Composite Joint Assembly With Recessed Screw Zones to Prevent Adhesive Gaps
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Solution Overview
Problem
Existing methods for producing composite components using adhesive and flow drill screws often result in gaps between joining elements due to material displacement, leading to reduced adhesive strength and the need for additional time-consuming pilot hole creation.
Innovation Solution
A method involving the formation of a recess in the second joining element around the screw position to accommodate displaced material, ensuring the adhesive fills the cavity and maintains uniform adhesion, with the recess being filled during assembly and screwing, preventing gap formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If flow drill screw is used to connect joining elements, then connection strength is improved, but material displacement causes gap formation and reduces adhesive strength
Solution Approach 1:
A recess is formed in the joining surface of the second joining element before the flow drill screw connection is established. This recess is specifically designed to accommodate the material that will be displaced during screw insertion, preventing gap formation and maintaining adhesive layer integrity.
Solution Approach 2:
The recess acts as an intermediary space that receives the displaced material, preventing it from creating gaps between joining elements. The adhesive material fills this recess, ensuring continuous adhesive coverage and maintaining bond strength throughout the connection area.
2Manufacturing precision
If pilot hole is created before flow drill screw insertion, then gap formation is reduced, but additional manufacturing steps and time are required
Solution Approach 1:
The recess formation process is integrated with the existing flow drill screw insertion process. The same flow drill screw machine that inserts the screws also forms the recesses, combining two operations into one manufacturing step without requiring additional equipment or process stages.
Solution Approach 2:
The flow drill screw machine performs the recess formation as a preliminary action during its own operation. The machine uses its existing capabilities to create the necessary recesses while positioned for screw insertion, making the process self-sufficient without external intervention or additional machinery.
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 approach ensures a composite component with uniformly high adhesive strength between joining elements, eliminating uncontrolled deformation and gap formation, while integrating the recess formation into existing production processes without additional steps or time.
Implementation Method 1
the adhesive thereby being distributed already between the joining elements and being formed to provide an as yet uncured adhesive layer between the joining elements
Implementation Method 2
During the forming of the hole and the thread, material is melted and displaced
Implementation Method 3
The material which is displaced by the flow drill screw is at least partially accommodated by the recess
Data Source
AI summary
A method produces a composite component from a first joining element and a second joining element by use of an adhesive and a flow drill screw. Before attaching the second joining element to the first joining element, a recess is made around the at least one screw position in which the respective flow drill screw penetrates the second joining element, in a joining surface of the second joining element.