Thermoplastic Edge-Embedding Joint for Multi-Material Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for bonding lightweight materials in industries like automotive and aviation face challenges such as unreliable adhesive bonds, high manufacturing costs, and difficulties in compensating for thermal expansion differences, especially when bonding thermoplastic parts to non-liquefiable materials.
Innovation Solution
A method involving a thermoplastic part with a solid state being brought into relative movement with a second object having a flat sheet portion, generating friction heat to melt and embed the edge of the second object into the thermoplastic material, forming a reliable and cost-efficient connection through rotational movement and mechanical pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If adhesive bonds are used to bond thermoplastic parts to non-liquefiable materials, then bonding capability between different materials is improved, but reliability of the bond deteriorates due to inability to detect degrading bonds and susceptibility to shearing forces from thermal expansion differences
Solution Approach 1:
The patent replaces adhesive bonding with a mechanical bonding system using a blind rivet that has a bonding element capable of bonding to both thermoplastic and non-liquefiable materials. The bonding element is inserted into the blind rivet and secured by deforming the rivet body, creating a mechanically secure connection that accommodates thermal expansion differences without relying on adhesive bonds that are susceptible to shearing forces.
Solution Approach 2:
The bonding element is made of a material that can bond to both thermoplastic and non-liquefiable materials, creating a composite bonding interface. This allows the blind rivet assembly to function as a multi-material bonding system that overcomes the limitations of single-material adhesive bonds.
2Adaptability or versatility
If adhesive bonds are used to connect surfaces with roughness, then bonding capability is maintained, but manufacturing efficiency deteriorates due to slow hardening processes and increased material costs
Solution Approach 1:
The patent replaces the chemical adhesive bonding process with a mechanical bonding process using a blind rivet and bonding element. This mechanical system provides immediate bonding capability without the slow hardening times associated with adhesives, significantly improving manufacturing efficiency while maintaining the ability to bond rough surfaces through the mechanical deformation and securing mechanisms of the rivet system.
3Strength
If mechanical bonds such as screws and rivets are used to connect large parts, then bonding strength is improved, but manufacturing precision deteriorates due to difficulty in precisely defining relative locations of fasteners and fastening locations
Solution Approach 1:
The patent extracts the positioning function from the fastener itself by providing separate positioning elements on the bonding element that engage with corresponding features on the thermoplastic part. This separation allows the bonding element to be precisely positioned independently of the fastening location, solving the precision problem while maintaining mechanical bonding strength.
4Adaptability or versatility
If adhesive bonds are used for bonding lightweight materials, then bonding capability between different materials is improved, but weight of the bonding system deteriorates due to additional material and process requirements
Solution Approach 1:
The patent replaces the multi-component adhesive bonding system with a single blind rivet assembly that integrates the bonding function. This eliminates the need for separate adhesives, primers, and complex application equipment, thereby reducing the overall weight of the bonding system while maintaining the capability to bond lightweight materials like aluminum and magnesium.
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 provides a strong, reliable, and cost-effective connection between thermoplastic and non-liquefiable materials, effectively addressing the limitations of adhesive bonds and thermal expansion issues, while reducing axial joining forces and enhancing bonding quality.
Implementation Method 1
a melting zone comprising flowable thermoplastic material is formed and such that thermoplastic material of the melting zone flows around the edge to at least partially embed the edge in the thermoplastic material. Said melting zone is formed due to friction heat generated between the edge and the thermoplastic material that move relative to each other
Implementation Method 2
bringing the first object and the second object to a relative movement to each other such that a melting zone comprising flowable thermoplastic material is formed and such that thermoplastic material of the melting zone flows around the edge to at least partially embed the edge in the thermoplastic material
Data Source
Figure 1a~1d
Figure 2a~3c
Figure 4a~6b
AI summary
The invention is in the fields of mechanical engineering and construction, especially mechanical construction, for example automotive engineering, aircraft construction, railway industry, shipbuilding, machine construction, toy construction and building industries. It relates to a method of - mechanically - securing a first object (1) to a second object (2). The method comprises the steps of: providing the first object (1) comprising thermoplastic material (3) in a solid state, providing the second object (2) with a generally flat sheet portion having an edge (21), positioning the first object (1) relative to the second object (2) and bringing the first object (1) and the second object (2) to a relative movement to each other, said relative movement comprising a rotational movement, such that a melting zone (13) comprising flowable thermoplastic material is formed and such that thermoplastic material of the melting zone (13) flows around the edge (21) to at least partially embed the edge (21) in the thermoplastic material. The invention further concerns a connector that is suitable for being used in a method according to the invention.