Curable Mounting Dome for Secure Component Joining
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Solution Overview
Problem
Existing methods for connecting components, particularly flat components in the automotive industry, face challenges in creating suitable surfaces for screw threads and require complex process steps involving screw domes or fastening domes that are either molded or attached later, which are not tolerant to surface properties and require precise matching.
Innovation Solution
A method involving a mounting dome made of curable material applied to one component, which hardens to form a dome shape, allowing a fastener to pass through and connect with another component, using a thermoplastic material that is initially soft and adaptable, eliminating the need for precise surface preparation and additional adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screw domes or fastening domes are molded or attached later to provide suitable surfaces for screw threads, then the connection between components is secured, but the process steps become complex and costly
Solution Approach 1:
The patent combines the fastening dome formation with the component molding process itself. The fastening domes are formed integrally with the components during the injection molding process, eliminating the need for separate molding or attachment steps. This merging of operations simplifies the overall process while maintaining reliable connections.
Solution Approach 2:
The fastening domes are formed in advance as integral parts of the components during the initial molding process. This preliminary formation of the fastening surfaces eliminates the need for subsequent attachment operations, reducing process complexity while ensuring connection security.
2Manufacturing precision
If screw domes are attached later by gluing or welding to components, then suitable surfaces for screw threads are provided, but additional complex process steps are required
Solution Approach 1:
The patent merges the fastening dome formation with the component manufacturing process. The fastening domes are formed integrally with the components during injection molding, eliminating separate attachment steps by gluing or welding, thereby simplifying manufacturing while maintaining surface suitability for screw threads.
3Reliability
If joining sections are precisely matched and components are prepared to accommodate fastening domes, then secure connection is achieved, but the joining process becomes complex requiring adhesive application and light-curing
Solution Approach 1:
The patent extracts the complex adhesive joining process entirely from the system. Instead of using joining sections that require adhesive application and light-curing, the invention uses self-contained fastening domes with integrated thread formations that directly receive and secure screws without any additional joining materials or processes.
4Adaptability or versatility
If thermoplastic material is used in thermoplastic aggregate state for the fastening dome, then the material adapts to component contours and increases contact surface, but the material must maintain dimensional stability to preserve dome shape
Solution Approach 1:
The patent utilizes parameter changes of the thermoplastic material - specifically temperature-induced changes in viscosity and flow characteristics. The material is applied in a molten or softened state where it flows and adapts to the component contours, then cools and solidifies to maintain the formed dome shape and dimensional stability, achieving both adaptability and stability through controlled parameter changes.
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 provides a secure and cost-effective connection that is tolerant to surface properties and inaccuracies, allowing for easy alignment and secure attachment of components without the need for complex preparation or precise matching of surfaces.
Implementation Method 1
a mounting dome of curable material is applied to the first component, the mounting dome hardens on the first component
Implementation Method 2
The material cannot be liquid, since this would not allow the formation of a dome. The material must have a certain dimensional stability in order to be able to form the shape of a dome, i.e. an elevation, and to be able to maintain it until the material hardens
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A method for joining a first component (1) to a second component (2), wherein - a mounting boss (3) made of curable material is applied to the first component (1), - the mounting boss (3) cures on the first component (1), and - a connecting element (6) is guided through the second component (2), the first component (1) and at least partially through the mounting boss (3).