Joining Thermoplastic Fiber Composite Panels Using Melt-In Fasteners

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The invention describes a process and device for joining flat bodies, specifically where at least one body is made from a thermoplastic fiber-reinforced composite. The method involves locally melting the thermoplastic matrix of the composite, inserting a pointed, rod-shaped thermoplastic joining element into the molten area, and then plastifying and shaping this element after it passes through both the composite and any additional bodies. This creates a strong, stable bond without disrupting the fiber alignment and force transfer in the material.

Use CasesContent extracted from patent full text and abstract with AI.

• Joining composite panels in automotive or aerospace manufacturing
• Fabricating lightweight structural parts for transportation or sports equipment
• Creating durable, high-strength joints in thermoplastic-based assemblies
• Repair and joining of fiber-reinforced thermoplastic structures in construction

BenefitsContent extracted from patent full text and abstract with AI.

• Enables strong and stable joining of thermoplastic fiber-reinforced composites without compromising the internal fiber structure
• Prevents interruption of force flow along the fiber direction, maintaining the material’s strength
• Provides a reliable joining method for complex and lightweight structures
• Potentially reduces joining defects compared to traditional mechanical fastening or bonding techniques
• Offers automation opportunities for high-volume manufacturing

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Inventors & Applicants

Patent Abstract

The invention relates to methods and devices for joining flat bodies and thermoplastic flat body composites, wherein at least one of the bodies consists of a thermoplastic fiber composite material. The methods and devices are characterized in particular by the fact that a stable connection of these flat bodies can be realized. For this purpose: – the thermoplastic matrix of the body or bodies made of the thermoplastic fiber composite material is partially melted by at least one heating device, – a thermoplastic, rod-shaped joining element provided with a tip is introduced into the partially melted region of the body or bodies made of the thermoplastic fiber composite material, – the thermoplastic joining element is plastified and formed after penetrating both the body made of the thermoplastic fiber composite material and the opening of at least one body not consisting of a thermoplastic fiber composite material or the bodies made of the thermoplastic fiber composite material. During insertion, the continuous fibers of the body or bodies are axially displaced by the joining element without the force flow in the fiber direction being interrupted by the fiber deflection.