Thermoplastic Add-On Anchoring in Thermoset Plastic Components
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Solution Overview
Problem
Existing plastics components with thermoset matrices require additional anchor components like thermoplastic pins or dowels for securing add-on parts, increasing production complexity and costs.
Innovation Solution
The add-on part, particularly in its anchoring region, is made from thermoplastic material that is plasticized using energy input, such as ultrasound vibrations, to bond intimately with the thermoset matrix of the core, eliminating the need for additional anchoring components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional anchor components (thermoplastic pins or dowels) are used to secure add-on parts to plastics components with thermoset matrices, then reliable anchoring is achieved, but production complexity and costs increase
Solution Approach 1:
The invention merges the add-on part with the anchoring function by making the add-on part itself form the anchoring connection directly with the thermoset matrix, eliminating the need for separate anchor components like thermoplastic pins or dowels. The add-on part is pressed into the core and bonds intimately with the thermoset matrix through energy input, creating an integrated anchoring solution.
Solution Approach 2:
The invention extracts the anchoring function from separate anchor components and transfers it directly to the add-on part. By removing the need for additional anchoring parts and integrating the anchoring capability into the add-on part itself, the solution simplifies the overall structure while maintaining reliable anchoring.
2Reliability
If additional anchor components are used to fasten add-on parts, then secure connection is achieved, but production costs increase
Solution Approach 1:
The invention combines the add-on part with the anchoring function into a single integrated component. The add-on part is made from thermoplastic material that bonds directly with the thermoset matrix of the core, eliminating the need for separate anchor components and reducing production costs associated with multiple parts and assembly steps.
Solution Approach 2:
The add-on part serves dual functions: it provides the add-on functionality and simultaneously creates its own anchoring connection. The thermoplastic material of the add-on part bonds directly with the thermoset matrix through energy input, allowing the part to anchor itself without requiring additional anchoring components.
3Reliability
If thermoplastic material is plasticized using energy input (ultrasound vibrations) to bond with thermoset matrix, then intimate bonding is achieved, but energy consumption increases
Solution Approach 1:
The invention uses ultrasound vibrations (mechanical vibration) to plasticize the thermoplastic material of the add-on part, enabling it to bond intimately with the thermoset matrix. The mechanical energy from ultrasound vibrations temporarily softens the thermoplastic material, allowing it to flow and bond with the core, then solidifies to create a strong anchoring connection.
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 securely anchors the add-on part without additional components, reducing production outlay and enabling cost-effective, efficient assembly by allowing the thermoplastic material to penetrate and solidify within the core, forming a stable connection.
Implementation Method 1
bonds to the thermoset matrix of the core in a fluid state created by means of an input of energy and in particular by means of ultrasound vibrations
Implementation Method 2
After the thermoplastic material of the anchoring region solidifies and hardens, it forms a secure anchoring in the plastics component
Data Source
AI summary
A plastic component having a core that has a thermoset matrix and an add-on part anchored to the core. At least the securing region of the add-on part can be formed from a thermoplastic and is secured by the securing region to the core of the plastic component, the securing region being attached to the core or inserted or pressed into the core, bonding, in a fusible state produced by the application of energy, in particular by ultrasonic vibrations, with the core and being anchored thereto or therein after solidification, in particular, as a connection anchor.