Resin-foam Core Plate Fastening via Compression Periphery
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Solution Overview
Problem
Resin-foam core composite plates in vehicles face challenges with existing fastening methods, as the soft resin foam interferes with resistance welding and bolt fastening, leading to reduced fastening force over time due to thermal expansion and contraction, and these methods cannot maintain robust fastening for long periods.
Innovation Solution
A fastening structure that includes a through-hole and a compression periphery part around the resin foam core, where a metallic fastening member is crimped or welded to the compression periphery part, allowing for robust coupling to a counterpart member using either bolt fastening or resistance welding, and optionally featuring a pedestal-attached cylindrical, hat-shaped, or bowl-shaped fastening member to enhance the fastening process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If resistance welding is used to fasten metal plates, then welding speed and productivity are improved, but the soft resin foam core prevents effective welding and reduces fastening reliability
Solution Approach 1:
The invention divides the fastening function into two separate components: a metal plate for welding and a resin foam core for cushioning. By segmenting the structure so that only the metal plate undergoes welding while the resin foam remains intact, the patent achieves both high welding productivity and reliable fastening without the resin foam interfering with the welding process.
Solution Approach 2:
The metal plate acts as an intermediary between the welding process and the resin foam core. The welding is performed on the metal plate surface, which mediates the connection while protecting the resin foam core from direct thermal exposure and mechanical interference, thereby maintaining both welding efficiency and fastening reliability.
2Force
If bolt fastening is used to robustly fasten the composite plate, then initial fastening force is improved, but resin foam enters the fastening region over time causing fastening force to reduce
Solution Approach 1:
The resin foam core is pre-compressed during assembly to create a dense, stable structure that prevents foam migration. This beforehand cushioning of the foam core eliminates the void spaces that would otherwise allow resin foam to enter the fastening region over time, maintaining consistent fastening force throughout the service life.
Solution Approach 2:
The patent changes the density parameter of the resin foam core by applying compression during assembly. This parameter change transforms the foam from a loose, migratable state to a dense, stable state that resists further compression and prevents material migration into the fastening region, ensuring long-term fastening durability.
3Stability of the object's composition
If the resin foam core is compressed around the through-hole to create a compression periphery part, then structural stability is improved, but the foam material is difficult to compress uniformly
Solution Approach 1:
The resin foam core is pre-compressed around the through-hole region before final assembly. This preliminary compression action creates a stable, dense compression periphery part that provides structural support while preventing foam migration. By performing this compression beforehand, the manufacturing process becomes more controlled and easier to execute.
Solution Approach 2:
The patent applies local quality by compressing the resin foam core selectively around the through-hole region rather than uniformly throughout the entire core. This localized compression creates a compression periphery part with enhanced structural stability at the critical fastening zone while maintaining ease of manufacture by focusing the compression effort only where needed.
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 solution enables long-term robust fastening of resin-foam core composite plates to counterpart members using either bolt fastening or resistance welding, maintaining the fastening force despite thermal cycles and vibrations, and allows for easy resistance welding applications.
Implementation Method 1
a metallic fastening member inserted into the through-hole is coupled to the compression periphery part by crimping or welding
Implementation Method 2
a metallic fastening member inserted into the through-hole is coupled to the compression periphery part by crimping or welding
Implementation Method 3
a compression periphery part at which the core of the resin foam is compressed around the through-hole
Implementation Method 4
The entered resin foam having a great thermal expansion coefficient escapes gradually due to a temperature difference, repetition of expansion and contraction caused by a heating/cooling cycle
Data Source
AI summary
In the present invention, a through-hole (2) and a compression periphery part (3a) at which the core of the resin foam (1c) is compressed are provided in a fastening part of a resin-foam core composite plate (1). A cylindrical part (11a) of a metallic fastening member (11) is inserted into the through-hole (2) from the proximal end side of a wall part (4). The fastening member (11) is crimped to the distal end of the wall part (4) via an eyelet member (12) placed on the outside of the wall part (4) so as to forcibly spread the cylindrical part (11a). The fastening member (11) and a counterpart member (A) are fastened together by tightening a nut (14) onto a bolt (13) inserted into the cylindrical part (11a).