniform curing results.
Solution Approach 2:
The patent changes the material parameter of the flange to be UV-transmissive rather than opaque. This parameter change enables UV light to penetrate the flange and cure the adhesive from the front side, transforming the installation process from manual mechanical operations to automated UV curing operations.
2Productivity
If traditional adhesive potting is used, then strong attachment is achieved, but curing time increases and productivity decreases
Solution Approach 1:
The patent substitutes the traditional time-consuming mechanical potting and thermal curing process with UV light curing. The UV-transmissive flange allows UV light to penetrate and cure the adhesive in seconds rather than hours, dramatically reducing cycle time while maintaining attachment strength.
Solution Approach 2:
The patent utilizes the phase transition of UV light interaction with the adhesive - the UV-transmissive flange allows UV light to pass through and trigger photopolymerization of the adhesive, causing rapid curing from liquid to solid state in a controlled manner.
3Strength
If the flange is made opaque for structural strength, then mechanical strength is improved, but UV light transmission is blocked and adhesive curing fails
Solution Approach 1:
The patent applies different material properties to different parts of the fastener. The body is made of UV-opaque material for structural strength, while the flange is made of UV-transmissive material for light transmission. This local differentiation of material quality allows each component to fulfill its specific function optimally.
Solution Approach 2:
The patent uses composite construction with the body made of one material (UV-opaque) and the flange made of a different material (UV-transmissive). This composite approach allows the body to provide structural strength while the flange enables UV light transmission for adhesive curing.
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 proposed fastener design enables consistent and efficient attachment to panels, reduces adhesive curing time, and facilitates automated installation processes, thereby improving quality and reducing cycle times.
Implementation Method 1
The first material comprises a lower transmissibility of UV light than the second material... passing UV light through the translucent flange and to the adhesive and curing the adhesive
Implementation Method 2
positioning adhesive between the translucent flange and the second side of the panel... curing the adhesive
Data Source
AI summary
A fastener configured to be attached to a panel and to support an item. The fastener has a body constructed from a first material and with the body having an opening that extends into the body at a first end. A flange constructed from a second material is connected to the body and sized to extend laterally outward beyond the body. The first material has a higher melting point than the second material. The first material has a lower transmissibility of UV light than the second material.