Torsional welding method applied in the interconnecting of vehicle spoiler components and spoilers obtained using this method

Abstract

The present invention relates to a torsional welding method used for interconnecting spoiler components in the automotive sector. Specifically, it addresses the interconnection of spoiler parts developed to enhance the aerodynamic performance of vehicles by reducing air resistance and controlling the airflow beneath the vehicle. The method ensures high strength, applicability to sensitive surfaces, and prevents the occurrence of visual defects during the interconnection of spoiler components.

Description

[0001] DESCRIPTION

[0002] TORSIONAL WELDING METHOD APPLIED IN THE INTERCONNECTING OF VEHICLE SPOILER COMPONENTS AND SPOILERS OBTAINED USING THIS METHOD

[0003] Technical Field

[0004] The present invention relates to a spoiler assembly and welding method developed to enhance the aerodynamic performance of vehicles in the automotive sector. Specifically, it pertains to a spoiler arrangement and welding method that ensures high strength, applicability to sensitive surfaces, and prevention of visual defects when interconnecting spoiler components, thereby improving vehicle handling by reducing air resistance and controlling airflow beneath the vehicle.

[0005] Prior Art

[0006] Spoiler components are typically aerodynamic additions mounted on sports cars, either on the rear, above or below the windshield, or at the front of the vehicle. Besides serving an aesthetic purpose, they are crucial for enhancing vehicle performance and handling. Spoilers improve vehicle handling by reducing air resistance and controlling the airflow beneath the vehicle. Particularly at high speeds, they apply pressure to the rear of the vehicle, ensuring that the rear wheels maintain a tighter grip on the road. By increasing the vehicle's aerodynamic performance, spoilers achieve lower air resistance, resulting in a better driving experience at higher speeds. The installation of a spoiler component onto a vehicle is accomplished using screws and clips attached to connection points on the support piece.

[0007] A spoiler component consists of two main parts: the aesthetic (shell) and the support (carrier) piece. Due to aesthetic constraints, the connection figures on the rear surface of the aesthetic piece must be minimized. Therefore, connection points are added to the design of the support piece. The installation of the spoiler component onto the vehicle is achieved using screws and clips attached to these connection points on the support piece.

[0008] Currently, spoiler components are manufactured using three different joining methods: Welding (usually Ultrasonic Welding Method), Adhesion (typically with 2K Polyurethane Adhesive), and Hybrid Methods (Chemical + Mechanical joins). When traditional ultrasonic welding is used to join the aesthetic and support pieces, errors are likely to occur on painted surfaces. Additionally, because welding is performed in a vertical direction, the material thickness of the parts must be substantial.

[0009] In spoiler components, polyurethane adhesives and welding methods are used to join the aesthetic and support pieces. The welding method is expected to secure the two parts together without deviating from the designated points, avoid visual surface defects during welding, and prevent the two parts from separating.

[0010] Patent application TR 2018 / 09584 - EP13729253.8 titled "Rear Spoiler Arrangement for a Vehicle" relates to a rear spoiler arrangement for a vehicle with at least one rear door. The mentioned rear spoiler arrangement includes at least one side spoiler equipped with at least one side air directing element that can be adjusted between a driving position, where the contours are extended to aerodynamically direct air, and a base position when the rear door is open. According to the invention, the side spoiler in this case includes a swing element that allows the mentioned element to be fixed to the rear door in a pivotable manner, a side air directing element is hung on the swing element in a pivotable manner via at least one second pivot joint, and the front end region of the side air directing element includes a locking element designed to fix and lock the mentioned element in a releasable manner on the commercial vehicle.

[0011] In the production of spoiler components, using the well-known ultrasonic welding method to join the aesthetic and support pieces has a high probability of encountering errors on painted surfaces. Moreover, because welding is performed in a vertical direction, the material thickness of the parts must be substantial. Excessive material thickness is a negative factor that increases both cost and vehicle weight. In this context, using torsional welding instead of ultrasonic welding for joining the aesthetic and support pieces offers significant advantages.

[0012] Due to the frequent occurrence of low strength and visual defects in the aforementioned joining methods, there is a necessity to develop a new method in this field. Upon examining the application related to the known state of the art and the existing requirements mentioned above, the inventor has developed a new method to interconnect spoiler components used in vehicles. This method ensures high strength, applicability to sensitive surfaces, and prevents visual defects.

[0013] Brief Description of the Invention

[0014] The primary purpose of the invention is to ensure the interconnection of spoiler components (aesthetic and support pieces) with high strength using a torsional welding method.

[0015] Another purpose of the invention is to enable its application to sensitive surfaces.

