Hollow Profile Fastening Insert for High-Load Vehicle Mounting
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Solution Overview
Problem
Existing fastening arrangements for high-load components in motor vehicles, particularly in space frame bodies, face challenges in achieving secure connections with minimal installation space and low production costs while maintaining structural integrity.
Innovation Solution
A connection element with a rectangular profile extension and flange surface is inserted laterally into a hollow profile, providing vertical support and allowing for screwing of high-load components without the need for primary welding, thus reducing installation space and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional welding methods are used to fasten high-load components to hollow profiles, then connection strength is improved, but installation space requirements increase and production costs rise
Solution Approach 1:
The patent introduces an intermediate connecting element with a profile extension that fits into the hollow profile's cavity. This mediator transfers loads between the hollow profile and the high-load component through mechanical interfaces (flange surfaces, notches, recesses) rather than direct welding, reducing installation space and complexity while maintaining connection strength
Solution Approach 2:
The connecting element is segmented into distinct functional parts: a profile extension for insertion into the hollow profile, a flange surface for component attachment, and notches/recesses for mechanical interlocking. This segmentation allows each part to optimize its function independently, reducing overall complexity
2Strength
If traditional welding methods are used to fasten high-load components to hollow profiles, then connection strength is improved, but production costs increase
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical insertion and interlocking system. The connecting element is inserted into the hollow profile and secured through notches and recesses, eliminating welding operations and associated costs while maintaining structural integrity
Solution Approach 2:
The connecting element appears to be a cost-effective alternative to welding, using simple geometric features (notches, recesses, flanges) that can be manufactured through conventional forming processes rather than expensive welding operations
3Reliability
If larger installation space is provided for fastening components, then connection reliability is improved, but vehicle body space efficiency decreases
Solution Approach 1:
The profile extension of the connecting element is nested within the cavity of the hollow profile. This nesting allows the connection mechanism to be housed within the existing structural space without requiring additional external space, maintaining vehicle body space efficiency while ensuring reliable connection through internal mechanical interfaces
Data Source
Figure 1~4
Figure 5~8
AI summary
A connecting element for attaching a high-load component to a hollow profile in a motor vehicle, wherein the connecting element (1) has a profile extension (2) with a rectangular cross-section comprising a top surface (3) and a bottom surface (4) of the cross-section of the profile extension (2), wherein the connecting element (1) further comprises a flange surface (9) which has a cross-section of the flange surface (9) projecting beyond the cross-section of the profile extension (2), wherein the profile extension (2) and/or the flange surface (9) has a bore (10) for bolting the high-load component.