Helical Thermoplastic Anchoring for Brittle Foam and Composites

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Solution Overview

Problem

Existing methods for anchoring objects in lightweight and brittle materials, such as fiber composites and dense foams, face challenges with low anchoring strength and the risk of material damage, particularly when using conventional fasteners or adhesive bonds.

Innovation Solution

A method involving a first object with helical protrusions made of thermoplastic material, which is vibrated mechanically to penetrate into a second object, creating a thread-like connection and potentially a positive-fit connection by allowing thermoplastic material to flow and interpenetrate the second object's structures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional fasteners (screws with high thread pitch and depth) are used to anchor in dense brittle foam, then anchoring strength is improved, but the foam material cracks and anchoring strength is severely limited

Engineering Contradiction:

Improveanchoring strengthVSAvoidmaterial cracking

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent applies mechanical vibration to the connector during insertion into the brittle foam. The vibration reduces the insertion force required and prevents crack formation in the foam material, while still achieving sufficient anchoring strength through the helical protrusions that create a thread-like connection in the vibrated material.

Inventive Principle:

Principle #18Mechanical vibration

Solution Approach 2:

The patent changes the physical state of the connector material by heating it to become flowable, allowing it to penetrate into the foam structure and create a positive-fit connection upon cooling. This parameter change (temperature-induced flowability) enables anchoring without cracking the brittle foam, resolving the contradiction between anchoring strength and material damage.

Inventive Principle:

Principle #35Parameter changes

2Strength

If adhesive bonds are used to connect lightweight materials, then light and strong connection is achieved, but manufacturing cost rises and long-term reliability control is impossible

Engineering Contradiction:

Improvebond strengthVSAvoidmanufacturing cost and process complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent replaces the adhesive bonding mechanism with a mechanical anchoring system using helical protrusions that create a thread-like connection. This mechanical approach eliminates the need for adhesives, reducing material costs and simplifying the manufacturing process while maintaining connection strength and enabling quality control through mechanical means.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If adhesive bonds are used for anchoring, then surface connection is achieved, but anchoring strength is limited by surface material strength

Engineering Contradiction:

Improveanchoring strengthVSAvoidsuitability for brittle and elastic objects

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent uses helical protrusions that nest into the foam material, creating a thread-like connection that extends deeper into the material than surface adhesives can reach. This nested mechanical connection provides superior anchoring strength for brittle and elastic objects by distributing loads throughout the material volume rather than relying solely on surface adhesion.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 enhances anchoring strength and reduces the risk of material damage in lightweight and brittle materials, achieving a secure and stable connection through a combination of mechanical interlocking and material interpenetration.

Implementation Method 1

mechanical vibration is coupled into the first object from a proximally facing coupling-in face thereof so as to drive the first object into the second object in a manner that the vibration and pressing cause the first object to be subject to a helical movement relative to the second object

Methodology Applied

Scientific EffectMechanical vibration: Vibration

Implementation Method 2

the mechanical vibration is also coupled into the first object to cause thermoplastic material of the first object to become flowable and to penetrate into structures of the second object to yield, after re-solidification, a positive fit connection with the second object

Methodology Applied

Scientific EffectThermoplastic material flowability: Melting

Data Source

PatentUS12292076B2Anchoring a first object in a second object

Publication Date: 2025.05.06 MULTIMATERIAL WELDING AG

AI summary

A method of anchoring a first object in a second object is described. The first object extends along an axis between a proximal end and a distal end and has a circumferential surface. The circumferential surface comprises at least one helical protrusion of a thermoplastic material. For anchoring, the first object is brought in contact with the second object, and mechanical vibration is coupled into the first object from a proximally facing coupling-in face thereof so as to drive the first object into the second object in a manner that the vibration and pressing cause the first object to be subject to a helical movement relative to the second object and cause thermoplastic material of the first object to become flowable and to penetrate into structures of the second object to yield, after resolidification, a positive fit connection with the second object.