Bollhoff & DELO Develop ONSERT, an Innovative Joining Method for Automotive

The assembly specialist Bollhoff and the adhesive expert DELO have developed an innovative joining method. With a bonded bolt called ONSERT, composites, thin sheet metals, plastics and other materials are equipped with a multi-purpose connection element. Bollhoff and DELO have tested this technology in a series of pilot projects. The last one was about fixing of cables, claddings and other components of the BMW i3. After this technique has proven its capabilities in series production, it will now be launched.

Composite materials, such as CFRP and GFRP, take established joining technologies including welding, screwing and riveting to their limits. This technology based on stud welding combines bonding and screwing by equipping fastening elements, such as threaded metal bolts, with a transparent plastic base and bonding it to fiber composite materials. The threaded rod of the ONSERT can be screwed and ? when necessary ? removed again.

The special feature of this technique is its speed. The adhesive is cured within about 4 seconds using an LED lamp. It is possible to fully automate this process. The bonded connection can be loaded immediately. Bonded bolts with a base diameter of 25 mm achieve a pull-off strength up to 2,000 N on CFRP. When applying higher forces, a predetermined breaking point in the base ensures that the laminate of the composite material remains intact and no fibers are torn out. Nevertheless, the ONSERTs are robust as shown by salt spray and VDA climate tests.

In addition, ONSERTs excel due to their flexibility in design and production. First, the structural shape can be defined by the user to a great extent, particularly in terms of rod length and base diameter. Second, they provide much freedom in production as bonded bolts can be attached to the raw body and prior to final assembly of lacquered elements.

Developed for the automotive industry, aviation and white goods.

ONSERTs are suitable for a broad variety of tasks where components must be fixed. Possible applications include cable harnesses, control units, sensor retainers, brake lines, claddings or exterior attachment components. Cover plates, insulating materials or floor panels in airplanes are also imaginable. Finally, white goods also open up multiple application possibilities.

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