Metal Sheet Flange Joining Structure for Higher Torsional Rigidity
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Solution Overview
Problem
Current joining structures for automobile vehicle bodies face challenges in achieving cost reduction, weight reduction, and increased rigidity simultaneously, particularly due to limitations in resistance spot welding methods that compromise structural integrity and weight efficiency.
Innovation Solution
A joining structure that involves overlapping inward flanges on a metal-formed sheet with a constant sectional shape, where the end surfaces of the flanges face each other and are integrally joined by a single mass of melted metal, optimizing the distance and extension length between the flanges to enhance torsional rigidity while minimizing material usage and welding costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If resistance spot welding is used to join structural members, then joining strength is achieved, but welding costs increase and weight reduction is compromised
Solution Approach 1:
Multiple flanges are joined to a single flange by a single welding operation, merging multiple joining actions into one. This reduces the number of welding operations required and lowers welding costs while maintaining joining strength
Solution Approach 2:
The structural member is divided into multiple flanges that can be separately formed and then joined together, allowing for optimized welding arrangements that reduce overall welding requirements
2Strength
If multiple flanges are joined by separate welding operations, then joining strength is ensured, but welding range expands and manufacturing complexity increases
Solution Approach 1:
Multiple flanges are positioned to be joined to a single flange simultaneously in one welding operation, consolidating multiple welding tasks into a single operation and reducing welding range expansion
3Strength
If flanges are overlapped extensively to improve rigidity, then torsional rigidity increases, but material usage increases and weight reduction is compromised
Solution Approach 1:
Flanges are designed with specific local geometries and positioning that concentrate strengthening where needed rather than through extensive overlapping, optimizing rigidity while minimizing material usage
Solution Approach 2:
Flanges are pre-formed with optimized shapes and positions before joining, allowing for efficient material distribution that achieves required rigidity without excessive material usage
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 approach allows for a well-balanced achievement of cost reduction, weight reduction, and higher rigidity in structural bodies by stabilizing the welding process and improving torsional rigidity without expanding the welding range or increasing material costs.
Implementation Method 1
the end surfaces that face each other are integrally joined to the first metal sheet by means of a single mass of melted metal
Data Source
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AI summary
A joining structure of the invention includes a first metal sheet and a pair of second metal sheets. Each of the pair of second metal sheets is overlapped on the first metal sheet in a state where an end surface of one of the second metal sheets and an end surface of the other second metal sheet face each other, and the end surfaces that face each other are integrally joined to the first metal sheet by means of a single mass of melted metal.