Conductive Element for Thermoplastic Vehicle Structure Bonding
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Solution Overview
Problem
Thermoplastic materials used in vehicle structures are often more expensive than metallic materials, making them costly for automotive applications, and existing assembly methods do not effectively integrate additional functional components like grounding or electromagnetic functionality.
Innovation Solution
A manufacturing method that involves placing an electrically conductive element between thermoplastic parts, generating heat through an electric current to secure the parts together, while also integrating functions such as grounding, antenna functionality, or electromagnetic shielding, using the conductive element to melt the thermoplastic materials and create a bond.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If thermoplastic materials are used to replace metal in vehicle structures, then weight is reduced, but manufacturing cost increases
Solution Approach 1:
The patent combines the attachment function and grounding function into a single integrated process. The conductive element serves dual purposes: attaching thermoplastic parts together and providing electrical grounding, thereby eliminating separate grounding components and reducing overall manufacturing cost despite using expensive thermoplastic materials
Solution Approach 2:
The attachment element is designed to perform multiple functions simultaneously: mechanical attachment of parts and electrical grounding. This multi-functionality reduces the number of separate components needed, offsetting the higher material costs of thermoplastics through design efficiency
2Strength
If traditional assembly methods (gluing, screws, rivets) are used to attach thermoplastic parts, then structural integrity is achieved, but manufacturing cost increases
Solution Approach 1:
The patent replaces traditional mechanical attachment methods (screws, rivets, gluing) with a thermal welding process. Heat is generated through the conductive element to melt and fuse thermoplastic parts together, eliminating the need for separate mechanical fasteners and reducing manufacturing complexity
Solution Approach 2:
The attachment process utilizes phase transition of thermoplastic materials. Heat generated by the conductive element melts the thermoplastic parts (solid to liquid phase transition), allowing them to fuse together, then cools to form a strong bond (liquid to solid phase transition), achieving structural integrity without traditional fasteners
3Reliability
If separate grounding components are added to thermoplastic structures, then electrical grounding is achieved, but device complexity increases
Solution Approach 1:
The patent merges the attachment element and grounding element into a single integrated conductive component. This element simultaneously performs mechanical attachment and electrical grounding functions, eliminating the need for separate grounding components and reducing overall device complexity
Solution Approach 2:
The conductive attachment element is designed with multi-functionality, serving both as a mechanical connector and an electrical ground path. This universal design approach ensures reliable grounding while maintaining simple device architecture without additional grounding components
4Weight of moving object
If thermoplastic materials are used instead of metal, then weight is reduced, but additional functions (grounding, antenna) must be integrated separately
Solution Approach 1:
The conductive element is designed to perform multiple functions: mechanical attachment, electrical grounding, and antenna functionality. This multi-functional design allows thermoplastic structures to achieve the same versatility as metal structures without additional components, maintaining adaptability while benefiting from weight reduction
Solution Approach 2:
The patent combines multiple functions (attachment, grounding, antenna) into a single integrated conductive element. This merging approach ensures that thermoplastic structures can provide all necessary functions without requiring separate components, maintaining full functionality while achieving weight reduction
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 reduces the cost of thermoplastic vehicle structures by integrating additional functions like grounding and electromagnetic capabilities, enhancing the structural integrity and functionality while maintaining cost-effectiveness.
Implementation Method 1
generating heat by creating an electric current in the element electrically conductive
Implementation Method 2
the electrically conductive element serving for attachment... pressing the first and second surfaces together, generating heat by creating an electric current in the element electrically conductive
Data Source
Figure 1~3
Figure 4~6
Figure 7~8
AI summary
The method includes a step of fixing the first and second surfaces (3, 7) to each other by placing an electrically conductive element (9) between the first and second surfaces (3, 7) and creating an electric current in the electrically conductive element (9). According to the invention, the electrically conductive element (9) is used to integrate an additional function into the structure: grounding, radio antenna, Wi-Fi antenna, or electromagnetic shielding.