Reducing vehicle weight has been a priority in the automotive industry for decades, but there is always scope for further lightweighting in next generation models given the availability of newly emerging materials.
For designers seeking to utilise lightweight materials in new designs, however, there will often be the challenge of how to securely attach components without adding cost or complexity in production. Hence why it is critical to overcome such fastening challenges – and identify them at the earliest stage – to enable weight reduction goals to be met viably.
Vehicle manufacturing is increasingly turning to innovative materials which have the ability to maintain the strength, durability or safety of the vehicle, such as honeycomb structures, PIR, EPP foams and thin sheet metals or composites. And EJOT’s innovative fastening systems are ensuring designers can realise their potential.
How EJOT TSSD is ‘bossing it’
An example of a novel fastening solution used in lightweight materials is a parcel shelf attachment that EJOT originally developed in conjunction with Audi back in 2014. The TSSD (Thermischer Stoff-Schluss-Dom), which translates into English as ‘thermal adhesive bonding boss’, is a 9mm diameter fibreglass reinforced thermoplastic polymer boss.
The joining process involves installing the plastic boss with a certain rotational speed, which generates heat to create a bond, and axial load. Once inserted, the TSSD boss can then be used in conjunction with EJOT screws specifically designed for use in plastics, chiefly the Delta PT or EVO PT screw.
The fastening system found its first live application by enabling designers to create a fast,high-strength joint in a parcel shelf manufactured from a PUR fibreglass and paper honeycomb composite. It has since evolved in the UK to incorporate different drive options, including fully automated systems and hand held DC tools. Several variants have been developed too, including a boss with a ball-headed ‘snap-on’ connector moulded in and a male and female hinged connection.
A proven fastening solution for the EV generation
In 2023, the EJOT TSSD was identified for a similar application by a premium British vehicle manufacturer. In the development of a new model, which includes EV versions within the range, EJOT UK was approached by the design team to explore the potential for using a closed cell foam with fabric stiffener for the parcel shelf, into which the TSSD boss would be inserted to accommodate the parcel shelf hinge pin.
EJOT UK’s fastening specialists worked closely with the manufacturer to develop the concept and following a series of test cycles demonstrate that the resulting fastening element would meet the brief. Although yet to be deployed, it is an example of how EJOT can help manufacturers to realise their weight reduction ambitions by utilising lightweight materials, whilst at the same time delivering a secure joint that is able to reflect the premium quality associated with many brands.
The TSSD is just one of a wide range of fastening solutions available from EJOT for automotive applications. The company has been facilitating innovation in vehicle manufacturing for decades, and today it is working closely with designers around the world to optimise the performance of fully electric and hybrid vehicles.
Find out more about EJOT UK’s fastening systems for automotive at https://www.ejot.co.uk/Industrial-Fasteners/Applications/Automotive-Industry/c/DE_AUTO.
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