Bruce L. Bergman wrote:

So. Did you notice where I mentioned a backup mechanical connection
besides the adhesive?

Yes I did. And if we used pop rivets, we would be laughed
out of the industry. When we start shipping, I'll post a
link to our product as well as a link to a comparable item
that uses pop rivets, and you will see what I am talking
about. Theirs btw, almost works for the look they are trying
to achieve, but they still fall short of a finished looking
product.

I appreciate the concern you express, but there is no
constant load, only very short term load spikes. For the
finished item, appearance is everything. If the parts do not
fly with adhesive, we have a back up plan to use a metal
stud to tie the ends together. This will require some
alteration to the internal design, but we really don't see
it as being necessary.

I keep forgetting, but my partner used to work for Failure
Analysis, and is well versed in testing, and still has
connections with people that have diverse knowledge. I took
it upon myself to start asking some questions before I
brought it up to him, I wanted to present at least some
data. But he saw right away that we really did need to test
for the worst case. Now that we have decided to really nail
down a definitive answer, we're going to determine actual
maximum load conditions and maximum worst case temps, and
test under those conditions.

Our gut feeling right now is that we have a 10x safety
factor at room temp. Life critical safety factors generally
run 2x to 3x, and we suspect we are still within that range
at 200F. Tests will tell....

Thanks,

Jon