Press-Hardened Molded Component With Integrated Friction Structure
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Solution Overview
Problem
Conventional screw connections in motor vehicle components, which rely on separate washers for force distribution, often fail to provide a reliable and slip-proof connection under strong static and dynamic loads.
Innovation Solution
A molded component with a metallic component body and an embossed, hardened friction structure surrounding the mounting opening, produced through hot molding and press hardening, which integrates the friction structure into the component body for enhanced connection stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If separate washers are used for screw connections, then force distribution is achieved, but connection reliability under strong loads deteriorates
Solution Approach 1:
The invention merges the washer function with the friction structure by integrating both into the molded component body. The friction structure serves dual purposes: it distributes forces like a washer and simultaneously provides friction to prevent slipping, eliminating the need for separate washers and improving connection reliability under strong loads.
Solution Approach 2:
The friction structure is produced from a composite material consisting of a thermoplastic matrix and fibrous reinforcement. This composite structure provides both the force distribution capability of a washer and the high friction necessary to prevent slipping under strong static and dynamic loads.
2Force
If separate washers are used for screw connections, then force distribution is achieved, but device complexity increases
Solution Approach 1:
The invention combines multiple functions (force distribution and friction provision) into a single integrated friction structure that is molded as part of the component body. This eliminates the need for separate washers and reduces mounting complexity, as the friction structure is already in place during the molding process.
3Reliability
If conventional surface structures are produced by laser or embossing processes, then friction is increased, but production rationality deteriorates
Solution Approach 1:
The friction structure is produced as an integral part of the molded component body during the hot molding process itself, before the component is removed from the mold. This preliminary action eliminates the need for subsequent laser or embossing operations, improving production rationality while maintaining high friction characteristics.
4Force
If separate washers are used, then force distribution is achieved, but weight increases
Solution Approach 1:
The invention merges the washer function into the friction structure, which is already an integral part of the molded component body. This eliminates the need for additional separate washers, reducing overall component weight while maintaining force distribution capability through the integrated friction structure.
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 integrated friction structure significantly increases the friction between joining partners, resulting in a more reliable and durable screw connection that withstands heavy loads, while also contributing to lightweight construction by eliminating the need for additional washers.
Implementation Method 1
The component body consists of a hardenable steel and is hot-formed and press-hardened, the friction structure being produced during hot molding of the component body, in particular by embossing
Implementation Method 2
The friction structure is embossed and hardened... The friction structure is produced during hot molding of the component body, in particular by embossing
Implementation Method 3
The component body consists of a hardenable steel and is hot-formed and press-hardened
Data Source
AI summary
A molded component has a metallic component body with a mounting opening and a friction structure surrounding the mounting opening. The component body consists of a boron-alloyed steel and is hot molded and press-hardened. The friction structure is produced in the press tool during hot molding. The mounting opening is produced timely in parallel in the component body.