Thermoplastic Connector Anchoring in Low-Density Core Layers
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Solution Overview
Problem
Existing methods for securing connectors to lightweight building elements, such as sandwich boards, face challenges with low anchoring strength due to low density core layers and require costly and time-consuming processes, especially when the core layer has low density, and adhesive bonds lack long-term reliability and are costly.
Innovation Solution
A method involving a connector with liquefiable thermoplastic material that is pressed against a low density layer, subjected to mechanical vibration to compress and deform the layer, allowing the thermoplastic to interpenetrate and solidify within the deformed structure, providing a strong and reliable anchoring mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive bonds are used to secure connectors to lightweight building elements, then the bonding process can be simplified, but the long-term reliability deteriorates due to adhesive degradation and the manufacturing cost increases due to slow hardening processes
Solution Approach 1:
The patent replaces the chemical adhesive bonding system with a mechanical anchoring system. The connector is mechanically anchored into the core layer through a pressing and vibration process that creates friction-based anchoring, eliminating the need for adhesives and their associated reliability issues with degradation and slow hardening.
Solution Approach 2:
The patent changes the physical state and mechanical properties of the connector material through controlled heating and vibration during the anchoring process. The material is heated to a flowable state during pressing, then cooled to solidify, creating a permanent mechanical anchor that improves both ease of manufacture and long-term reliability.
2Device complexity
If connectors are pressed into low density core layers without mechanical vibration, then the process is simpler, but the anchoring strength deteriorates because the connector cannot penetrate sufficient depth
Solution Approach 1:
The patent applies mechanical vibration to the connector during the pressing process. This vibration energy facilitates deeper penetration of the connector into the low-density core layer by reducing friction and enabling the material to flow around the connector, thereby significantly improving anchoring strength while maintaining acceptable process complexity.
Solution Approach 2:
The pressing process incorporates periodic vibration cycles that alternate between high-frequency oscillation for penetration and brief pauses for material settling. This periodic action enables progressive deep insertion of the connector into the core layer, achieving substantial anchoring strength without excessive process complexity.
3Strength
If the connector material remains solid during pressing, then the material strength is maintained, but the ability to interpenetrate and anchor within the core layer deteriorates
Solution Approach 1:
The patent utilizes phase transition of the connector material from solid to flowable state during the anchoring process. The material is heated above its melting point or glass transition temperature during pressing, allowing it to flow and interpenetrate the core layer structures, then cooled to solidify and lock in place, achieving both anchoring capability and maintaining final material strength.
Solution Approach 2:
The patent temporarily changes the temperature and viscosity parameters of the connector material during the anchoring process. By controlling the heating rate, peak temperature, and cooling rate, the material transitions to a flowable state for easy insertion, then solidifies to maintain strength, optimizing both anchoring capability and final material properties.
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 achieves substantial anchoring strength with reduced costs and time, even with low-density core layers, and ensures long-term reliability by creating a positive-fit connection within the deformed low-density layer.
Implementation Method 1
coupling mechanical vibration energy into the connector to cause the low density layer to be compressed between the connector and the first building layer to yield a compressed portion of the low density layer, wherein the compressed portion has a compressed structure, until a flow portion of the liquefiable material becomes flowable
Implementation Method 2
The connector is pressed into the low density layer while energy impinges on the connector, in particular while friction heat is generated
Implementation Method 3
The flow portion is caused to interpenetrate structures of the compressed portion and is caused to re-solidify, in particular to intertwine with the discrete elements
Data Source
AI summary
A method of anchoring a connector in a first object includes providing the connector, the connector having a liquefiable material that is liquefiable by mechanical vibration, such as a thermoplastic material, bringing the connector into contact with low density layer that has an arrangement of discrete elements and gas-filled (empty) spaces between the discrete elements, pressing the connector against the low density layer and coupling mechanical vibration energy into the connector to cause the connector to penetrate into the low density layer to deform the discrete elements, until a flow portion of the liquefiable material becomes flowable and is caused to interpenetrate spaces between the deformed discrete elements so that an intertwined structure of the liquefiable material and the deformed discrete elements results, and stopping the mechanical vibration energy and causing the flow portion to re-solidify to anchor the connector in the low density layer.