Folded Flange Overlap Joint With Stamped Positive Locking
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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 reduced component quality.
Innovation Solution
A method involving a stamping tool that forms connection regions on the folded flange by piercing the first component through the second component at specific points, creating a positive connection and preventing relative movement, which can be implemented without additional connecting elements or complex welding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a folded flange is used to connect two components, then the connection can be formed without additional connecting elements, but relative movements between the components cannot be reliably prevented
Solution Approach 1:
The connection is divided into two distinct parts: the folded flange structure that provides the basic connection geometry, and the separately formed connection region with stamping points that provides mechanical interlocking. This segmentation allows each part to fulfill its specific function optimally.
Solution Approach 2:
The connection region is formed in advance on the folded flange before the final assembly. This preliminary formation of the connection region with its specific geometry ensures that when components are assembled, the mechanical interlocking occurs automatically without requiring additional operations.
2Reliability
If stamping is used to create connection regions on the folded flange, then a positive connection is achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The folded flange structure itself serves as the tool for creating the connection region. By forming the flange in a specific way, the connection region is created automatically during the folding process, eliminating the need for separate stamping tools or additional manufacturing steps.
Solution Approach 2:
The formation of the folded flange and the creation of the connection region are merged into a single integrated process. The same forming operation that creates the folded flange geometry also simultaneously creates the connection region with its stamping points, reducing overall process complexity.
3Reliability
If multiple connection regions are formed on the folded flange, then relative movements are better prevented, but the manufacturing time increases
Solution Approach 1:
Instead of forming connection regions across the entire surface of the folded flange, only specific partial regions are stamped with connection points. This partial action provides sufficient mechanical interlocking to prevent relative movements while minimizing the total manufacturing time and material deformation.
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 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 complex welding.
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.