APPLICATION TECHNOLOGY
Lamborghini solves fastening challenge
The new Lamborghini Aventador is made with a lightweight carbon shell. How to securely fix this key structural element presented Lamborghini with a fastening challenge.
T
he carbon shell was too thin for an embedded insert and incompatible with the rivets or traditional fastening methods designed for metal. The solution was to surface bond bigHeads. Surface bonded with a structural
adhesive, the bigHeads provide a secure mechanical fixing for the shell without diminishing in any way its integral strength and stability. Over 50 bigHeads are used to secure the shell and the interior fit-out.
bigHead has seen a steady increase in the use of its bonding
fasteners in carbon fibre automotive applications. bigHead explains that the high strength and versatility of a surface bonded bigHead make it well suited for carbon fibre. Another supercar manufacturer, Aston Martin, has been
using bigHeads to mechanically secure a carbon fibre diffuser for many years.
Lesjöfors develops tool for Ericsson invention
A whole new way of producing so-called ‘honeycombs’ that improves the ventilation of electronic modules has been developed by Ericsson. In close cooperation, Lesjöfors has developed a unique tool for bending of the steel strip material used.
I
n order to improve the ventilation of electronic modules where electromagnetic shielding is required, so-called ‘honeycombs’ are often used. Honeycombs are a lightweight structure made of steel material, shaped hexagonal, which provides superior ventilation properties. Air permeability is 95% compared to 55% - 60%
for traditional perforated sheet. Ericsson has recently developed a new method for bending the material, which ultimately streamlines the manufacturing process.
Design and manufacturing of prototype tools For many years, Ericsson has established working relations with Lesjöfors in
various development projects. It was therefore natural for Ericsson to use Lesjöfors as a development partner for the tool concept for the new honeycomb manufacturing method. The cooperation is unusual, because Ericsson owns the patent and Lesjöfors knowledge and capacity for the bending technology. “In March 2009 the first contact was taken, so the process has been long and we
have been a speaking partner from the beginning. We started out with a pre-study in which opportunities and problem areas were analysed. Then we developed two prototype tools, one small-scale tool and one for production of full-scale prototypes,” says Marcus Hartvigsson, project manager at Lesjöfors in Värnamo, Sweden.
Attractive solution for other industries The new manufacturing method has already attracted considerable interest.
“We see great business potential in this. There are many industries where honeycombs are already used for the phenomenal ventilation and shielding properties. The problem is that manufacturing today is relatively expensive. We are now working towards a competitive production concept compared to traditional methods of manufacture,” adds Marcus Hartvigsson.
www.fastenerandfixing.com 139
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