Foamable Connecting Element for Sealed Structural Joints
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Solution Overview
Problem
Existing methods for structurally connecting vehicle parts, such as sheet metal components, often require separate sealing operations to prevent air and moisture ingress, and struggle with accessing regions for structural reinforcement, leading to increased assembly effort and potential corrosion.
Innovation Solution
A connecting element utilizing a foamable material with a plug-in part and break-open mechanism, allowing for fluid-tight separation of chambers containing reactants that mix to form a foaming reaction, providing structural reinforcement and sealing without manual intervention, even in hard-to-reach areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesives are used to bond structural parts, then sufficient strength and stiffness are achieved, but fluid-tight sealing is inadequate
Solution Approach 1:
The patent combines bonding and sealing functions into a single integrated process by using foamable material that simultaneously provides both adhesive bonding and fluid-tight sealing. The foamable material is introduced into cavities of structural parts, where it expands to fill gaps and create a sealed connection, eliminating the need for separate sealing operations.
Solution Approach 2:
The patent utilizes parameter changes by introducing foamable material in a controlled state (as liquid or granulate) that transforms into a expanded foam structure. This phase change enables the material to adapt to cavity shapes, fill irregular spaces, and provide both bonding and sealing functions that neither state could achieve alone.
2Reliability
If separate sealing operation is performed, then fluid-tight sealing is achieved, but assembly effort and complexity increase
Solution Approach 1:
The patent merges bonding and sealing operations into a single integrated process. The foamable material simultaneously provides adhesive bonding between structural parts and creates fluid-tight sealing by expanding to fill cavities and gaps, eliminating the need for separate sealing steps and reducing assembly complexity.
Solution Approach 2:
The foamable material performs self-service by automatically expanding to fill cavities and create seals without requiring additional manual intervention or separate sealing components. The material adapts to the cavity geometry and provides both bonding and sealing functions through its own expansion characteristics.
3Strength
If structural foam is introduced into cavities, then structural reinforcement is achieved, but accessibility to reinforcement points becomes difficult
Solution Approach 1:
The patent introduces foamable material through accessible exterior surfaces of structural parts, allowing the material to expand into three-dimensional cavities that are otherwise inaccessible. This approach enables reinforcement of internal structures without requiring direct access to the reinforcement points, as the foam expands to fill cavities from the introduction location.
Solution Approach 2:
The foamable material acts as an intermediary that bridges the gap between accessible exterior surfaces and inaccessible internal cavities. By introducing the material through accessible points, it expands to reach and reinforce remote internal regions that would otherwise be difficult or impossible to access directly.
4Reliability
If multiple separate operations are performed for bonding and sealing, then sufficient strength and sealing are achieved, but assembly time and productivity decrease
Solution Approach 1:
The patent combines bonding and sealing operations into a single simultaneous process using foamable material. The material provides both adhesive bonding and fluid-tight sealing in one application step, eliminating multiple separate operations and significantly reducing assembly time while maintaining the quality of both bonding and sealing functions.
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
The solution enables simple, high-strength, and fluid-tight structural connections with improved NVH properties and energy absorption, while reducing assembly effort and preventing corrosion by directing the foaming material to inaccessible regions.
Implementation Method 1
the mixing of which triggers a foaming reaction, during which foaming material is formed
Data Source
AI summary
A connecting element for producing a structural connection between a first structural part and a second structural part by a foamable material, the connecting element includes a plug-in part and at least two chambers separated from one another in a fluid-tight manner by a partition, the at least two chambers each accommodating a reactant; a plug-in delimiting part mechanically connected to the plug-in part and configured to delimit displacement of the plug-in part in the plug-in direction; and a break-open mechanism configured to damage the partition, as a result of a break-open force supplied to the break-open mechanism, such that the fluid-tight manner between the at least two chambers is canceled, wherein reactants are selected such that mixing thereof causes a foaming reaction, which extends radially outward beyond the circumferential surface of the plug-in part.