Threaded Sandwich Component Assembly for Modular Vehicle Structures
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Solution Overview
Problem
Existing sandwich components for vehicles are difficult to manufacture and require a large number of production steps, limiting their versatility and ease of use as load-bearing structural components.
Innovation Solution
A sandwich component comprising a first and second cover layer with a core material in between, connected by joining elements with internal and external threads, allowing for a mechanical connection that simplifies manufacturing and reduces the number of components needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional sandwich components are manufactured using conventional methods, then structural integrity can be achieved, but the manufacturing process becomes complex and requires many production steps
Solution Approach 1:
The patent combines multiple functions into the joining elements: they simultaneously serve as mechanical connectors between cover layers, provide fastening elements for component attachment, and create threaded connections. This integration reduces the number of separate components and manufacturing steps while maintaining structural integrity
Solution Approach 2:
The joining elements are designed with multi-functionality: they connect cover layers mechanically, provide threaded fastening for additional components, and enable modular assembly. This universal design simplifies the overall manufacturing process by eliminating the need for separate connection elements and fasteners
2Ease of operation
If multiple separate components are used to achieve mechanical connections and fastening, then functional requirements are met, but the number of components and production steps increases
Solution Approach 1:
The patent merges the functions of connection elements and fastening elements into a single integrated joining element. This reduces the total component count and simplifies assembly operations while maintaining all necessary functional capabilities for mechanical connection and fastening
3Strength
If conventional joining methods are used, then mechanical connection between cover layers is achieved, but the ease of manufacture is reduced
Solution Approach 1:
The joining elements are pre-formed with threaded structures and fastening elements before assembly. This preliminary preparation allows for simplified assembly operations and reduces the complexity of the manufacturing process while ensuring strong mechanical connections between cover layers
Data Source
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AI summary
The invention relates to a sandwich component for a vehicle, in particular a land vehicle and/or motor vehicle, comprising a first cover layer, a second cover layer spaced apart from the first cover layer, a core material situated between the first cover layer and the second cover layer, and a plurality of joining elements for producing a mechanical connection between the first cover layer and the second cover layer; the joining elements are situated at least partially between the first cover layer and the second cover layer and/or the joining elements are guided at least partially through the core material, at least one joining element having at least one fastening element by means of which a mechanical connection can be produced or is produced between a structural element and the sandwich component.