Organic Sheet Joint Structure With Aligned Holes for Minimal Overlap
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Solution Overview
Problem
The efficient use of organic sheet metal in structural components is hindered by the need for large overlap areas for secure fastening, which is complex and wasteful, and requires precise temperature control during hot pressing.
Innovation Solution
A structural component comprising two or more organic sheet pieces with aligned holes for a positive connection, allowing secure fastening with minimal overlap, and optionally reinforced with injection molding material through aligned holes, enabling efficient material use and forming of heavily stressed areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If large overlap areas are used to securely fasten organic sheet pieces, then the reliability of the connection is improved, but the loss of substance increases due to wasteful material use
Solution Approach 1:
The connection system is segmented into discrete elements: individual holes punched through the organic sheet pieces, separate fastening elements (such as clips or connectors) that engage with these holes, and defined overlap zones. This segmentation allows the connection to be achieved through precise localized engagement points rather than relying on large continuous overlap areas, thereby reducing material waste while maintaining connection reliability.
Solution Approach 2:
A fastening element acts as an intermediary component that bridges the two organic sheet pieces. This intermediary element engages with holes in both sheets, providing a secure mechanical connection without requiring the sheets themselves to have large overlapping areas. The intermediary fastener concentrates the connection function at specific points, enabling reliable joining with minimal material consumption.
2Manufacturing precision
If precise temperature monitoring is implemented during hot-pressing to ensure secure adhesion, then the manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
The patent utilizes the inherent thermal properties of the thermoplastic matrix material, which melts at a specific temperature range during hot-pressing. By controlling the heating process to reach and maintain this melting temperature, the matrix naturally transitions from a solid to a molten state, enabling adhesion without requiring complex real-time temperature monitoring systems. The material's phase change parameter serves as the primary control mechanism.
Solution Approach 2:
The thermoplastic matrix material performs self-monitoring and self-regulation of the bonding process through its melting behavior. When the material reaches its melting point, it naturally softens and becomes adhesive, providing visual and tactile feedback that the correct temperature has been achieved. This self-service mechanism eliminates the need for complex external temperature monitoring and control systems, reducing device complexity while maintaining manufacturing precision.
3Stability of the object's composition
If multiple organic sheet pieces are hot-pressed with large overlap areas to ensure stability, then the stability of the structural component is improved, but the productivity decreases due to complex production requirements
Solution Approach 1:
The structural component is designed as an assembly of discrete organic sheet pieces joined at specific locations through holes and fastening elements. This segmentation allows each sheet piece to be manufactured independently using standardized processes, and then quickly assembled together. The connection points are localized and defined by the hole positions, enabling rapid assembly without requiring complex hot-pressing of large overlapping areas, thereby improving productivity while maintaining structural stability.
Solution Approach 2:
Fastening elements serve as intermediaries that enable quick mechanical connection between organic sheet pieces without requiring extensive hot-pressing operations. These fasteners can be inserted through the pre-punched holes and secured with simple operations, dramatically reducing assembly time compared to traditional hot-pressing methods. The intermediary fasteners provide immediate structural stability, allowing for high-speed production and improved manufacturing efficiency.
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 allows for a secure, efficient use of organic sheet metal with reduced waste and improved stability by enabling secure attachment with minimal overlap and precise control over the manufacturing process, particularly in the automotive sector.
Implementation Method 1
When the organic sheet is molded with a plastic material, the thermoplastic matrix can melt, creating a bond with the molded plastic material.
Implementation Method 2
the thermoplastic matrix can melt, creating a bond with the molded plastic material
Data Source
Figure 1A~1C
Figure 2A~2D
Figure 3
AI summary
The invention relates in particular to a structural component comprising at least two organic sheet pieces (10A-10E) which lie on top of one another at least in sections and which each have a fiber layer (100), wherein at least one pair of aligned holes (101) is formed at least in the fiber layers (100) of the organic sheet pieces (10A-10E), on which the organic sheet pieces (10A-10E) are connected to one another in a form-fitting manner. The invention further relates to a method for producing a structural component.