Embossed Joining Element Assembly for Dissimilar Material Bonding
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Solution Overview
Problem
The automotive industry faces challenges in joining lightweight materials, as traditional welding or soldering methods are not suitable for material pairs like aluminum and steel or fiber composite materials, limiting the application of established joining methods.
Innovation Solution
A component assembly method using an auxiliary joining element with a retaining portion pressed into a through-hole, which is expanded by an indentation, providing a force- and/or form-fitting connection, allowing for the joining of components made from different materials, including lightweight materials like aluminum and steel, through a materially bonded connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional welding or soldering methods are used to join components, then strong connections are achieved for steel materials, but these methods are not suitable for lightweight materials like aluminum and steel or fiber composite materials
Solution Approach 1:
The patent introduces an auxiliary joining element as an intermediary component that bridges two different materials (e.g., aluminum and steel). This auxiliary element has a first portion that can be joined to one material and a second portion that can be joined to the other material, enabling connections between incompatible materials without requiring direct welding or soldering between them.
Solution Approach 2:
The auxiliary joining element is divided into multiple functional portions: a first portion for joining to the first material and a second portion for joining to the second material. This segmentation allows each portion to be optimized for its specific material interface, with different geometries, materials, or joining methods tailored to each material type.
2Adaptability or versatility
If auxiliary joining parts with rivet- or nail-like form are used, then joining of different materials is enabled, but the connection strength and reliability are reduced compared to direct welding
Solution Approach 1:
The auxiliary joining element features different local qualities in its different portions. The first portion may have properties optimized for joining to aluminum (e.g., aluminum-compatible material, specific surface treatment), while the second portion has properties optimized for steel (e.g., steel-compatible material, welding-optimized geometry). This local optimization ensures maximum connection strength at each interface.
Solution Approach 2:
The auxiliary joining element itself may be constructed as a composite structure, combining different materials in a single component. This allows the element to inherently bridge material incompatibilities while providing optimized joining surfaces for each material type, thereby achieving high connection strength across dissimilar materials.
3Weight of moving object
If components made of different metal materials or material types are joined, then lightweight material usage is enabled, but traditional joining methods cannot be applied
Solution Approach 1:
The auxiliary joining element serves as a mediator that enables joining processes for lightweight materials without requiring direct welding or soldering between incompatible materials. This approach maintains the weight benefits of lightweight materials while providing a feasible manufacturing process through the intermediary component.
Solution Approach 2:
The invention changes the joining parameters by introducing an auxiliary element with specific geometric parameters (dimensions, shape, positioning) that are optimized for the particular material combination. This parameter optimization enables reliable joining of lightweight materials using processes suitable for each material type rather than forcing a single joining method on all materials.
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 high strength connections while reducing hydrogen embrittlement and edge cracking sensitivity, enabling the joining of materials that would otherwise be difficult to solder, weld, or bond, and is suitable for thin-sheet connections.
Implementation Method 1
The retaining portion of the auxiliary joining element has been pressed into the through-hole and is connected to the hole wall in a force- and/or form-fitting manner
Implementation Method 2
the through-hole is expanded at at least one peripheral region by an indentation
Implementation Method 3
The auxiliary joining element is connected in a materially bonded manner to the second component or to a second auxiliary joining element provided in the second component
Data Source
AI summary
A component including at least one joint, at which a joining connection to a further component is to be formed later, is provided. A joining element having a holding section is pressed into the component, and the joining element also has a functional section, by way of which at least one further function can be implemented. The holding section of the joining element is arranged in a passage hole, and the passage hole is widened in at least one edge region by an embossing. The holding section of the joining element is pressed into the passage hole and is connected to the hole wall in a force-fitting and/or form-fitting manner and engages in the embossing. A component combination of at least two components which includes such a component and a method for producing the component and the component combination are also provided.