Carbon-Fiber Thermoplastic Fastening With Induction-Heated Heads
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Solution Overview
Problem
Existing fastening methods using fiber-reinforced resin fasteners require heating the fastener-forming dies to high temperatures, leading to prolonged cooling times and slower fastening processes.
Innovation Solution
A fastening method employing a high-frequency induction coil for non-contact heating of the shaft part, allowing direct heating of the carbon-fiber-reinforced thermoplastic resin fastener, which reduces the need for heating the fastener-forming dies and enables quicker cooling and faster fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If both fastener-forming dies are heated to high temperature to heat the shaft body, then the shaft body can be softened and plastically deformed to form head parts, but the fastener-forming dies maintain high heat for a long time causing prolonged cooling time
Solution Approach 1:
The heating function is extracted from the fastener-forming dies and transferred to a separate induction heating device. The induction heating device applies electromagnetic induction directly to the shaft body (which contains carbon fibers) to generate heat internally, while the fastener-forming dies remain at ambient or lower temperatures, eliminating the prolonged cooling time issue.
Solution Approach 2:
The thermal conduction heating method (mechanical/thermal system) used in the prior art is replaced with electromagnetic induction heating. The induction heating device generates an electromagnetic field that induces eddy currents in the carbon fiber-reinforced shaft body, converting electromagnetic energy directly into heat within the workpiece without requiring the heating of the forming dies.
2Temperature
If conventional contact heating method is used with heated fastener-forming dies, then the shaft body can be heated, but the process takes a long time due to heat transfer limitations
Solution Approach 1:
Conventional thermal conduction heating through the fastener-forming dies is replaced with electromagnetic induction heating. The induction heating device generates an electromagnetic field that directly induces eddy currents in the carbon fibers of the shaft body, converting electromagnetic energy into heat rapidly and efficiently within the workpiece itself, dramatically reducing heating time and increasing productivity.
Solution Approach 2:
The induction heating device applies periodic electromagnetic fields at high frequency to the shaft body. This periodic electromagnetic action generates continuous eddy currents and rapid heating effect, allowing the shaft body to reach the required temperature for plastic deformation much faster than conventional heating methods, thereby improving fastening speed.
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 allows for rapid fastening of multiple workpieces using fiber-reinforced resin fasteners by directly heating the shaft part without adhering to the heat source, resulting in quicker formation and cooling of the fasteners.
Implementation Method 1
a shaft-part heating process that heats the shaft part in a noncontacting state while the shaft part is inserted through each of the through holes of each of the workpieces; wherein the shaft-part heating process is performed using a high-frequency induction coil capable of induction heating the shaft part
Implementation Method 2
the shaft body is heated by both of the fastener-forming dies, changes to a plastically deformable softened state, and is plastically deformed, owing to the pressure applied by the two fastener-forming dies
Data Source
AI summary
In a fastening method and fastening apparatus, workpieces are fastened using a fastener made of a thermoplastic polymer comprising carbon fibers. The method and apparatus involve induction heating of the carbon fibers to soften the thermoplastic polymer and then plastically deforming axial ends of the fastener using a die or dies to form first and second heads while a shaft body or a shaft part of the thermoplastic polymer comprising the carbon fibers is inserted through respective through holes formed in the workpieces.