Protective Element for Fiber-Reinforced Plastic Fastener Integration
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Solution Overview
Problem
The existing methods for attaching connecting elements to fiber-reinforced plastic components in the automotive sector are complex, often resulting in insufficient adhesive bonds, component weakening, and require additional work steps, with mold conversion needed for different connecting elements, making the process inefficient and costly.
Innovation Solution
A method involving a protective element with an inner geometry matching the connecting element's holding section, positioned in a mold receptacle, ensures precise placement and sealing, allowing for a stable integration of the connecting element within fabric layers during plastic material filling, facilitating easy mold removal and adaptation to various connecting elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the fastener is cast into the component during manufacture using a recess in the mold, then the fastener positioning is precise and the bond strength is improved, but the mold reconfiguration becomes complex when different fasteners are used
Solution Approach 1:
The invention separates the fastener positioning function from the mold structure by introducing a separate positioning element. This positioning element can be easily removed and replaced between production runs, allowing different fasteners to be accommodated without complex mold reconfiguration. The mold cavity remains simple while the positioning element adapts to different fastener geometries.
Solution Approach 2:
The positioning element acts as an intermediary between the mold cavity and the fastener. It provides the necessary positioning and support functions during manufacturing, then can be easily removed. This intermediary component simplifies the overall system by decoupling the mold from the specific fastener geometry requirements.
2Strength
If the fastener is cast into the component during manufacture, then the bond strength is improved, but additional work steps are required for cleaning and mold removal
Solution Approach 1:
The invention extracts the positioning function from the final product structure. The positioning element is temporarily introduced during manufacturing to ensure proper fastener placement, then completely removed after the plastic solidifies. This extraction eliminates the need for cleaning operations and simplifies mold removal, as the positioning element is not part of the final component.
Solution Approach 2:
The positioning element is prepared and placed in the mold cavity before the plastic injection process begins. This preliminary positioning ensures that the fastener is correctly positioned before the plastic material is injected, eliminating the need for post-manufacturing adjustments or cleaning operations.
3Ease of manufacture
If adhesive bonding is used to attach the fastener to the finished plastic component, then the manufacturing process is simplified, but the bond strength becomes insufficient
Solution Approach 1:
The fastener is positioned and secured within the mold cavity before the plastic injection process begins. This preliminary action ensures that the fastener becomes an integral part of the molded component, achieving strong mechanical bonding through the plastic material itself rather than relying on separate adhesive bonding operations.
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 enables a more flexible and efficient production of fiber-reinforced plastic components with improved bonding strength, reduced mold conversion costs, and simplified post-processing, while ensuring precise positioning and protection of the connecting element from plastic material contamination.
Implementation Method 1
The liquid plastic material can flow into the internal or external geometry of the fastener and harden there
Data Source
Figure 1~3b
Figure 3c~4b
AI summary
The invention relates to an assembly (26) for producing an in particular fiber-reinforced plastic component (10), having an in particular metal connecting element (16) which has an anchoring section (20) cast integrally with the plastic component (10), and a holding portion (18) having a holding geometry (22) protruding from the plastic component, comprising at least one protective element (34) having an inner geometry (36) corresponding to the outer geometry of the holding portion (18), and which can be placed on the holding portion (18) of the connecting element (16). The protective element (34) has an in particular standardized outer geometry and a mold (28) for the plastic component (10), wherein the mold has at least one receptacle (38) for the at least one protective element (34).