Thermoplastic Friction Anchoring in Pre-Shaped Indentations
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Solution Overview
Problem
Existing methods for anchoring lightweight building elements, such as those used in automotive and aerospace industries, face challenges with limited anchoring strength, reliability, and high energy consumption due to the use of lightweight materials like fiber composites and foams, which are prone to delamination and require complex process control.
Innovation Solution
A method involving a pre-shaped indentation in the first object and a thermoplastic second object, where mechanical energy is applied to cause friction and liquefaction of the thermoplastic material, allowing it to flow into the indentation and secure the second object, utilizing the mechanical strength of the first object's outer layer for enhanced stability and reducing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional fasteners (screw pins or rivets) are used to anchor lightweight building elements, then the anchoring process is simple, but the anchoring strength is limited
Solution Approach 1:
The patent changes the physical state of thermoplastic material from solid to liquid through friction heating, enabling it to flow into the indentation and create strong anchoring. This parameter change (temperature/state) allows the material to adapt to the indentation shape and provide superior anchoring strength compared to conventional fasteners
Solution Approach 2:
The patent employs friction heating through relative motion between the second object and the first object to generate heat that liquefies the thermoplastic material. This mechanical energy conversion to thermal energy enables the material to flow and penetrate structures, creating strong anchoring without requiring complex heating equipment
2Strength
If mechanical energy is coupled into the connector to cause liquefaction of thermoplastic material, then anchoring strength is improved, but energy consumption increases
Solution Approach 1:
The system uses its own kinetic energy during the anchoring process to generate the heat required for material liquefaction. The friction heating occurs naturally as the second object is pressed into the first object, converting mechanical work directly into thermal energy without requiring external heating sources
Solution Approach 2:
The patent replaces complex thermal processing equipment with a simple friction-based heating mechanism. Instead of using external heaters or complex temperature control systems, the mechanical pressing action itself generates the necessary heat through friction, simplifying the overall system while maintaining effective anchoring
3Strength
If the connector is pressed deeply into the lightweight building element to achieve strong anchoring, then anchoring strength is improved, but the risk of pushing through the second building layer increases
Solution Approach 1:
The patent creates the indentation in advance before inserting the second object. This preliminary shaping of the receiving structure provides a defined path and depth limit, preventing the second object from being pressed too deeply and potentially damaging the second building layer, while still allowing sufficient depth for strong anchoring
Solution Approach 2:
The indentation is created only at the specific location where anchoring is needed, concentrating the structural modification locally. This local quality change allows the thermoplastic material to flow into a pre-defined cavity, providing controlled anchoring depth and preventing damage to surrounding areas or the second building layer
4Ease of manufacture
If the first outer building layer is removed or penetrated to access the interlining layer, then anchoring access is improved, but additional processing steps or energy are required
Solution Approach 1:
The indentation is formed in advance as a preparatory step, creating direct access to the interlining layer through the first outer building layer. This preliminary action eliminates the need for separate removal or penetration operations, simplifying the overall manufacturing process while ensuring proper anchoring access
Solution Approach 2:
The indentation structure nests within the first outer building layer, creating a cavity that extends through to the interlining layer. This nested structure allows the second object to be anchored directly into the interlining through the pre-formed indentation, avoiding the need for separate access operations and reducing processing complexity
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 method provides improved anchoring strength, reliability, and reduced energy consumption by leveraging the mechanical strength of the first object's outer layer, enhancing stability against both axial and lateral forces, and allowing for precise shape definition of the indentation independent of interlining layer properties.
Implementation Method 1
coupling mechanical vibration energy into the second object so as to cause energy absorption due to friction between the lateral outer surface and the lateral wall
Implementation Method 2
coupling mechanical vibration energy into the second object
Implementation Method 3
cause energy absorption due to friction between the lateral outer surface and the lateral wall, until a flow portion of the thermoplastic material becomes flowable
Implementation Method 4
cause energy absorption due to friction... until a flow portion of the thermoplastic material becomes flowable
Implementation Method 5
a flow portion of the thermoplastic material becomes flowable and flows relative to the respective other object
Data Source
AI summary
A method of manufacturing an assembly is disclosed. The method includes providing a first object, wherein the first object has an indentation with a sidewall, and providing the second object, wherein the second object has a lateral outer surface portion, and wherein one of the sidewall and the lateral outer surface portion is a thermoplastic material. The lateral outer surface portion of the second object is in physical contact with the sidewall of the first object, and mechanical energy is coupled into at least one of the first and second objects to cause energy absorption due to friction between the lateral outer surface portion and the sidewall, until a flow portion of the thermoplastic material becomes liquefiable and flows. After re-solidification of the thermoplastic material, the flow portion secures the second object to the first object.