Stud Attachment Through Surface Coatings With Recess Sealing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for attaching bolts to substrates with surface layers, such as paint or corrosion protection, are time-consuming and dependent on user expertise, requiring extensive surface preparation and visual inspection for connection quality.
Innovation Solution
A method involving creating a recess in the substrate with a defined surface area larger than the bolt diameter, liquefying the substrate material, and covering it with a cover element to simplify the fastening process and ensure a sealed joint, which may include a sealing ring and deformation of the cover element for enhanced sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If extensive surface layer removal is performed before bolt attachment, then the bonding quality is improved, but the process time and complexity increase significantly
Solution Approach 1:
The recess is created only in the specific area where the bolt will be attached, rather than removing the surface layer extensively. The surface layer is removed locally to expose the substrate only where necessary for bonding, while the rest of the surface layer remains intact, thus reducing preparation time while maintaining bonding quality.
Solution Approach 2:
The recess is created in advance before the bolt attachment process. By pre-preparing the recess area with the surface layer removed, the actual bonding process can proceed immediately without extensive surface preparation at the time of attachment, reducing overall process time.
2Reliability
If the surface layer is removed extensively, then the bonding area is improved, but the need for cleaning and repainting increases process complexity
Solution Approach 1:
The surface layer is removed only in the localized recess area where bonding is needed, rather than extensively across the entire surface. This localized approach maintains the surface layer elsewhere, eliminating or reducing the need for additional cleaning and repainting operations, thus simplifying the overall process.
3Reliability
If a recess is created with surface layer removal, then the bolt bonding is improved, but additional processing steps are required
Solution Approach 1:
The creation of the recess and the bolt attachment process are combined into a streamlined sequence. The recess is created and then the bolt is immediately attached in the same operational flow, eliminating separate surface preparation and bonding steps, thus improving overall productivity.
Solution Approach 2:
The recess is prepared in advance before the actual bolt attachment. This preliminary action allows the bolt to be attached directly to the pre-prepared surface without additional preparation steps during the attachment process itself, improving fastening process efficiency.
4Reliability
If the cover element is used to seal the joint, then the sealing quality is improved, but the device complexity increases
Solution Approach 1:
The cover element acts as a flexible sealing component that covers the recess and bolt joint. This thin film or shell structure provides effective sealing against the environment without requiring complex multi-component joint structures, thus improving sealing quality while minimizing added complexity.
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
This method simplifies the fastening process by eliminating the need for extensive surface preparation and ensures a reliable, sealed connection between the bolt and substrate, independent of user experience, with improved sealing and bonding.
Implementation Method 1
an electric current is applied. As soon as the electric current flows between the stud and the substrate, the stud is lifted from the substrate by the formation of an electric arc. Due to the energy released, the material of both the stud and the substrate partially liquefies.
Implementation Method 2
the material of both the stud and the substrate partially liquefies. The electric current is then switched off, and the stud is immersed in the liquefied material, which cools and solidifies.
Implementation Method 3
the stud is immersed in the liquefied material, which cools and solidifies. The stud is then metallurgically bonded to the substrate.
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A method for fastening a stud to a substrate having a surface coating in which a recess is created in the substrate, the stud in the recess is connected to the substrate and the recess around the stud is covered.