Friction-Welded Connection Element for Drill-Free Composite Joining
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Drilling through fiber-reinforced composite materials like CFRP to secure attachments disrupts the fiber pattern, reduces load-bearing capacity, and can lead to delamination, while traditional adhesive bonding methods are inefficient for automated serial production.
Innovation Solution
A two-part connection element with a main part and a functional part, utilizing friction welding with a bead for secure bonding, allowing for flexible adaptation to different tasks and materials, enabling secure attachment without drilling and facilitating process-reliable, automated assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If drilling is used to secure attachments to fiber-reinforced composite materials, then mechanical connection is achieved, but the fiber pattern is disrupted and load-bearing capacity is reduced
Solution Approach 1:
The connection element is divided into two separate parts: a main part that is friction-welded to the composite component surface, and a functional part (such as a screw or attachment) that is secured to the main part. This segmentation allows the main part to be attached without drilling, preserving the fiber pattern and load-bearing capacity of the composite material.
Solution Approach 2:
The main part acts as an intermediary element between the composite component and the functional part. It is friction-welded to the surface of the composite component and provides a mounting surface for the functional part, thereby avoiding the need to drill into the composite material while still achieving secure mechanical connection.
2Strength
If traditional adhesive bonding is used to secure connection elements, then drilling is avoided, but curing time is long and automation is difficult
Solution Approach 1:
The patent replaces chemical adhesive bonding with mechanical friction welding. The main part is attached to the composite component through friction welding, which is a mechanical process that generates heat through friction and creates a strong bond without requiring long curing times or complex adhesive application procedures, thereby enabling easier automation and higher production efficiency.
3Adaptability or versatility
If a two-part connection element is used with friction welding, then automated assembly is enabled and adaptability is improved, but device complexity increases
Solution Approach 1:
The main part is designed as a universal component that can be attached to composite materials through friction welding and can accommodate various functional parts (such as screws, attachments, or other connectors). This universality allows the same main part to be used for different securing tasks and applications, improving adaptability while keeping the overall system relatively simple.
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
The connection element provides a strong, flexible, and cost-effective solution for attaching components without compromising the material's integrity, enabling efficient serial production of high-performance lightweight components with adaptable design and material optimization.
Implementation Method 1
securing a connection element to a component made of a fiber-reinforced composite material... by friction welding
Implementation Method 2
the bead 'supplies' the welding addition during friction welding
Data Source
AI summary
A connection element for securing to a component, in particular a component made of a fiber 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 may be interlocking.