Adhesive Screw Connection Cover for Flow Drill Screwing

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Solution Overview

Problem

The existing methods for producing adhesive screw connections using flow drill screws often result in adhesive being swirled up and escaping from pre-drilled holes, leading to contamination of the screw-in device and components, and compromising torque control, especially when the upper component is unsuitable for flow drill screwing.

Innovation Solution

A method where a cover is placed over the pre-drilled hole in the upper component, which is perforated by the flow drill screw before it penetrates, preventing adhesive escape and ensuring stable torque control during the screwing process, allowing for continuous adhesive application and improved bond strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If adhesive is applied at the screw-in point, then bond seam continuity and connection strength are improved, but adhesive escapes through the pre-drilled hole causing contamination and torque control issues

Engineering Contradiction:

Improvebond seam strengthVSAvoidadhesive escape and contamination

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

A cover element is introduced as an intermediary component between the adhesive application area and the pre-drilled hole. This cover prevents adhesive from escaping through the hole while allowing the screw to pass through, thus maintaining continuous adhesive application without contamination

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The screw connection system is segmented into distinct functional zones: the cover element seals the adhesive application area, the screw shaft provides mechanical fastening, and the self-forming thread creates the connection. This segmentation allows each component to perform its specific function without interfering with others

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If the upper component has material thickness or hardness unsuitable for flow drill screwing, then component design flexibility is improved, but flow drill screwing cannot be performed directly requiring pre-drilled holes

Engineering Contradiction:

Improvematerial selection flexibilityVSAvoidscrew-in process complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The pre-drilled hole is created in advance as a preliminary action to enable subsequent screw insertion. The cover element is also pre-installed to prepare the adhesive application area before the actual screwing operation, simplifying the overall manufacturing process

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If the screw tip impacts the adhesive layer during screw-in, then adhesive is swirled up and escapes, but this causes dirtening of the screw-in device and components

Engineering Contradiction:

Improveadhesive flow behaviorVSAvoiddevice and component contamination

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The cover element acts as a protective intermediary that contains the adhesive layer during screw insertion. It prevents the screw tip from directly impacting and swirling up the adhesive, thereby eliminating contamination of the screw-in device and components

Inventive Principle:

Principle #24Intermediary (Mediator)

4Strength

If adhesive exits from the pre-drilled hole, then bond seam continuity is improved, but torque control of the screw-in device is impaired

Engineering Contradiction:

Improvebond seam continuityVSAvoidtorque control accuracy

Core Design Contradiction:

StrengthVSMeasurement precision

Solution Approach 1:

The cover element serves as a mediator that allows adhesive to be applied continuously for bond seam continuity while simultaneously preventing adhesive from exiting through the pre-drilled hole during screw insertion, thus maintaining accurate torque control

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This method prevents adhesive contamination and maintains stable torque control, enabling continuous adhesive application and enhancing the strength and corrosion resistance of the connection.

Implementation Method 1

a flow drill screw, which penetrates or extends through the upper component at the joining point through a pre-drilled hole and is screwed together with the lower component while forming a flow hole

Methodology Applied

Scientific EffectFlow hole forming: Deformation

Implementation Method 2

the self-forming thread section of the flow drill screw, impact on the previously applied adhesive layer

Methodology Applied

Scientific EffectSelf-forming thread: Deformation

Data Source

PatentUS10584734B2Method for producing an adhesive screw connection using a flow drill screw, and composite component produced thereby

Publication Date: 2020.03.10 BAYERISCHE MOTOREN WERKE AG

AI summary

A method is provided for producing an adhesive screw connection between at least one upper component and at least one lower component using a flow drill screw, which penetrates the upper component at a joining point through a pre-drilled hole and is screwed together with the lower component, forming a flow-drilled hole. The pre-drilled hole in the upper component is covered by a secured cover which is first perforated by the flow drill screw before the latter penetrates into the pre-drilled hole and is then screwed together with the lower component.