Joint Indentation Fastener Bond Gap Design
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Solution Overview
Problem
Existing joint technologies face challenges in achieving high energy absorption and peel resistance, as adhesives have low peel performance and mechanical fasteners require clamping pressure that can squeeze adhesive out, reducing the bond gap and adhesive toughness.
Innovation Solution
A joint configuration that includes a component with an indentation and a fastener with a head wider than the indentation, allowing the fastener to contact the component's thick portion and maintain a larger bond gap, using a flow drill screw or self-tapping screw with an adhesive layer for enhanced toughness and reduced cycle time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If adhesives are used to join components, then stress concentrations are reduced, but peel performance is low
Solution Approach 1:
The joint system merges both adhesive bonding and mechanical fastening methods. The adhesive layer provides continuous stress distribution and reduces stress concentrations, while the mechanical fastener provides peel resistance. The combination of these two methods achieves both benefits simultaneously.
Solution Approach 2:
The indentation acts as an intermediary element between the fastener head and the component body. It allows the fastener head to be supported by the component without transmitting clamping pressure to the adhesive layer, thereby preserving the adhesive's stress distribution properties while adding peel resistance through the mechanical fastener.
2Strength
If fastener head width is increased to prevent clamping pressure, then adhesive toughness is maintained, but manufacturing precision requirements increase
Solution Approach 1:
The indentation is formed as a preliminary feature before fastener installation, allowing for controlled geometry and consistent dimensions. This preliminary formation ensures that the indentation provides reliable support for the fastener head while maintaining manufacturability through standard forming processes.
Data Source
AI summary
Joints and methods of forming the same are disclosed. The joint may include a first component including an indentation formed therein having a width, a second component, an adhesive layer disposed between the first and second components, and a fastener extending through the indentation. The fastener may join the first and second components and have a head with a width greater than a minimum width of the indentation. The method may include forming an indentation having a width in a first component, applying an adhesive to one of multiple components, and stacking the components. The indentation may form a bond gap between two components. A fastener may be inserted having a head with a width greater than the width of the indentation into the indentation to join the components. The indentation may space the components apart to provide a larger bond gap for the adhesive.