Hybrid Component Bonding via Segmented Adhesive and Rivets
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Solution Overview
Problem
Existing methods for producing hybrid components from different materials often result in large-area material connections, leading to surface unevenness and thermal expansion issues due to material differences, which affect the rigidity and appearance of the final product.
Innovation Solution
A hybrid component is produced by partially bonding a profile component to a flat component using a combination of adhesive and riveted connections, with strategically placed holes or embossings to minimize large-area connections and manage thermal stresses, thereby enhancing rigidity and reducing weight and surface irregularities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a large-area material-bonded connection is used to join different material components, then the connection strength is improved, but surface irregularities and thermal expansion issues occur
Solution Approach 1:
The bonding area is segmented into discrete bonding zones rather than a continuous large-area connection. Rivets are positioned at specific intervals to create localized connection points, dividing the bonding function into multiple small segments that reduce thermal stress accumulation and prevent surface irregularities while maintaining overall connection strength.
Solution Approach 2:
Different connection methods are applied to different regions: material-bonded connections (adhesive or solder) are used in specific bonding zones where strength is critical, while form-fit connections are used in other areas. This localized application of different connection qualities allows optimal performance in each region without the drawbacks of uniform large-area bonding.
2Stability of the object's composition
If different materials are bonded over a large area, then the structural rigidity is improved, but thermal expansion differences cause surface irregularities
Solution Approach 1:
The structure is divided into modular sections with discrete bonding zones. Rivets are positioned at specific intervals rather than continuous bonding, creating thermal expansion joints that allow each material section to expand and contract independently, preventing the accumulation of thermal stresses that would cause surface irregularities while maintaining overall structural rigidity.
Solution Approach 2:
Rivets serve as intermediary elements between the material-bonded connection zones and the free sections. These intermediaries provide mechanical fastening while allowing for thermal movement, mediating between the need for strong connection and the need to accommodate thermal expansion differences between materials.
3Reliability
If a combination of adhesive and riveted connections is used, then the connection reliability is improved, but the manufacturing complexity increases
Solution Approach 1:
The connection system is segmented into discrete bonding zones and rivet positions that are pre-defined in the tooling. This segmentation allows for automated application of adhesive in specific zones followed by automated rivet placement at predetermined locations, reducing manufacturing complexity through standardization while maintaining high reliability through multiple connection methods.
Solution Approach 2:
Adhesive is applied in preliminary action before rivet installation. The adhesive is applied to specific bonding zones first, allowing it to set partially or fully before rivets are positioned and installed. This preliminary bonding action ensures that components remain aligned and positioned correctly during the riveting process, improving connection reliability while the pre-planned sequence reduces manufacturing complexity.
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
The method achieves high rigidity and improved surface appearance by avoiding large-area material connections and thermal expansion issues, resulting in a lightweight and resilient hybrid component with reduced surface irregularities.
Implementation Method 1
an adhesive material, in particular an adhesive, is applied section by section between the component and the flange areas
Implementation Method 2
rivet connections are formed outside the sections of the flange areas provided with the adhesive material, forming a force-fit and/or form-fit connection
Implementation Method 3
These precisely defined round or elongated holes relieve the differing thermal stresses between the profile component and the hybrid component, thus preventing surface irregularities
Data Source
Figure 1~3
Figure 4~6
Figure 7~8
AI summary
The invention relates to a hybrid component (1) that is formed by a profiled component (2) of a first material, which is materially bonded in certain sections to a component (3) made of a second material, and is connected by means of a form-fit and/or force-fit connection (7) outside the sections with a material bond (6). This creates sections that relieve the strains resulting from differing thermal expansion. The invention further relates to a method for producing a hybrid component (1).