Integral Chassis Joint Cartridge with Thermal Welding

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Solution Overview

Problem

Chassis components face issues with large construction space, high cost, weight, tolerance fluctuations, and corrosion-prone areas due to complex assembly and coating processes, particularly in integrating joints into structural components.

Innovation Solution

A method involving a precoated structural component securely connected to a precoated joint cartridge using a material bonding joining process, such as thermal welding, which simplifies assembly, reduces tolerances, and allows for independent coating of components, thereby enhancing accuracy and reducing handling complexities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the joint is integrated into the structural component using force fitting, screwing or welding, then the joint is securely connected to the structural component, but the construction space increases, weight increases, and tolerance fluctuations occur

Engineering Contradiction:

Improvejoint connection strengthVSAvoidchassis component weight

Core Design Contradiction:

StrengthVSWeight of stationary object

Solution Approach 1:

The joint and structural component are merged into a single integral housing structure, eliminating the need for separate joint components and their associated fastening elements. This integration reduces the overall number of parts, decreases weight, and eliminates tolerance accumulation between separate components while maintaining secure connection through the integral design

Inventive Principle:

Principle #5Merging (Combining)

2Strength

Engineering Contradiction:

Improvejoint connection strengthVSAvoidnumber of individual parts

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The joint and structural component are merged into a single integral housing structure, eliminating the need for separate joint components and their associated fastening elements. This integration reduces the overall number of parts, simplifies the assembly process, and maintains secure connection through the integral design

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integral housing serves multiple functions simultaneously: it provides the structural component function, the joint housing function, and the connection function. This multi-functionality eliminates the need for separate specialized components, reducing part count and simplifying the overall structure

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If the joint and structural component are precoated independently, then different coatings can be applied to each component, but the assembly process becomes complex and requires subsequent cleaning before coating

Engineering Contradiction:

Improvecoating varietyVSAvoidassembly and coating process simplicity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The housing is precoated with the structural component coating before the joint is assembled into it. This preliminary coating action allows the housing to receive its coating while still open, avoiding the need for complex post-assembly coating operations and subsequent cleaning steps

Inventive Principle:

Principle #10Preliminary action

4Strength

If the joint components are assembled at the structural component, then the joint is integrated into the structural component, but tolerances add up in an unfavorable manner

Engineering Contradiction:

Improvejoint integrationVSAvoidjoint position tolerance

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The joint and structural component are merged into a single integral housing structure, eliminating the need for separate joint components and their associated fastening elements. This integration reduces the overall number of parts, simplifies the assembly process, and maintains secure connection through the integral design

Inventive Principle:

Principle #5Merging (Combining)

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 achieves higher accuracy and reduced tolerances in joint integration, simplifies handling, and allows for easy implementation of different coatings, resulting in a more efficient and cost-effective production process with improved durability and environmental protection.

Implementation Method 1

a material bonding joining process, such as thermal welding

Methodology Applied

Scientific EffectThermal welding: Welding

Implementation Method 2

The material bonding joining process particularly is or comprises beam welding, preferably laser welding

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Data Source

PatentUS9227480B2Method for producing a chassis component

Publication Date: 2016.01.05 ZF FRIEDRICHSHAFEN AG

AI summary

A method of producing a chassis component. The method including the steps of coating an outside of a structural component, coating an outside of a joint cartridge which has been preassembled as a joint, and permanently and securely connecting the structural component to the joint cartridge using a material bonding or joining process.