Hollow-Shaft Connecting Element for High-Shear Layer Joining
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connecting elements for superimposed component layers lack sufficient shear strength, leading to inadequate bonding between layers.
Innovation Solution
A connecting element with a hollow-cylindrical shaft and driver structures arranged circumferentially, capable of rotating to sever a slug from the top layer and weld it to the base layer, enhancing shear strength through positive connections in both shear and axial directions, with optional features like a shoulder and raised driver structures for improved penetration and material reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional connecting elements are used to connect superimposed component layers, then the connection can be established, but the shear strength between layers is insufficient
Solution Approach 1:
The connecting element is segmented into distinct functional zones: a hollow-cylindrical shaft for slug accommodation, driver structures for rotational engagement, and a shoulder for axial positioning. This segmentation allows each zone to perform its specific function optimally, contributing to enhanced shear strength through the welded slug connection.
Solution Approach 2:
The invention transitions from conventional linear connections to a multi-dimensional connection mechanism. The slug is rotated in the circumferential direction while being welded to the base layer, creating a three-dimensional welded joint that provides superior shear strength compared to traditional linear rivet connections.
2Strength
If more material is used to enhance connection strength, then shear strength increases, but the overall mounting height and material usage increase
Solution Approach 1:
The hollow-cylindrical shaft is designed to accommodate and reuse the slug material cut from the top layer. Instead of discarding this material, it is retained within the shaft and welded to the base layer, creating a strong connection while minimizing additional material usage and maintaining compact mounting height.
Solution Approach 2:
Conventional rivets require additional material to form the connection, whereas this invention inverts the approach by using the material removed from the top layer (the slug) as the connection element itself. This inversion eliminates the need for extra material while achieving superior connection strength through welding.
3Strength
If driver structures are added to rotate the slug, then shear strength is enhanced, but the device complexity increases
Solution Approach 1:
The driver structures serve multiple functions: they engage the slug to initiate rotation, maintain circumferential rotation during the welding process, and ensure proper positioning of the slug within the hollow shaft. This multi-functionality enhances shear strength without requiring separate mechanisms for each operation, thereby limiting the increase in device complexity.
4Loss of substance
If the shaft is made hollow to accommodate the slug, then material usage is reduced, but the structural strength may be compromised
Solution Approach 1:
The hollow-cylindrical shaft is designed with optimized parameters including wall thickness, diameter, and length to maintain sufficient structural strength while accommodating the slug. The shaft's hollow design reduces material usage compared to solid rivets, while its dimensional parameters are tuned to ensure adequate strength for the connection application.
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
Significantly increases shear strength between component layers by creating a strong, reliable connection that withstands axial forces, while minimizing material usage and overall mounting height.
Implementation Method 1
driver structures acting in the circumferential direction of the hollow-cylindrical shaft are arranged in the hollow space... to rotate the slug along with the shaft, so that rotation of the slug together with the connecting element allows the slug to be welded to the base layer
Data Source
AI summary
The invention relates to a connecting element (10) having a hollow-cylindrical shaft (12) and a drive (16), via which the shaft (12) can be driven in a direction of rotation, wherein the hollow-cylindrical shaft (12) has at least one free end, wherein the drive (16) is arranged opposite the free end, wherein a hollow space is formed by the hollow-cylindrical shaft (12). The invention is characterized in that driver structures (22) acting in the circumferential direction of the hollow-cylindrical shaft (12) are arranged in the hollow space, which, projected on the lateral surface, are arranged to extend in the setting direction on the lateral surface, rectilinearly parallel to the element mid-axis (M) or with an angular deviation of at most 20° with respect to the element mid-axis (M), and/or are arranged at the end on the drive side.