Conductive Fastener Anchoring on Weldable Polymers
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Solution Overview
Problem
High-frequency welding of polymer materials struggles to efficiently anchor construction parts to bearing structures while maintaining leak-proof seams, leading to complex and costly manufacturing processes.
Innovation Solution
The method involves using electrically conductive fastener means with a primer layer and a high-frequency weldable connecting layer, typically PVC or PU, applied directly to the fastener means and construction parts, allowing for simplified anchoring through high-frequency welding, where the fastener means act as electrodes to secure overlapping portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional anchoring methods (tailored pockets with carrier lists) are used, then construction parts can be anchored in bearing structures, but the manufacturing and assembly process becomes complex and expensive
Solution Approach 1:
The invention merges the anchoring function with the high-frequency welding process itself. The fastener means are integrated directly into the welding electrodes, combining two previously separate operations (anchoring and welding) into a single unified process, thereby simplifying manufacturing and reducing complexity
Solution Approach 2:
The welding electrodes are given multiple functions: they serve both as the welding tool for joining construction parts and as the anchoring tool for securing fasteners to bearing structures. This multi-functionality eliminates the need for separate anchoring mechanisms and reduces overall system complexity
2Productivity
If traditional anchoring methods are used, then construction parts can be secured to bearing structures, but manufacturing time increases
Solution Approach 1:
By combining anchoring and welding into a single simultaneous operation using the same electrodes, the invention eliminates the sequential time required for separate anchoring and welding steps, thereby reducing total manufacturing time and improving productivity
Solution Approach 2:
The fastener means are pre-integrated into the welding electrodes during electrode fabrication, so that when the welding operation occurs, the anchoring function is already prepared and ready to act simultaneously, eliminating setup and preparation time during the actual manufacturing process
3Reliability
If fastener means are located by high-frequency welding, then anchoring can be achieved, but maintaining leak-proof seams becomes difficult
Solution Approach 1:
The invention applies different material properties to different parts of the fastener means: an electrically conductive material for electromagnetic coupling during welding, and a polymer material weldable by high-frequency welding for creating leak-proof seams. This local differentiation of material properties allows simultaneous achievement of electrical function and sealing function
Solution Approach 2:
The fastener means utilize composite construction with multiple materials (electrically conductive material and polymer material) bonded together, allowing the single component to fulfill multiple functions: electrical conduction for welding and polymer bonding for leak-proof sealing, thereby simplifying the manufacturing process while maintaining reliability
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 approach significantly simplifies the anchoring process, reduces manufacturing time and costs, and ensures strong, leak-proof connections in end products like truck tarps and inflatable products, enhancing efficiency in industries such as car manufacturing and building.
Implementation Method 1
both materials are, in an overlapping welding area, pressed together between two welding electrodes or between a welding electrode and a ground plane and are exposed to a high-frequency electromagnetic field, usually 27.12 MHz. The combination of the heat generated and pressure brings about a welding seam.
Data Source
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AI summary
A method of providing, by high-frequency welding of at least two construction parts (4,4') containing polymer material weldable by high-frequency welding to an assembled large unit in which said construction parts are comprised, fastener means (1) on said unit, said fastener means being intended for anchoring and building up said unit. The fastener means (1) are made of an electrically conductive material, and a primer layer (2) is arranged on a surface of the fastener means (1) and is bonded by means of a first hardening. A material weldable by high-frequency welding is arranged on top of said primer layer and is bonded thereto by means of a second hardening for building up a connecting layer (3). The invention also relates to anchoring parts (5) for use for that purpose.