UV-Transmissive Fastener Flange for Rapid Panel Adhesive Curing
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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 to cure the adhesive quickly and efficiently, while the body provides structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional potted fasteners are used with manual installation, then the fasteners can be installed in vehicle interiors, but the installation process is inconsistent and fails quality specifications
Solution Approach 1:
The patent replaces the traditional mechanical potting process with UV light curing. The fastener body is made translucent to allow UV light to pass through and cure the adhesive quickly, enabling automated installation while maintaining consistent quality. This substitution of curing mechanism eliminates manual installation inconsistencies.
Solution Approach 2:
The patent changes the material properties of the fastener body from opaque to translucent, allowing UV light transmission. This parameter change enables the adhesive to be cured rapidly through the fastener body, transforming the installation process from manual and inconsistent to automated and precise.
2Productivity
If traditional potting adhesive is used, then the fasteners can be secured to panels, but the curing time is four hours which adds to overall cycle times
Solution Approach 1:
The patent substitutes traditional slow-curing potting adhesive with UV-curable adhesive. The translucent fastener body allows UV light to penetrate and cure the adhesive in minutes rather than hours, dramatically reducing both installation cycle time and adhesive curing time loss.
Solution Approach 2:
The patent uses periodic UV light exposure to cure the adhesive rapidly. Instead of relying on slow chemical curing, the UV light is applied in controlled periods to achieve complete curing in minutes, significantly improving productivity while minimizing time loss.
3Loss of time
If the fastener body is made translucent to allow UV light transmission, then adhesive curing time is reduced, but the body strength may be compromised
Solution Approach 1:
The patent employs composite material construction for the fastener body, combining translucent properties for UV transmission with reinforcing elements or material formulations that maintain structural strength. This allows the body to be both translucent for rapid curing and strong for mechanical support.
Solution Approach 2:
The patent applies local quality by making specific portions of the fastener body translucent where UV light transmission is needed, while maintaining strength in other areas. The translucent properties are localized to the adhesive interface region, while structural portions retain higher strength characteristics.
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 enables consistent and efficient attachment of fasteners 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. positioning adhesive between the translucent flange and the second side of the panel; and securing the fastener to the panel by passing UV light through the translucent flange and to the adhesive and curing the adhesive
Data Source
Figure 1A~1B
Figure 2A~2C
Figure 3
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.