Helical Adaptor for Thermal Expansion Tolerance Compensation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The challenge in mechanical engineering and construction industries, particularly in bonding lightweight materials like aluminum, magnesium, or polymers with metal parts, lies in compensating for tolerances and thermal expansion differences, where existing methods often require precise positioning and sliding connections, which can be complex and inefficient.

Innovation Solution

A fastening method using an adaptor with an anchoring part and an adjustment part, where the anchoring part and adjustment part define a common axis that is not perpendicular to the z-direction, allowing for z-position adjustment through the relative orientation of the adjustment part, and secured using thermoplastic material and mechanical vibration to create a fixed, irreversible connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If sliding connections are used to compensate for thermal expansion differences, then adaptability to different thermal expansion coefficients is improved, but device complexity increases due to the need for grooves, slots, and slideable nuts

Engineering Contradiction:

Improvecompensation of thermal expansion differencesVSAvoidcomplexity of sliding connections

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The invention extracts the tolerance compensation function from complex sliding connections and concentrates it into a single adjustable fastening element. The fastening element can be positioned at different locations along the connection element, eliminating the need for grooves, slots, and slideable nuts while maintaining the ability to compensate for thermal expansion differences and manufacturing tolerances.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The fastening element acts as an intermediary between the two objects being connected. It provides a flexible connection point that can be adjusted along the connection element, enabling tolerance compensation without requiring complex sliding mechanisms in either object. This intermediary approach simplifies the overall connection structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If precise positioning is required for fasteners, then manufacturing precision is improved, but ease of manufacture deteriorates due to the difficulty of achieving precise positions

Engineering Contradiction:

Improvepositioning precision of fastenersVSAvoidease of achieving precise positions

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The invention introduces dynamic adjustability to the fastening element, allowing its position to be varied along the connection element. This dynamic positioning capability enables precise alignment to be achieved after assembly, rather than requiring precise pre-positioning during manufacturing. The fastening element can be moved to the optimal position to accommodate tolerances and achieve the desired precision.

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If slidable connections are used for tolerance compensation, then adaptability is improved, but loss of time increases due to the complexity of assembly and adjustment

Engineering Contradiction:

Improvetolerance compensation capabilityVSAvoidassembly and adjustment time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The fastening element is designed with pre-defined adjustment capabilities along the connection element, allowing for quick positioning without complex assembly procedures. The element can be rapidly moved to the appropriate position to compensate for tolerances, significantly reducing the time required for assembly and adjustment compared to traditional sliding connections.

Inventive Principle:

Principle #10Preliminary action

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 enables precise z-tolerance compensation without rotational movements, ensuring stable and irreversible anchoring, suitable for large objects with different thermal expansion coefficients, improving the efficiency of bonding lightweight materials to metal parts.

Implementation Method 1

the anchoring part and the first object are bonded to each other in an irreversible manner

Methodology Applied

Scientific EffectMechanical vibration: Vibration

Implementation Method 2

secured using thermoplastic material and mechanical vibration to create a fixed, irreversible connection

Methodology Applied

Scientific EffectThermoplastic material bonding:

Data Source

PatentUS10337543B2Securing a second object to a first object

Publication Date: 2019.07.02 MULTIMATERIAL WELDING AG

AI summary

An adaptor is secured to a first object. The adaptor includes an anchoring part and an adjustment part. The anchoring part includes a distally facing anchoring surface and a proximally facing first control surface. The adjustment part has a distally facing second control surface positioned to abut against the first control surface. The first control surface or the second control surface or both is/are helical. Thereby a relative z position of the adjustment part with respect to the anchoring part is defined by the relative orientation of the adjustment part with respect to the common axis while the second control surface abuts against the first control surface. This is used to adjust the z position of the adjustment part relative to the first object, in connection with the orientation of the adjustment part being defined and possibly fixed by the function of the adaptor/the adjustment part.