0941/15.02Door moduleInnovative joint solutionsfor the door module

CarCars have been manufactured for morethan a century. There is no other invention ofcomparable influence on our life and economysuch as the car. It was the car that firstgranted universal and individual mobility.Since cars were first invented, there havealways been milestones of innovation.DoorWe join in!In this overview, the large number of possibleuses of our joint solutions and assemblysystems are pointed out. By the example ofthe door module, on the following pages weillustrate a selection of concrete examplesfrom practice.2As a leading system supplier for fasteningand assembly technology we are a recognised partner for automotive manufacturersand their suppliers.No matter in which of the car modules yousearch, you will find one of our solutionsthere.Let's start the expedition with the doormodule.

DoorThe following count among the essentialfunctional elements of a vehicle door:n Door systemsn Window regulatorsn Locking systemsn Drivesn Electronic controlsComfort and aesthetics of the vehicle interior arestrongly influenced by the vehicle doors.Ergonomically shaped armrests, functional compartments, easy handling of window regulators andmirrors.The vehicle doors are an impressive example ofintegration potential.The basic division of a vehicle door is the distinctionbetween wet and dry area. The “dry” door halfcontains all electrical and electronic componentswhile the “wet” half contains all mechanicalcomponents. In the door area, there are diversematerials employed – such as thermoplastic hightech composite materials, metal-plastic hybridmaterial, etc.Due to high strengths, doors essentially contributeto the protection of the passengers in caseof a lateral impact but also in head-on collision.Vehicle doors bear much potential for!ppy to joaheraWe3

Your joint solutionstheStrong thread?HELICOIL – Thread inserts for thread reinforcementin lightweight materials.Thin-walled components?RIVKLE – The solution for fastening a highstrength nut or stud thread to a thin-walledcomponent.Threads in plastics?AMTEC – Metal inserts for threadreinforcement of plastic parts.Easy compensation oftolerances?FLEXITOL – Systems for automatic compensation of productiontolerances.Snapping and decoupling?SNAPLOC – Vibration- and noise-decouplingfastening system.Screw fastening and decoupling?RIVKLE Elastic – A detachable blind rivet joint withvibration- and noise-decoupling function.4

indoor moduleJust in case?TEPRO – High-precision technical mouldedparts and components.Direct screw-fitting?UNITEC K’ in K’ (plastic in plastic) –Screws and screw driving systems as aplastic fastening solution.Easy opening andclosing?QUICKLOC – Quarter turn pressurelocks for quick and repeatedly detachable joints and quick assemblies.Easy bonding?Quick and process-reliable bondingof fastening elements with light-curingadhesives.Joining for all purposes?RIVSET – High-strength joining of steels, aluminiumand plastics without loss of performance.Assembly of fasteners?As the leading system supplier in fastening andassembly technology, we also supply the matchingassembly solutions for the fasteners.5

Fastening of door handle with FLEXITOL Your advantages – an overview:FLEXITOL metalFLEXITOL hybridFLEXITOL plasticEspecially the automotive industry is ever morebecoming a highly automatic assembly industry. Highdemands on reliable function and quality require smartsolutions. This does also apply to the installation of thedoor handle. Installation must be performed so that thedoor trim below is evenly fastened.Nothing easier than that with FLEXITOL metal. Thismetal system consists of an adjustment element and afastening element. In the first step, the tolerancecompensation at the door module must be mountedwith a RIVKLE blind rivet nut. After that, the doorhandle is aligned in the desired assembly position.Upon screwing, the compensation distance betweendoor module and door handle is steplessly and automatically compensated. The friction element serves tomove the adjustment element.The adjustment element is connected to the fasteningelement via a left-hand thread. While screwing in thescrew rightwards, the adjustment element drives outuntil touching the door handle. Afterwards, the screw isfurther screwed in until the entire assembly is securedby the screw preload-force. The door trim is thusinstalled tension-free.6nTension-free installation of the door trimnCost reduction upon component productionnAssembly from one sidenEasy installation due to approved blind rivettechnologyMounting partReceiving partScrewAdjustmentelementFastening elementFriction elementCompensation distanceMin. height

