SMC Plate Sleeve Connection for High Torque Stability
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Solution Overview
Problem
Existing structural parts in vehicles, such as convertible top compartment covers, face instability issues, particularly under high tightening torques, due to insufficient connection stability between plate-like sections and add-on parts.
Innovation Solution
A structural part with a sleeve having a threaded bore insert, delimited by an end plate and a perforated disk, bonded to the plate-like section, which absorbs stresses and provides high fatigue strength, allowing for low overall height and cost-effective connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a threaded sleeve is glued to or molded into a plate-shaped SMC component, then the connection can be assembled, but sufficient stability is not ensured under high tightening torques
Solution Approach 1:
The connection device is divided into multiple functional components: a sleeve with insert, an end plate, and a perforated disk. This segmentation allows each component to perform its specific function - the insert provides threading, the end plate distributes load, and the perforated disk enables bonding - thereby achieving high connection stability and fatigue strength under high tightening torques
Solution Approach 2:
The connection device combines different materials and joining methods: metallic or plastic sleeve with threaded insert, bonding material for adhesive bonding, and mechanical fastening via screw. This composite approach integrates the advantages of both chemical bonding (distribution of stresses) and mechanical fastening (high torque resistance), ensuring sufficient connection stability and reliability
2Ease of manufacture
If a threaded sleeve is used to connect add-on parts to plate-like sections, then connection is achieved, but tolerance compensation creates stress in the connection
Solution Approach 1:
A layer of bonding material is introduced as an intermediary between the sleeve (with end plate and perforated disk) and the plate-like section. This bonding layer serves as a stress-absorbing intermediary that compensates for tolerances in a stress-free manner, preventing stress concentration in the connection while maintaining connection stability
3Productivity
If conventional connection methods are used, then assembly is simple, but high fatigue strength cannot be achieved
Solution Approach 1:
The invention merges multiple connection methods into a single integrated device: the sleeve with insert combines threaded mechanical fastening with bonding surface, while the end plate and perforated disk integrate load distribution and adhesive bonding functions. This unified design achieves high fatigue strength without complicating the assembly process, as the entire connection device can be installed as one unit
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
The solution ensures high fatigue strength and stability under high torques, with tolerance compensation through the bonding material, making it suitable for various vehicle applications and materials, including SMC and metallic components, while maintaining low component and assembly costs.
Implementation Method 1
The insert and the orifice plate abut the plate-like section via a layer of bonding material
Data Source
Figure 1
Figure 2~3
AI summary
The part has a plate-like portion i.e. inner shell (14), provided with a threaded sleeve (20) for attaching an attachment part. The plate-like portion comprises a threaded bore. The sleeve comprises an insert provided with the threaded bore. An annular disk rests against a face plate facing away to the insert. The insert and the annular disk abut over a bonding material layer at the plate-like portion. The attachment part is secured on the sleeve by a screw unit intervening in the threaded bore. The plate-like portion is made of a plastic material such as sheet molding compound (SMC) material.