Metallic Force Introduction Element for Plastic Component Connection
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Solution Overview
Problem
Existing force introduction devices for plastic components in vehicle construction are complex and expensive, requiring a simpler and more cost-effective solution for connecting components with adjacent parallel walls.
Innovation Solution
A connection arrangement using a metallic force introduction element with frustoconical or spherical segment-shaped depressions on the plastic component, featuring an adhesive layer and a metallic material composition that is easy to produce and assemble, providing enhanced stability and corrosion protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a hybrid design force introduction device is used, then the force transmission capability is improved, but the manufacturing cost and device complexity increase
Solution Approach 1:
The force introduction element is made entirely of metallic material, creating a homogeneous structure that eliminates the complexity of hybrid designs while maintaining sufficient strength through the metal's inherent properties and optimized geometry
Solution Approach 2:
The metallic material parameters and geometric parameters (frustoconical shape, wall thickness) are optimized to achieve the required force transmission capability, allowing a single-material design to meet performance requirements previously requiring hybrid construction
2Strength
If a hybrid design force introduction device is used, then the force transmission capability is improved, but the manufacturing cost increases
Solution Approach 1:
The metallic force introduction element can be produced cost-effectively through standard metal forming processes, and if necessary, replaced or recycled, avoiding the high costs of hybrid material construction while maintaining sufficient service life for the application
Solution Approach 2:
By changing from hybrid material composition to single metallic material with optimized geometric parameters, the manufacturing process is simplified and cost is reduced while maintaining the required force transmission capability
3Area of stationary object
If frustoconical or spherical segment-shaped depressions are used, then the adhesive surface area is increased, but the manufacturing precision requirements increase
Solution Approach 1:
The frustoconical and spherical segment shapes provide curved surfaces that naturally increase adhesive contact area compared to flat surfaces, while these geometric forms can be produced with standard forming processes without requiring ultra-precise manufacturing tolerances
Solution Approach 2:
The specific geometric parameters of the depressions (cone angle, spherical radius, depth) are optimized to provide sufficient adhesive surface area while remaining within the capabilities of standard manufacturing processes, avoiding excessive precision requirements
4Ease of manufacture
If the force introduction element is made of metallic material only, then the manufacturing simplicity is improved, but the corrosion resistance may deteriorate
Solution Approach 1:
A coating layer is applied to the metallic force introduction element as an intermediary protective barrier that prevents direct contact between the metal and corrosive environment, thereby maintaining manufacturing simplicity while providing adequate corrosion resistance
Solution Approach 2:
The force introduction element consists of a metallic base material combined with a protective coating layer, creating a composite structure that leverages the strength and manufacturability of metal with the corrosion resistance of the coating material
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 enables efficient and durable force transmission with increased adhesive surface area, allowing for stable support and moment absorption, while being easy to manufacture and assemble, thus simplifying the connection process in vehicle construction.
Implementation Method 1
a connection arrangement between a plastic component with at least two adjacent and at least approximately parallel walls and another component with at least one via an adhesive connection on the plastic component
Data Source
AI summary
The invention relates to a connecting arrangement between a plastic component (1) with at least two mutually adjacent and at least approximately parallel walls (1a, 1b) and another structural element, having at least one force-introduction element (2) which is adhesively bonded to the plastic component (1) via an adhesive bond (5) on the plastic component (1) in frustoconical or spherical-segment-shaped depressions (3, 4) in the mutually adjacent walls (1a, 1b) of the plastic component (1), and which force-introduction element (2) has a carrying structure for the other structural element. With the exception of a possibly provided coating, the force-introduction element (2) is composed only of metallic material and has a plate (2a) which is adapted to the depression (3) in the outer wall (1a) of the plastic component (1), which outer wall (1a) is adjacent to the other structural element, the edge of which plate (2a) rests with interposition on the outer wall in the surrounding region of the depression (3), wherein the plate (2a) is connected via a web (2c) to an end section (2b) of the force-introduction element (2), which end section (2b) is adapted to the depression (4) in the other inner wall (1b) of the plastic component, and the depression (3) is configured in the outer wall (1a) at any rate without a bottom to such an extent that the end section (2b) of the force-introduction element (2) can be inserted through the outer wall (1a) into the recess (4) of the inner wall (1b).