Fastening of door mounting parts with RIVKLE HRT AluminiumThe HRT process (High-Resistance Thread) resultedfrom the further development of the RIVKLE technology. Progressive materials and processesallow to produce a reinforced, hardened thread whichconsiderably improves the mechanical properties ofthe RIVKLE blind rivet nut.RIVKLE This lead in development also pays off when fasteningouter and inner door parts to the door frame. Inaddition, the inner door panel is screw-fastened tothe unit carrier.Usually, these parts are welded. However, welding isnot possible for magnesium inner door panels. Screwfastening was the solution found. The installation of thealuminium RIVKLE HRT blind rivet nut comprises foursteps. It is spinned on, inserted into the mounting holeof the outer frame, upset and spinned off. Then, thecomponents can be screw-fastened with an 8.8 screw.Your advantages – an overview:nIncreased torques allow increased preloadforces in the jointnReduced weightnCorrosion resistancecold-workedhead for maximum stiffnessunder load77area of hardenedaluminium formaximum threadresistancearea of ductilealuminium for settingwith RIVKLE settingtools7The RIVKLE HRT aluminium blind rivet nut is theoptimal combination of lightweight material and highresistance.Fastening of window regulator with UNIQUICK VarioWhen installing the window regulator, UNIQUICK Vario75 ensures high process reliability and reducedassembly times. It is fastened with 4 x 20 mm AMTEC screws, 3.5 mm countersunk head.Your advantages – an overview:nFully automatic screw fasteningnProcess reliabilitynReduced assembly timesFor screw fastening, two feed stroke screw driving unitswith a fastening spindle are integrated into a specialcustomer machine. What is so special about thisapplication? Integration in the machine is performedon the inside and outside.the screw from falling back and thus ensures highavailability.With an electric screw driver, the screw is horizontally /vertically processed. An intermediate cylinder preventsAnother example of the high flexibility of UNIQUICK systems.7

Fastening locks with AMTEC Your advantages – an overview:nLow-stress interference in plastic materialnNo relaxationnAssembly advantageSONICSERT In the area of the door lock, a SONICSERT compression limiter with an M 5 x 26 captive screw is used.The two-component fastening element consists of acompression limiter and a reduced-shank bolt. To jointhe screw captively with the compression limiter, thecompression limiter is upset after the screw has beeninserted. Upsetting results in the formation of an inwardbulge in the area of the groove. This is how the screwis mounted captively.The two-component SONICSERT fastener is “cold”inserted into the corresponding drill hole of the bearingbracket (PBT). The longitudinal knurling of the limiterallows easier insertion. After that, the door lock isfastened.Thanks to this solution, there is no loss of preload uponscrew fastening to the through hole.Fastening to door trim with AMTEC Your advantages – an overview:nHigh-strength and torsion-proof threadsnOptimum assembly characteristicsnRetrofittingQUICKSERT For this application, a possibility to screw-fasten thespeaker to the door trim must be provided.Since retrofitting is required, the QUICKSERT Hex, aself-tapping bush, is the optimal solution. It consists ofa cylindrical basic body with internal thread (M 4) and aspecial external thread (d 7 l 8 mm).8The profile of the external thread has an extremely smallflank angle and expands asymmetrically towards thethread root. The advantages are most obvious. The slimthread flanks ensure minimum radial tension.

