Thermoplastic Connector Element for Stable Bonding to Foamed Substrates
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Solution Overview
Problem
Existing methods for bonding connectors to lightweight substrates, such as foamed plastics, face challenges in achieving robustness and preventing protrusion collapse during the bonding process, especially under high pressures.
Innovation Solution
A connector element with a base portion and distally extending protrusions made of thermoplastic material, which liquefies when pressed and mechanically excited, along with link members that stabilize and guide the protrusions for enhanced penetration and bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the protrusions are made thick or voluminous to provide sufficient robustness during bonding, then the stability and robustness of the connector element is improved, but the penetration capability into the substrate deteriorates
Solution Approach 1:
The connector element is divided into a base portion and multiple protrusions that are distributed across the distal surface. This segmentation allows the protrusions to be thinner individually while collectively providing sufficient stability through their distributed arrangement and interconnection via link members.
Solution Approach 2:
The protrusions are designed as thin structures rather than thick voluminous forms. The link members connecting the protrusions function as thin film-like structures that provide stability without significant thickness, enabling the protrusions to penetrate the substrate effectively while maintaining structural integrity during bonding.
2Length of moving object
If the protrusions are made thin or lean to achieve sufficient penetration into the substrate, then the penetration capability is improved, but the robustness and stability during bonding deteriorates
Solution Approach 1:
Multiple protrusions are merged into a unified structure through link members that connect them to each other and to the base portion. This merging creates a stable network where the protrusions support each other during bonding, providing robustness without requiring individual protrusions to be thick.
Solution Approach 2:
The connector element functions as a composite structure combining the base portion, protrusions, and link members made of thermoplastic material. This composite architecture allows thin protrusions to achieve both penetration capability and bonding stability through the integrated structure's collective properties rather than individual component thickness.
3Strength
If traditional mechanical connectors like screws, nails and rivets are used to bond to lightweight substrates, then the bonding strength may be sufficient, but the substrate material is damaged and production speed is reduced
Solution Approach 1:
The bonding process utilizes parameter changes in the thermoplastic material of the protrusions and link members. Through application of heat and pressure, the thermoplastic material transitions from solid to molten state and back, enabling bonding without mechanical damage to the substrate and allowing for rapid production cycles.
Solution Approach 2:
The thermoplastic material undergoes phase transitions during the bonding process. The protrusions and link members are heated to melt the thermoplastic material, allowing it to flow and bond with the substrate, then cooled to solidify and create a strong bond. This phase transition-based bonding eliminates the need for damaging mechanical fasteners and enables high-speed production.
4Strength
If traditional mechanical connectors like screws, nails and rivets are used to bond to lightweight substrates, then the bonding strength may be sufficient, but the substrate material is damaged
Solution Approach 1:
The mechanical fastening system (screws, nails, rivets) is replaced with a thermal bonding system. The protrusions and link members made of thermoplastic material are heated to melt and bond with the substrate, then cooled to solidify. This substitution eliminates mechanical damage to the substrate while maintaining bonding strength.
Solution Approach 2:
The bonding process utilizes parameter changes in the thermoplastic material. By controlling temperature and pressure parameters, the material transitions between solid and molten states, enabling bonding without mechanical intrusion into the substrate. This prevents damage to lightweight substrates while achieving strong bonds.
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 provides a stable and efficient bonding process by preventing protrusion collapse and achieving a firm anchoring of the connector element into the substrate, while also allowing for reduced protrusion size and weight.
Implementation Method 1
mechanically exciting the connector element and the substrate relative to each other when being pressed together
Implementation Method 2
the plurality of protrusions comprise a thermoplastic material configured to liquefy when the connector element is pressed to the substrate and mechanically excited
Data Source
AI summary
A connector element is disclosed for being bonded to a substrate by pressing the connector element and the substrate together and mechanically exciting the connector element and the substrate relative to each other when being pressed together. The connector element includes a base portion having a distal surface and plural protrusions distally extending from the distal surface of the base portion. The protrusions are formed of a thermoplastic material configured to liquefy when the connector element is pressed to the substrate and mechanically excited. Link members are formed of a thermoplastic material configured to liquefy when the connector element is pressed to the substrate and mechanically excited. Each link member connects two neighboring protrusions of the protrusions.