Joining Element Undercut Bonding for Thin Lightweight Components
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing joining processes for lightweight materials, such as aluminum and fiber composites, face challenges as direct welding or soldering is often not possible, and existing joining aids do not effectively address the need for flexible connections between diverse materials.
Innovation Solution
A method involving a joining aid element with a retaining section is pressed into a through-hole, which is widened by an indentation, forming a force and form-lock connection, allowing material bonding and additional functional sections for diverse materials like aluminum and steel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a joining aid is pressed into a through-hole to connect lightweight materials, then the connection strength is improved, but the component thickness is reduced
Solution Approach 1:
The patent introduces an indentation feature that creates a radial dimension change in the through-hole geometry. By widening the hole at specific locations through indentation, the joining aid element engages in multiple dimensions (axial pressing + radial engagement), distributing the connection strength across different spatial dimensions rather than relying solely on thickness
Solution Approach 2:
The solution employs a composite joining aid element consisting of a retaining section and a functional section with different materials optimized for specific functions. The retaining section material is selected for optimal pressing and retention characteristics, while the functional section material is chosen for welding or bonding compatibility, creating a composite structure that achieves high connection strength without requiring increased component thickness
2Ease of manufacture
If existing joining aids are used for diverse materials, then the joining process is simplified, but the adaptability to different material pairings is reduced
Solution Approach 1:
The joining aid element is designed with a universal retaining section geometry that can be pressed into standard through-holes across different component types, while the functional section offers multiple material options (weldable material, bondable material, or both) to accommodate diverse material pairings. This multi-functional design maintains process simplicity while enhancing adaptability to aluminum, steel, and composite materials
Solution Approach 2:
The patent enables adaptability through parameter changes in the functional section material composition and properties. By selecting different materials for the functional section with varying weldability, bondability, and mechanical properties, the same joining aid structure can be adapted to different material pairings without changing the overall joining process flow
3Strength
If the through-hole is widened by indentation, then the force-lock connection is improved, but the manufacturing complexity increases
Solution Approach 1:
The indentation is created as a preliminary action during component manufacturing, before the joining aid is installed. This pre-formed geometric feature prepares the through-hole for optimal joining aid engagement, creating the force-lock connection geometry in advance rather than during the joining process itself, thereby reducing overall 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
This method achieves high strength connections with reduced component thickness, minimizing hydrogen embrittlement and edge cracking, enabling the joining of lightweight materials using existing welding systems, particularly suitable for thin sheets.
Implementation Method 1
the retaining section of the joining aid element is pressed into the through-hole and is connected to the hole wall by force and/or form locking
Implementation Method 2
the retaining section of the joining aid element is pressed into the through-hole and is connected to the hole wall by force and/or form locking
Implementation Method 3
the through hole is widened at at least one edge region by an indentation, wherein the retaining section of the joining aid element is pressed into the through hole and is connected to the hole wall by force and/or form locking, and the retaining section engages in the indentation
Implementation Method 4
forming a material-fit connection by welding, soldering or bonding, wherein the joining aid element is material-fitted to the base material of the second component
Implementation Method 5
forming a material-fit connection by welding, soldering or bonding, wherein the joining aid element is material-fitted to the base material of the second component
Implementation Method 6
forming a material-fit connection by welding, soldering or bonding, wherein the joining aid element is material-fitted to the base material of the second component
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a component (2) in which, at at least one joint, at which a joining connection to a further component is to be formed later, a joining element (4) having a holding section (7) is pressed into the component, and the joining element (4) also has a functional section (8), by means of which at least one further function can be implemented. According to the invention, the holding section (7) of the joining element (4) is arranged in a passage hole (13), and the passage hole is widened in at least one edge region by an embossing (14), wherein the holding section (7) of the joining element (4) is pressed into the passage hole (4) and is connected to the hole wall in a force-fitting and/or form-fitting manner and engages in the embossing (14). The invention further relates to a component combination of at least two components which are joined at at least one joint, comprising the component (2) according to the invention having a joining element (4), and to a method for producing the component and the component combination.