Dissimilar Metal Joining Structure with Resin-Filled Gap
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Solution Overview
Problem
Existing joining structures for dissimilar metallic materials, such as aluminum and steel, face challenges in achieving strong, corrosion-resistant connections without complex manufacturing processes, as they often require sealants that may delaminate and fail to prevent moisture immersion, leading to reduced durability.
Innovation Solution
A joining structure that separates dissimilar members with a gap filled with resin, injected between them, using protrusions or through-holes, which provides reinforcement and prevents corrosion by ensuring a solid resin bond without gaps, thus enhancing rigidity and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a steel connection member is inserted into an aluminum member to join dissimilar metallic materials, then the joining strength is improved and intermetallic compound formation is avoided, but the positioning accuracy deteriorates and corrosion resistance requires additional sealant application steps
Solution Approach 1:
A resin layer is introduced as an intermediary substance between the steel connection member and aluminum member. This resin layer serves multiple functions: it maintains the separation distance to prevent intermetallic compound formation, provides positioning accuracy through the protrusion structure, and eliminates the need for additional sealant application by filling gaps and providing corrosion resistance.
Solution Approach 2:
The resin layer performs multiple functions simultaneously: it acts as a spacer to maintain separation distance, provides positioning accuracy, serves as a sealant to prevent corrosion, and contributes to the overall joining strength. This multi-functionality reduces the number of separate components and manufacturing steps required.
2Object-affected harmful factors
If sealant is applied to the boundary between aluminum member and steel connection member to ensure corrosion resistance, then the corrosion protection is improved, but the number of manufacturing steps increases and long-term durability deteriorates due to sealant delamination
Solution Approach 1:
The spacing function and sealant function are merged into a single resin layer. The resin layer simultaneously maintains the separation distance between dissimilar metallic materials and provides corrosion protection by filling gaps and preventing moisture ingress, eliminating the need for separate sealant application steps.
Solution Approach 2:
The resin layer is self-positioning through the protrusion structure, which automatically maintains the correct separation distance during assembly. This self-service capability eliminates the need for precise manual positioning and additional sealant application steps, while ensuring long-term corrosion resistance.
3Ease of manufacture
If resin is provided on the surface of one metallic member before combining with another metallic member, then the manufacturing process is simplified, but gaps may form between the resin and the other metallic member allowing moisture immersion and reducing corrosion protection
Solution Approach 1:
The protrusion structure is pre-formed on one of the metallic members before assembly. This preliminary action ensures that when the resin is applied and the members are combined, the protrusion automatically maintains the correct separation distance and prevents gap formation, ensuring both manufacturing simplicity and effective corrosion protection.
Data Source
AI summary
A joining structure includes a first member, a second member of a material different from that of the first member, and a separation mechanism provided between the first member and the second member and that separates the first member and the second member from each other, wherein a resin is filled into the space between the edge of at least one member among the first member and the second member, and the other member.