Folded Flange Overlap Joint with Stamped Anti-Slip Connection
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Solution Overview
Problem
Existing methods for producing overlapping connections in vehicle body components using folded flanges fail to reliably prevent relative movements between components, leading to inconsistencies and potential disassembly during handling or processing.
Innovation Solution
A method that forms connection regions on the folded flange by using a stamping tool with a stripper and movable support, featuring a single or double tip, to create positive connections by piercing through the first component into the second, thereby preventing relative movement without additional connecting elements or complex welding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a folded flange is used to connect two components, then the connection process is simple and fast, but the connection cannot reliably prevent relative movements between components
Solution Approach 1:
The connection is divided into two functional parts: the folded flange provides initial positioning and clamping, while the separately inserted stamping element provides positive mechanical interlocking. This segmentation allows each element to perform its specific function optimally without compromising the other.
Solution Approach 2:
The stamping element is inserted into a cavity within the folded flange structure. The stamping element fits nested within the folded flange, creating a combined connection system where the inner element (stamping element) reinforces the outer element (folded flange).
2Reliability
If additional connecting elements or complex welding processes are used to prevent relative movements, then connection stability improves, but device complexity and manufacturing cost increase
Solution Approach 1:
The stamping element is designed to be inserted and positioned by the components themselves during the folding process, without requiring external fixing devices or complex positioning mechanisms. The folded flange structure itself provides the cavity and guiding features for the stamping element.
Solution Approach 2:
The stamping element acts as an intermediary component that mediates between the folded flange and the overlapping components. It transfers and distributes the mechanical interlocking function, enabling stable connection without direct welding or complex external fixtures.
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 method ensures high reproducibility and stability of the overlapping connection, reducing relative movements and allowing immediate processing of components, while eliminating the need for additional assembly coordination and costly welding, and is applicable to both steel and aluminum components.
Implementation Method 1
a stamping tool embosses the first component (10) through the second component (20) at at least one stamping point (34), with displaced material of the first component (10) passing into the second component (20) and producing a positive connection
Data Source
AI summary
The disclosure relates to a method for producing a overlapping connection, in which at least two overlapping components are connected to one another via a folded flange, with a first edge of a first component being folded over a second edge of a second component to form the folded flange, along with a body component that includes such an overlapping connection for a vehicle and a stamping tool for such a body component. According to the disclosure at least one connection region is formed on the folded flange, in which the stamping tool stamps the first component through the second component at least one stamping point, with displaced material of the first component passing into the second component and producing a positive connection.