Friction-Welded Joining Element With Debris Removal Profile
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Solution Overview
Problem
Existing joining elements for composite components face challenges in reliably forming friction-welded zones, especially when connecting layers in composite constructions, due to foreign matter entering the welded joint.
Innovation Solution
A joining element with a shaft featuring a removal region and a holding region, where the removal region accommodates material from the top component layer to prevent it from entering the welded joint, and the holding region forms a metallically pure contact surface with the bottom layer, enhancing the quality of partial friction-welded joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a joining element is used to connect component layers, then the connection between layers is achieved, but foreign matter from the component layers enters the welded joint, adversely affecting the formation of a reliable welded joint
Solution Approach 1:
The invention extracts and removes foreign matter from the welding zone by providing a removal region with removal structures (such as grooves or channels) on the joining element. These structures actively take out contaminants from the interface between component layers during the joining process, preventing foreign matter from interfering with welded joint formation and thereby improving joint reliability
Solution Approach 2:
The joining element is segmented into functionally distinct regions: a holding region for maintaining component layers in position and a removal region for eliminating foreign matter. This segmentation allows each region to perform its specific function optimally, with the removal region specifically dedicated to improving welded joint reliability by eliminating contaminants
2Length of moving object
If the shaft length is limited to less than five times the maximum outer diameter, then the joining element maintains compact dimensions, but the holding region and removal region must be efficiently arranged within the constrained length
Solution Approach 1:
The joining element employs a conical shaft design where the outer diameter varies along the length, creating dynamically adapted regions. The holding region has a larger diameter to effectively clamp components, while the removal region has a smaller diameter to accommodate removal structures. This dynamic dimensional variation allows efficient arrangement of multiple functional regions within a compact overall length
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 solution improves the quality and reliability of the friction-welded joints by preventing foreign material from entering the joint and creating a metallically pure contact surface, resulting in a stronger and more consistent connection between the component layers.
Implementation Method 1
the friction-welded zone may exhibit partial friction-welded joints that are formed between the joining element and the bottom component layer
Implementation Method 2
Entraining material from the bottom component layer, i.e. the base layer, also improves the quality of the partial friction-welded joint, because this results in the creation of a metallically pure contact surface
Data Source
AI summary
The invention relates to a joining element (10, 50, 70, 100, 130) for connection to at least one component layer (34, 62, 84, 112), comprising a head (12, 52) having a head supporting surface (16, 140) for abutment against a component layer and at least one drive feature (14), via which the joining element can be rotated. The joining element further comprises a shaft (17), which ends via a hole forming element (18, 54, 90, 106) in a point (38), wherein the length of the shaft, from the head supporting surface to the point, is shorter than five times the maximum shaft outer diameter (DMax), wherein the shaft has a holding region (H) for connection to the component layer. A removal region having a removal profile (20, 56, 72, 102, 134) extends on the shaft, subsequent to the holding region in the direction of the point (38), and the removal region starts spaced apart from the head supporting surface at a distance of at least once the maximum shaft outer diameter.