Fastening of door handle/applique with UNIQUICK VarioAs the leading system supplier in fastening and assembly technology, we also supply the matching assemblysolutions for the fasteners. Screw driving systems andhand-held devices of the UNIQUICK series ensuremaximum precision and process reliability for the installation. From the handy telescopic screwdriver to thespecial multi-screw driving unit – we adapt our productsand services to our customers' supply chains andprecisely implement your individual screw driving task.The stationary UNIQUICK Vario screw driving systemis used for this application. This screw driving system iscompact and slim and especially designed for theadaptation into special machines. A feed stroke screwdriving system with two fastening spindles was integrated into an existing system at the customer facilities.The special challenge is the assembly of small screws –here the 2 x 6 mm AMTEC screw with a small countersunk head of 3.5 mm. High process reliability ensuresthe precise coordination of component support andYour advantages – an overview:nFully automatic screw fasteningnProcess reliabilitynReduced assembly timesscrew driving system (maximum tolerance is 0.2 mm).Screw feed is automatic. Due to the small head-lengthratio, screws are directly fed without nozzle jaws. Thisresults in a high availability.With an electrical screwdriver, screw fastening is carriedout vertically from above. The screw driving system isequipped with an integrated control. Interface communication is realised via PROFIBUS (PROcess FIeld BUS).For installation, the threaded bush is attached and screw-fastened with a rotatingmandrel into the door trim (PP 50 % long fibre) in a self-tapping process.The chosen hexagon socket drive allows efficient cold insertion since spinning onand off is not necessary.After that, the speaker can be screw-fastened.9

Fastening of speaker with RIVKLE Most diverse parts are fastened to the door unit carrier – one of them being the speaker system. To be ableto fasten this to an aluminium door unit carrier, RIVKLE steel blind rivet nuts with hexagonal body – opendesign – are used. This joint solution creates a highstrength nut thread even on a thin-walled workpiece.RIVKLE The chosen blind rivet nuts have an extra small countersunk head to achieve a very small overflushness. Thehexagon design provides for very good screw lockingperformance.Another advantage is the economical automaticprocessing with a CFA 803 (automatic setting head –press principle). The C-frame module was integratedinto a complex manufacturing cell (robotic system).The robotic system is so flexible that six different doorunit carriers can be processed. Without loss ofperformance!10Your advantages – an overview:nShort cycle timesnNo wearnNo loss of performance

Fastening of window stop with UNITEC K’ in K’The screw fastening principle of plastic in plastic(K’ in K’) is a Böllhoff-specific innovation. For thosejoints, thread geometry is of decisive importance sinceK’ in K’ threads have to self-form or self-tap a “holdingthread” into pre-fabricated cylindrical drill holes.UNITEC K’ in K’ The K’ in K’ system is characterised by special threadprofiles. The different system variants are self-locking,self-tapping, self-forming, adjustable and tolerancecompensating.An especially developed window stop absorbs noisewhen the window is stopped. This window stop isfastened to the glass plates of the side doors with aself-tapping UNITEC K’ in K’ screw.Rough tolerances of the glass drill hole can be compensated by the circumferential fins on the window stop.A clearance-free fit results from the taper recess of theK’ in K’ screw. This is possible due to the press fit in thecone of the window stop.Your advantages – an overview:nResists shear forces of 600 NnReduced costs due to full-plastic solutionnNoise isolationnReverse lockIn addition, the K’ in K’ screw has a reverse lock. Withthis joint solution, the stop of the window pane is noiseinsulated.11

Fastening of door handle and speaker / inner door fastening with AMTEC SPREDSERT 1AMTEC Your advantages – an overview:SPREDSERT 1:Compression-Limiter:nEfficient insertionnnRetaining flange and anchor rings ensure highdegree of safety against twist and tensile loadPreload-forces in the joint are maintained – norelaxation of the plasticnOutside knurling – optimal tight fit in thecomponentnScrew locking by reaction forces of the slottedbodyIn this application, two Böllhoff joint solutions areemployed: special SPREDSERT 1 M 5 x 9.5 and acompression limiter.At different fastening points, SPREDSERT 1 creates athread to fasten speaker and door handle to the innerdoor. The thread insert is inserted into the corresponding mounting hole until the retaining flange is completely anchored in the plastic body of the inner door.In that process, the slotted area is compressed. Byscrewing in a screw, the radially secured SPREDSERT 1is forced apart so that the anchor rings (low radialtension) penetrate the plastic and ensure the tight fit ofthe thread insert. In this process, the screw is locked.The large flange diameter provides a large contactsurface for easier installation. Variations in tolerance ofdrill hole diameters in the fastened component cannow easily be handled.Loss of preload?We also have an answer to this question – thecompression limiter.12It minimises the loss of preload-forces in existing screwconnections with through hole.The knurled external geometry of the element is anchored in the component and therefore results in anoptimal tight fit in the component (inner door). The innerdoor can now be easily fastened to the door frame.Principle

