Welded Friction Foil for Secure Workpiece Connection
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Solution Overview
Problem
Existing friction-increasing connecting elements for workpieces face challenges such as cumbersome manual assembly, risk of loss during handling, difficulty in distinguishing the connecting element from metallic components, and adverse effects on non-positive connections due to weld seams, leading to potential security risks and increased costs.
Innovation Solution
A method involving the secure fixation of a metallic foil with hard material particles on its surface, using locally limited weld points for assembly and transport, allowing for automated assembly and reducing the risk of damage, with laser or resistance welding as preferred methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the connecting element is made as a thin metallic foil (approx. 0.1 mm) for space-saving design, then the space requirement and visibility are improved, but the risk of loss during handling and assembly increases
Solution Approach 1:
The connecting element is pre-assembled onto the workpiece before final assembly. This preliminary action ensures the thin foil is already in position and secured, eliminating the risk of loss during subsequent handling and assembly operations.
Solution Approach 2:
Adhesive tape is used as an intermediary substance to temporarily secure the thin metallic foil connecting element to the workpiece. This mediator holds the foil in place during handling and assembly without requiring permanent fixation.
2Ease of operation
If the connecting element is made with protruding lugs or clamping wings for easy identification and manual pre-assembly, then the detectability and ease of operation are improved, but the handling difficulty and damage risk increase
Solution Approach 1:
The protruding lugs or clamping wings are extracted as separate pre-assembly features that are removed or flattened during the final assembly process. This allows the connecting element to be easily identified and handled during pre-assembly, then transformed into a compact form for final installation.
Solution Approach 2:
The connecting element transitions from a static compact form to a dynamic state with protruding features during pre-assembly, then returns to a compact form during final assembly. This dynamic transformation allows easy identification and handling when needed, while maintaining space-saving design when not in use.
3Reliability
If adhesive is used to fix the connecting element to ensure captiveness, then the reliability is improved, but the manufacturing complexity and cleaning requirements increase
Solution Approach 1:
Disposable adhesive tape is used instead of permanent adhesives requiring complex surface preparation. The tape can be applied directly to the connecting element without extensive cleaning or surface treatment, providing sufficient captiveness for the application while simplifying the manufacturing process.
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 solution provides a secure, space-saving, and damage-resistant connecting element with increased coefficient of friction, enabling reliable transmission of transverse forces and torques, and reducing the standard deviation of friction coefficients, thus enhancing process reliability.
Implementation Method 1
laser or resistance welding as preferred methods
Implementation Method 2
laser or resistance welding as preferred methods
Implementation Method 3
The connecting element consists of a spring-elastic foil made of steel, which carries particles of a defined size on its surface... The inherent strength of the film is at least as high as the inherent strength of the workpieces to be joined
Data Source
Figure 1a~1b
Figure 1c~1d
Figure 2a~2b
AI summary
The invention relates to a method for affixing to a metallic work piece a connection element for enabling a friction-increasing, clearance-free, reversible connection of work pieces to be joined, wherein the connection element comprises a metallic film with hard material particles on the joining surfaces thereof, said hard material particles being affixed to the metal film by way of a metallic binding phase, characterized in that the connection element is affixed to the metallic work piece by welding for secure mounting and transport, thereby forming localized welding points. The invention further relates to a component comprising a metallic work piece and a connection element affixed thereto through localized welding points for secure mounting and transport, wherein the connection element enables a friction-increasing, clearance-free, reversible connection of work pieces to be joined and comprises a metallic film with hard material particles on the joining surfaces thereof, said hard material particles being affixed to the metal film by way of a metallic binding phase. The components according to the invention are suitable for positive-fitted, friction-increasing, clearance-free, reversible connection of work pieces to be joined in machine, systems, and vehicle design.