Friction-Welded Connection Element for Drill-Free Composite Fastening
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Solution Overview
Problem
Existing methods for attaching components made of fiber-reinforced composite materials, such as CFRP, face challenges like fiber disruption and delamination due to drilling, and adhesive fastening technologies are inefficient for automated series production.
Innovation Solution
A two-part connecting element with a base part and a functional part, where the base part has an annular bead for friction welding, allowing for hole-less attachment and flexible adaptation to various fastening tasks, using a base part with a bead for friction welding and a functional part with a shaft and head for tensile force transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If drilling is used to attach fasteners to fiber-reinforced composite components, then fastening is achieved, but fiber disruption and delamination occur reducing load-bearing capacity
Solution Approach 1:
The patent replaces the mechanical drilling system with a friction welding system that uses rotational friction heat to join the base part to the composite component surface, eliminating fiber disruption and delamination while achieving strong attachment
Solution Approach 2:
The patent changes the joining parameters from mechanical removal (drilling) to thermal-mechanical bonding (friction welding), where the bead material undergoes phase change and flow during welding to create a strong bond without damaging the composite structure
2Strength
If adhesive bonding is used to attach fasteners to avoid drilling, then fiber disruption is avoided, but curing time is long and automation is difficult
Solution Approach 1:
The patent replaces the chemical adhesive bonding process with a mechanical-thermal friction welding process, eliminating long curing times and enabling automated production while maintaining fiber integrity
Solution Approach 2:
The patent utilizes phase transition of the bead material during friction welding, where friction heat melts and flows the thermoplastic material to create bonding, replacing the chemical curing process with a rapid thermal-mechanical process suitable for automation
3Adaptability or versatility
If a two-part design with base part and functional part is used, then adaptability to various fastening tasks is improved, but device complexity increases
Solution Approach 1:
The patent divides the connecting element into a base part for friction welding attachment and a functional part for various fastening functions, allowing independent optimization of each part and enabling multiple fastening applications with a single base part design
Solution Approach 2:
The patent creates a universal base part that can be combined with different functional parts (snap connection, screw connection, etc.) to achieve multiple fastening tasks, reducing overall system complexity through standardization
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
Enables process-reliable, automated, and cost-effective attachment of components without material restrictions, allowing for flexible design and adaptation to different applications, ensuring high strength and resilience while avoiding fiber disruption and delamination.
Implementation Method 1
for fastening to the surface of a component by friction welding
Implementation Method 2
The bead 'provides' the welding allowance during friction welding
Data Source
Figure 1a
Figure 1b
Figure 2~3
AI summary
The invention relates to a connection element for securing to a component, in particular a component made of a fibre composite material, comprising a main part, a functional part and a friction welding inlay, which in turn comprises a thermoplastic material. A tool application point is formed on an upper side of the main part. The friction welding inlay is interlockingly and/or force-lockingly connected to the main part.