Fastening of door handle with RIVKLE Your advantages – an overview:nSplash-proofnDamage-proofnEasy and economical installationRIVKLE For fastening the door handle, the closed version of anM 5 RIVKLE blind rivet nut is used.The closed version bears the advantages of sealingagainst splash water and avoiding damage from use oftoo long screws. In this process, riveting is also carriedout by a robotic system. The door unit carrier is pickedup by the robot and transported to the correspondinginstallation location. After that, feeding and riveting areperformed. An additional high-strength nut thread onthe thin-walled unit carrier results. The door handle canthen be installed. With cycle times of 3.5 seconds, anextremely high productivity can be achieved. Feedingand riveting are possible in all positions, even overhead.This tool can be used for large series with high qualitystandards. Rely on it!Fastening of door handle with RIVKLE Your advantages – an overview:nTolerance compensationnEasy and economical installationnProcessable in every production stephandle afterwards, a blind rivet nut with an extra largeflat head was chosen. This flat head allows screwfastening through a slotted hole.Riveting is performed automatically.RIVKLE As a partner for development and production offasteners, Böllhoff elaborates a great number ofapplication-specific designs.An M 5 RIVKLE blind rivet nut with an extra large flathead is used to fasten the door handle.After the blind rivet nut has been installed in the innerdoor, the door handle is screw-fastened. The handle isinserted with the corresponding fastening points fromthe inner side of the door through the trim and screwfastened to the door unit carrier. To re-align the dooropen versionclosed version13

From A to Z.Req. are we the partner for your projects – from the very first concept to the finalrealisation.uireOur dialogue with you is the thread of our working process.Thanks to smart innovation management and intensively taking your wishesinto account we develop tailor-made joint solutions along your supplychain – module after module.mentsá ááá á á á áGet to know us in person!ááCustomer-specific procurementand supply systems to optimisepurchase and logistics.áProduction with up-to-date technicalequipment comprises heterogeneousfields – two of which are plasticsengineering and metal working. Benefitfrom our competent production know-how.ááOur expertise in assembly technologyreaches from the assembly ofcomponent parts to the final productor subassemblies.The production of processing systemsperfects our support of your supply chain.14ááá

Our project management supports youwith management- and product-specificexpertise.ááááTo recognise future trends and manageinnovations is part of automotive-suitableengineering, as are our own prototypeconstruction and test fields. This way,products can already be optimised in thedevelopment phase.ááááIn our own certified laboratory, wecarry out mechanical and physicaltests as well as chemical materialanalyses.ááCustomer orientation – to us thisalso includes quality- andenvironment-oriented behaviour.To us – continuous improvementis a constant process.ááCertificationá15

Böllhoff International with companies in:ArgentinaAustriaBrazilCanadaChinaCzech keyUnited KingdomUSAApart from these 23 countries, Böllhoff supports its internationalcustomers in other important industrial markets in close partnershipwith agents and dealers.Made of paper certified with the Ecolab of the European Community(Reg No. FR/11/003).Printed by FSC -certified company GFA-COC-001790.Subject to technical change.Reprinting, even in extract form, only permitted with express consent.Observe protective note according to DIN 34.Böllhoff GroupPlease find your local contact on www.boellhoff.comor contact us under [email protected]

Fastening of door handle/applique with UNIQUICK Vario As the leading system supplier in fastening and assem-bly technology, we also supply the matching assembly solutions for the fasteners. Screw driving systems and hand-held devices of the UNIQUICK series ensure maximum precision and process reliability for the instal-lation.