Generative Joining Part for Lightweight Dissimilar Material Joints
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Solution Overview
Problem
Existing methods for joining components, such as bodywork components in vehicles, often result in joints with poor load bearing ability and joint cushioning, leading to negative impacts on vibration properties and increased weight.
Innovation Solution
A method involving a generative process to create a joining part with a first and second component receiving section, allowing for a strong and weight-reduced connection using materials and configurations optimized for the components, and potentially incorporating form fitting and integrally bonded connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional joining methods (screwing, riveting, adhesive bonding) are used to join bodywork components, then the components can be connected, but the joint locations have poor load bearing ability and poor joint cushioning, leading to negative impact on vibration properties
Solution Approach 1:
The joining part is created using generative methods with materials optimized for both load bearing and vibration damping. The patent specifies using fiber-reinforced plastics (such as carbon fiber, aramid fiber, or glass fiber reinforced plastic) combined with metal materials in the joining part to achieve both high strength and good joint cushioning properties, directly resolving the contradiction between load bearing ability and joint cushioning.
2Strength
If direct welding of different materials (steel and aluminum) is attempted, then a strong connection can be achieved, but it is often not possible or only possible under special preconditions or to a limited extent
Solution Approach 1:
The patent introduces a joining part as an intermediary element that connects different material components. This joining part is specifically designed with material compatibility for both steel and aluminum components, using fiber-reinforced plastics and metal materials that can be generatively created to interface with different base materials, thereby enabling strong connections between dissimilar materials without direct welding.
3Ease of manufacture
If functional elements are introduced via pressing to create connections between different materials, then a connection can be established, but the connection has relatively poor load bearing ability and the process is very expensive and costly
Solution Approach 1:
The patent replaces conventional mechanical pressing processes with generative manufacturing methods. The joining part is created using generative methods (such as 3D printing or additive manufacturing) that allow for complex geometries and optimized material distribution, achieving high load bearing ability while reducing manufacturing costs and process complexity compared to traditional pressing operations.
4Ease of manufacture
If conventional joining methods are used to connect components, then the components can be joined, but it leads to an excessive weight increase of the composite component
Solution Approach 1:
The patent utilizes generative methods to optimize the geometry and material distribution of the joining part. By changing design parameters and using fiber-reinforced plastics with high strength-to-weight ratios, the joining part achieves necessary mechanical properties while minimizing weight. The generative approach allows for topological optimization that reduces material usage while maintaining structural integrity.
Data Source
AI summary
A method for joining a first component to a second component includes providing a first component with a first joining part receiving section and creating a joining part on and/or in the first joining part receiving section via a generative method. The method also includes providing a second component with a second joining part receiving section, and joining the joining part to the second joining part receiving section of the second component.