Plastic Joining Element With Integrated Welded Supporting Plate

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Solution Overview

Problem

Joining thin plate-shaped components made of plastic materials is costly and prone to delamination and corrosion due to the complexity of existing methods, which often require multiple steps and the use of different materials.

Innovation Solution

A method involving a joining element with a supporting plate made of thermoplastic or thermosetting plastic material, which is welded to the first component, allowing for a direct and strong connection between the components without the need for rivets or separate fasteners, thereby reducing material weakening and corrosion risks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional joining methods (screws, rivets, plate nuts) are used to join thin plate-shaped plastic components, then the components can be connected, but the process becomes costly and complex requiring multiple steps

Engineering Contradiction:

Improvejoining reliabilityVSAvoidjoining process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple joining functions into a single integrated joining element consisting of a supporting plate with integrated connecting means (such as recesses for clips or hooks). This eliminates the need for separate plate nuts, multiple rivets, and complex assembly steps, thereby reducing device complexity while maintaining joining reliability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The joining element is segmented into functional components: a supporting plate for load distribution and integrated connecting means for mechanical attachment. This segmentation allows each component to be optimized for its specific function while simplifying the overall joining process compared to traditional multi-component systems.

Inventive Principle:

Principle #1Segmentation

2Strength

If multiple fastening elements (rivets, plate nuts) are used to join plastic components, then strong connections are achieved, but the risk of delamination and corrosion increases

Engineering Contradiction:

Improvejoint strengthVSAvoiddelamination and corrosion risk

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The supporting plate is made from the same plastic material as the components being joined, creating a homogeneous material system. This eliminates galvanic corrosion risks between dissimilar materials and reduces delamination risks by ensuring compatible thermal and mechanical properties throughout the joint structure.

Inventive Principle:

Principle #33Homogeneity

Solution Approach 2:

The invention extracts and eliminates metal fastening elements (rivets, plate nuts) from the joining system, replacing them with an integrated plastic joining element. This removal of dissimilar materials eliminates the sources of corrosion and delamination while maintaining joint strength through the integrated supporting plate and connecting means.

Inventive Principle:

Principle #2Taking out (Extraction)

3Ease of manufacture

If thin plate-shaped plastic components are joined using traditional methods, then connections are formed, but material thickness limitations prevent direct insertion of fasteners

Engineering Contradiction:

Improvejoining easeVSAvoidcomponent thickness

Core Design Contradiction:

Ease of manufactureVSLength of stationary object

Solution Approach 1:

The joining element utilizes the surface area of the thin plate in a different dimension by implementing a distributed supporting plate design with integrated connecting means. Instead of relying on thickness for fastener insertion, the solution spreads the connection across the surface plane, allowing thin components to be joined effectively without requiring direct fastener insertion through the thickness.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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

Enables rapid and simple production of strong, corrosion-resistant joints between plastic components with reduced risk of delamination and material weakening, as the weld joint integrates the supporting plate as an integral part of the first component.

Implementation Method 1

welding the supporting plate to the first component

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS9149984B2Method for joining a first component formed of a plastic material to a second component, and joining element and device

Publication Date: 2015.10.06 AIRBUS OPERATIONS GMBH

AI summary

A method for joining a first component made of a plastic material, in particular a thermoplastic and/or thermosetting plastic material, to a second component by applying a joining element on the first component, wherein the joining element has a supporting plate formed of a thermoplastic and/or thermosetting plastic material and comprising a connecting means and a supporting plate bore. A joining element for creating a junction in accordance with the method, is also disclosed. Furthermore, a device, in particular for performing the method, is disclosed.