Thermoplastic Strut Joint Assembly for Vehicle Components
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Solution Overview
Problem
Existing methods for producing strut devices for vehicles require precise alignment of joint parts and only allow prefabrication of the strut element, limiting flexibility and production efficiency.
Innovation Solution
A method where both the joint and strut element are prefabricated independently, with the strut end section inserted into or slipped over the connecting section, and the connecting section is reshaped to form a rigid, immovable connection, using a thermoplastic material that changes from a plastically deformable to a rigid state upon cooling, ensuring a secure and adaptable connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the strut end section is overmolded to form the joint, then the joint can be integrated with the strut element, but the production process becomes complex and time-consuming, and only the strut element can be prefabricated
Solution Approach 1:
The joint and strut element are separated into independent components that can be manufactured separately and then assembled. The joint is produced as a discrete component with a connecting section, while the strut element is produced separately with a strut end section. This segmentation enables both components to be prefabricated independently, improving production flexibility and efficiency.
Solution Approach 2:
Both the joint and the strut element are prefabricated in advance as separate components before final assembly. The joint is manufactured with its connecting section prepared, and the strut element is manufactured with its end section prepared, allowing both to be readied simultaneously and then quickly assembled together, thereby increasing overall productivity.
2Productivity
If the strut end section is inserted into the connecting section, then both joint and strut element can be prefabricated independently, but precise alignment is required during assembly
Solution Approach 1:
The strut end section is inserted into the connecting section of the joint, creating a nested arrangement where one component fits within another. This nesting mechanism facilitates easy assembly while maintaining precise alignment through the inherent geometric fit between the inserted strut end section and the receiving connecting section.
Solution Approach 2:
The connecting section is heated to change its physical state from rigid to plastically deformable, allowing the strut end section to be inserted more easily. After insertion, the connecting section cools and returns to its rigid state, locking the strut end section in place. This parameter change enables assembly with reduced alignment requirements while maintaining final precision.
3Reliability
If the connecting section is reshaped to form a rigid connection, then relative movement between joint and strut element is prevented, but additional processing steps are required
Solution Approach 1:
The connecting section undergoes a phase transition by being heated to become plastically deformable, allowing the strut end section to be inserted. After insertion, the connecting section cools and transitions back to a rigid state, permanently locking the components together. This phase transition approach creates a reliable rigid connection through a single integrated process rather than multiple separate steps.
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 simplifies and enhances the production of strut devices by allowing flexible assembly, preventing relative movement between the joint and strut element, and enabling more efficient manufacturing of articulated connections for vehicle components.
Implementation Method 1
using a thermoplastic material that changes from a plastically deformable to a rigid state upon cooling
Implementation Method 2
the connecting section is reshaped to form a rigid, immovable connection, using a thermoplastic material that changes from a plastically deformable to a rigid state upon cooling
Data Source
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AI summary
The invention relates to a method for manufacturing a strut device (1) for connecting two vehicle components of a vehicle, in which a strut element (2) is provided which has at least one strut end section (3, 4), in which at least one joint (5, 6) is made at least partially from a plastic material, wherein the joint (5, 6) has a connecting section (7), and in which the strut end section (3, 4) and the connecting section (7) overlap at least partially and are connected to each other to form a connection area (8, 9).In order to improve, simplify and/or make the manufacturing process more flexible, in particular to enable prefabrication of both the joint (5, 6) and the strut element (2), the method is characterized in that the strut end section (3, 4) is inserted into the connecting section (7) to form the connection area (8, 9) and/or the connecting section (7) is placed on the strut end section (3, 4) to form the connection area (8, 9).