[0016] A further purpose of the invention is to reduce the material thickness of the parts, as the distribution of energy on the surface increases.

[0017] Additionally, the invention aims to provide an environmentally and human health-friendly structure by reducing the weight of the parts, thereby decreasing the emission of harmful substances such as carbon into the environment.

[0018] Another purpose of the invention is to prevent the formation of visual surface defects.

[0019] To achieve the aforementioned purposes, the invention relates to the interconnection of the aesthetic piece and the support piece, which are the main components of spoilers used in vehicles within the automotive sector, by applying a torsional welding method through torsional welding areas created on the surface of the aforementioned support piece.

[0020] To realize all the advantages understood from the above and the detailed description below, the current invention brings numerous conveniences in terms of the mentioned features.

[0021] The structural and characteristic features and all advantages of the invention will be more clearly understood through the detailed description provided with reference to the figures below. Therefore, the evaluation should also consider these figures and detailed explanations. Brief Description of the Drawings

[0022] Figure la is a perspective view of a region related to the torsional welding application of the aesthetic and support pieces.

[0023] Figure lb is a cross-sectional view of a region related to the torsional welding application of the aesthetic and support pieces.

[0024] Reference numerals

[0025] 1. Aesthetic piece (shell)

[0026] 2. Support piece (carrier)

[0027] 3. Torsional welding region

[0028] Detailed description of the invention

[0029] The present detailed description explains the "torsional welding method used for interconnecting vehicle spoiler components" to enhance the understanding of the subject matter without imposing any limiting effects.

[0030] In the current technology, spoilers used in vehicles within the automotive sector consist of an aesthetic piece (1), namely the shell, and a support piece (2), the carrier. Due to aesthetic constraints, the connection features on the rear surface of the aesthetic piece (1) must be kept to a minimum. Therefore, connection points are added to the design of the support piece (2). The installation of the spoiler component onto the vehicle is accomplished using screws and clips attached to these connection points on the support piece (2). Ultrasonic welding methods are employed to join the aesthetic piece (1) and the support piece (2).

[0031] In the torsional welding method, which is the subject of the invention, as shown in Figure la, a torsional welding region (3) is created on the surface of the mentioned support piece (2) to interconnect the aesthetic piece (1) and the support piece (2). The torsional welding method is a high-frequency friction welding process. Vibrations are transmitted tangentially; the sonotrode moves the support piece (2) circularly relative to the aesthetic piece (1) located below it. With a high vibration frequency of 30-50 kHz and welding pressure, a molten layer is formed between the parts to be joined. The torsional welding method is suitable for welding plastics and metals. The accessibility of the system is very good, and it provides short cycle times because the feeding movement of the welding system is limited to the Z-axis, as shown in Figure la.

[0032] Due to the tangential movement of the upper connecting piece, the support piece (2), the lower connecting piece, the aesthetic piece (1), is subjected to almost no stress. Therefore, this method is particularly suitable for applications where additional vibrations near the ultrasonic welding area pose a risk of damage and are therefore undesirable. When traditional ultrasonic welding is used, there is a higher probability of encountering errors on painted surfaces. Additionally, because welding is performed in a vertical direction, the material thickness of the parts is greater compared to the torsional welding method.

[0033] The invention subject to the torsional welding method can prevent visual defects. Compared to the ultrasonic welding method, a stronger joint can be achieved in terms of strength. On the other hand, since the distribution of energy on the surface is greater, it is possible to reduce the material thickness of the parts. Consequently, as the material thickness decreases, the weight of the parts is reduced, leading to vehicle weight reduction and a decrease in the emission of harmful substances such as carbon into the environment.

Claims

CLAIMS1. A torsional welding method for interconnecting spoiler components used in vehicles within the automotive sector, characterized by applying the torsional welding method through torsional welding regions (3) created on the surface of the support piece (2), thereby ensuring the interconnection of the aesthetic piece (1) and the support piece (2).

2. The torsional welding method according to claim 1, characterized by comprising the steps of:• Applying tangential vibrations from the torsional welding region (3) created on the surface of the support piece (2),• Moving the support piece (2) circularly relative to the aesthetic piece (1) by actuating the sonotrode located above the support piece (2),• Forming a molten layer between the said support piece (2) and the said aesthetic piece (1),• Interconnecting the aesthetic piece (1) and the support piece (2).

3. A spoiler characterized by the interconnection of at least one aesthetic piece (1) and at least one support piece (2) being achieved by a torsional welding method applied through torsional welding regions (3) created on the surface of the support piece (2).

4. The spoiler according to claim 3, characterized by comprising at least one aesthetic piece (1) and at least one support piece (2) interconnected by the torsional welding method.

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