Moldable Rivet for Composite Vehicle Assembly
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Solution Overview
Problem
Traditional manufacturing methods struggle to provide robust attachments for non-metallic, plastic, and composite materials like fiber-reinforced plastics in mass-market passenger vehicles due to issues such as inability to weld reinforced composites, corrosion of metallic fasteners, and compromised joint integrity from thermal expansion differences.
Innovation Solution
A joining system using a moldable outer body encasing a rigid support shank, with reinforcement materials, that is deformed and cured within overlapping apertures of vehicle components, ensuring secure bonding and resistance to movement, utilizing thermoplastic or thermosetting materials and temperature control for efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional metallic fasteners are used to attach non-metallic composite materials, then the attachment method is simple and widely applicable, but the fasteners corrode and joint integrity is compromised
Solution Approach 1:
The patent introduces a non-metallic fastener as an intermediary component that attaches to both non-metallic composite materials and metallic structures without causing corrosion. The fastener includes a moldable outer body made of non-metallic material that encases a support body, creating a compatible interface between dissimilar materials and eliminating the corrosion problem while maintaining structural integrity
Solution Approach 2:
The fastener employs composite construction with a moldable outer body encasing a rigid support body. This composite structure combines the corrosion resistance and thermal compatibility of non-metallic materials with the structural strength needed for load-bearing applications, resolving the contradiction between ease of manufacture and joint integrity
2Weight of moving object
If reinforced composite materials are used to reduce vehicle weight, then fuel efficiency improves, but traditional welding and metallic fastening methods become inapplicable
Solution Approach 1:
The non-metallic fastener serves as a mediator that enables joining of reinforced composite materials without requiring welding or traditional metallic fastening. The moldable outer body can be deform ed to mechanically interlock with composite materials, while the support body provides structural reinforcement, making the assembly process applicable to weight-reduced vehicle designs
Solution Approach 2:
The fastener utilizes parameter changes in the moldable outer body material, which can be deformed during installation and then sets to a rigid state. This phase or property change allows the fastener to adapt to different composite material substrates and joining configurations, expanding manufacturing applicability while maintaining weight reduction benefits
3Strength
If moldable outer body encasing rigid support shank is used for joining, then attachment robustness improves, but device complexity increases
Solution Approach 1:
The fastener design implements nesting by placing the rigid support body inside the moldable outer body. This nested configuration allows the simpler support shank to provide core structural function while the outer body provides adaptability and environmental protection, achieving robust attachment without excessive complexity through hierarchical organization
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 solution provides a robust and reliable attachment method for non-metallic materials, maintaining structural integrity and NVH performance while accommodating different thermal expansion properties, suitable for mass-market production.
Implementation Method 1
utilizing thermoplastic or thermosetting materials and temperature control for efficient assembly
Implementation Method 2
utilizing thermoplastic or thermosetting materials and temperature control for efficient assembly
Implementation Method 3
utilizing thermoplastic or thermosetting materials and temperature control for efficient assembly
Data Source
AI summary
A system for assembling vehicle components includes a die assembly securing first and second vehicle components having first and second apertures, respectively. The die assembly positions the first and second vehicle components with the first and second apertures overlapping, and at least one of the first and second vehicle components including a polymeric material. The system further includes a joining component extending through the first and second apertures. The die assembly supports the joining component, and the joining component including a support shank and a moldable body at least partially encasing the support shank. The system also includes a punch member selectively engaging and deforming the moldable body of the joining component. The die assembly guides the moldable body into engagement with the first and second vehicle components, and the die assembly locates the support shank within at least one of the first and second apertures.