Welded Ball-Stud Functional Element for High-Strength Component Joining
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Solution Overview
Problem
Existing component connection technologies, such as those described in WO 2012031652 A1, lack versatility and do not provide a high-strength, secure connection method for components with different materials or geometries, particularly when a ball-like fixing element is used.
Innovation Solution
A functional element comprising a plate-like main element with a ball or ball-like element welded to it, featuring an uneven circumferential edge for a strong connection to a first component, allowing for high-strength attachment via pressing, welding, or clinching, and enabling secure clipping or clamping of a second component onto the ball-like element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a ball-like fixing element is used for component connection, then the connection can be achieved with simple geometry, but the connection strength and reliability are insufficient
Solution Approach 1:
The functional element is divided into two distinct parts: a plate-like main element for connection to the first component and a ball-like element for connection to the second component. This segmentation allows each part to be optimized for its specific function, achieving high connection strength without overall structural complexity
Solution Approach 2:
The plate-like main element and ball-like element are merged into a single functional element through welding, creating an integrated component that combines the advantages of both geometries for different connection requirements
2Reliability
If a ball-like element is directly connected to the first component, then the connection is simple, but tilting cannot be prevented and connection reliability is reduced
Solution Approach 1:
The functional element features an asymmetric design with a plate-like main element having an uneven circumferential edge for preventing tilting during pressing, combined with a ball-like element for secure clipping. This asymmetric structure ensures reliable connection by preventing unwanted movements
Solution Approach 2:
The ball-like element provides a curved surface that prevents tilting during clipping operations, as the convex geometry naturally resists angular misalignment and ensures stable connection to the second component
3Adaptability or versatility
If the same connection method is used for all component types, then the process is simple, but versatility across different materials and geometries is limited
Solution Approach 1:
The functional element is designed as a universal connector that can be adapted to different materials (steel, aluminum) and geometries through its dual-geometry design. The plate-like main element can be connected via pressing, welding, or clinching, while the ball-like element accommodates various clipping and clamping configurations
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 solution provides a versatile, high-strength connection method that prevents tilting and achieves high pulling forces, suitable for various materials and geometries, including different materials like steel and aluminum, through a combination of welding, pressing, or clinching, ensuring a secure and reliable assembly.
Implementation Method 1
A functional element according to the invention has a plate-like main element (2) and a ball (3) or a ball-like element which is connected to the main element (2), in particular which is welded onto the main element (2)
Data Source
AI summary
A method is provided for manufacturing a combination of components. The method includes the following steps: manufacturing a functional element by providing a plate-type base element and integrally bonding a ball or a ball-shaped element to the plate-type base element, in particular by welding a ball or a ball-shaped element onto a flat plate-type element, and joining the functional element to a first component.