Sandwich Component Connection with Welded Ball and Adhesive Seal
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Solution Overview
Problem
Existing component connection methods lack versatility and effective application in areas requiring high electromagnetic compatibility and robust structural integrity, such as vehicle body construction.
Innovation Solution
A method involving a first component with a welded ball and a second component made of sandwich material with a plastic center layer between metal layers, where the ball projects into a through hole with a bent-up collar, allowing for a secure and moisture-resistant connection using laser welding and adhesive layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional connection methods are used, then manufacturing simplicity is maintained, but application spectrum and EMC compatibility are limited
Solution Approach 1:
The second component is constructed as a sandwich structure with a plastic center layer and metal surface layers, combining the advantages of plastic (design flexibility, cost) and metal (EMC shielding, strength). This composite structure enables the connection to be used in applications requiring both mechanical integrity and electromagnetic compatibility, thereby expanding the application spectrum without significantly increasing manufacturing complexity.
2Strength
If metal-to-metal connection is used, then structural integrity is achieved, but moisture accumulation and corrosion risk increase
Solution Approach 1:
The sandwich structure with plastic center layer and metal surface layers creates a barrier against moisture while maintaining structural strength. The plastic layer prevents direct contact between metal surfaces, eliminating capillary channels that would allow moisture accumulation, while the metal layers provide the necessary mechanical strength and EMC shielding.
Solution Approach 2:
The plastic center layer acts as a protective barrier film between the metal surface layers, preventing moisture ingress and accumulation. This thin plastic film maintains the structural integrity while protecting against harmful moisture effects.
3Manufacturing precision
If laser welding is used, then welding precision and speed are improved, but applicability to plastic materials is limited
Solution Approach 1:
The sandwich structure allows laser welding of the metal surface layers while the plastic center layer remains unaffected. This enables the use of high-precision laser welding technology for the metal components while maintaining the plastic layer's properties, thereby combining welding precision with material versatility.
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 method enhances the application spectrum by providing a strong, EMC-compatible connection suitable for vehicle body construction, ensuring durability and preventing moisture accumulation, while allowing for easy assembly and disassembly.
Implementation Method 1
welding a ball onto the first component
Implementation Method 2
the two components are glued to one another; i.e. an adhesive layer can be inserted between the two components
Data Source
AI summary
A component connection has a first component, which consists of a metal material, a ball likewise consisting of a metal material, which is welded to the first component, and a second component which has a through-hole and a collar which projects from a top side of the second component, is bent upwards and extends circumferentially around the through-hole. The two components are joined to each other such that the ball projecting from the first component projects into the through-hole provided in the second component or even partially through the through-hole. The second component is arranged so that the collar protrudes from the first component. The second component is a sandwich component which has a middle layer of a plastic material, the middle layer being located between an upper metal layer and a lower metal layer.