Self-Tapping Bolt for Composite Material Attachment
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Solution Overview
Problem
The attachment of bolt elements to composite materials, such as fiber-reinforced plastics, often requires drilling or punching, which weakens the material and generates waste, and existing methods are time-consuming and costly.
Innovation Solution
A method where the bolt element is pressed into the composite material with its tip to create a hole and form an internal thread, allowing the bolt to be securely seated without material weakening, using the material's softening at elevated temperatures to facilitate the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If drilling or punching is used to create holes in composite materials for bolt attachment, then the attachment process can be completed, but the material is weakened and waste is generated
Solution Approach 1:
The tip performs preliminary action by creating the hole and internal thread simultaneously in one insertion motion, eliminating the need for separate drilling operations that would weaken the material. The tip's geometry and insertion force prepare the material structure before the threading action begins.
Solution Approach 2:
The bolt element performs self-service by creating its own mounting hole and internal thread through the insertion and rotation process. The tip generates the hole while the thread cylinder forms the internal thread, allowing the bolt to attach itself without external drilling equipment that would compromise material integrity.
2Reliability
If threaded inserts or eyes are integrated into the plastic component during manufacture, then the attachment is secured, but the process is time-consuming and costly
Solution Approach 1:
The bolt element creates its own mounting hole and internal thread through the insertion and rotation process. The tip generates the hole while the thread cylinder forms the internal thread, allowing the bolt to attach itself without external drilling equipment that would compromise material integrity.
Solution Approach 2:
The hole creation and thread formation operations are merged into a single insertion and rotation process. The tip and thread cylinder work together to simultaneously create the hole and form the internal thread, combining multiple manufacturing steps into one efficient operation.
3Ease of manufacture
If drilling is used to create holes, then attachment holes can be made, but material residues and weakening occur
Solution Approach 1:
The tip creates the hole through material displacement rather than removal. As the tip is inserted, it pushes material aside to form the hole cavity, eliminating the generation of cuttings or punching slugs that would constitute waste material.
Solution Approach 2:
The insertion force that could potentially damage the material is converted into a beneficial action by using the tip's geometry to displace and compact material around the hole path, transforming what could be harmful stress into useful material rearrangement that strengthens the attachment zone.
4Productivity
If punching is used to generate holes, then holes can be created quickly, but punching slugs are wasted and the component is locally weakened
Solution Approach 1:
The tip creates the hole through material displacement rather than removal. As the tip is inserted, it pushes material aside to form the hole cavity, eliminating the generation of cuttings or punching slugs that would constitute waste material.
Solution Approach 2:
The tip performs preliminary action by creating the hole and internal thread simultaneously in one insertion motion, eliminating the need for separate drilling operations that would weaken the material. The tip's geometry and insertion force prepare the material structure before the threading action begins.
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 loss-free attachment of bolt elements to composite materials with minimal material weakening, automating the hole and thread formation, reducing waste and processing time, and enhancing the resistance against press-out.
Implementation Method 1
the tip is pressed through the component until the side of the component adjacent the head part of the bolt element enters into contact with the thread cylinder and the tip thereby generates a hole in the component
Implementation Method 2
the bolt element is subsequently turned so that the thread of the thread cylinder forms an internal thread in the wall of the hole
Implementation Method 3
the contact surface is brought into engagement against the said side of the component
Data Source
Figure 1A
Figure 1B~1C
Figure 2A
AI summary
A method for the attachment of a bolt element to a component is described. The bolt element has a head part having a contact surface and a shaft part extending away from the head part, the shaft part having a tip provided at its end remote from the head part, the tip merging into a thread cylinder, optionally via a cylindrical region. The bolt element is pressed with the tip to the fore against the component and the tip is pressed through the component until the side of the component adjacent the head part of the bolt element enters to contact the thread cylinder and the tip thereby generates a hole in the component. The bolt element is subsequently turned so that the thread of the thread cylinder forms an internal thread in the wall of the hole. A bolt element is also claimed.