Hybrid joining method applied in the interconnecting of vehicle spoiler components and spoilers obtained using this method

Abstract

The invention relates to a spoiler arrangement and hybrid joining method developed for the automotive sector, which interconnects spoiler components designed to enhance a vehicle's aerodynamic performance by reducing air resistance and controlling airflow beneath the vehicle to provide better handling, while increasing strength, reducing costs, and maintaining the stability of the parts during the curing process.

Description

[0001] DESCRIPTION

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

[0003] Technical Field

[0004] The invention relates to a spoiler arrangement and hybrid joining method developed for the automotive sector, which interconnects spoiler components designed to enhance a vehicle's aerodynamic performance by reducing air resistance and controlling airflow beneath the vehicle to provide better handling, while increasing strength, reducing costs, and maintaining the stability of the parts during the curing process.

[0005] Prior Art

[0006] Spoiler components are typically aerodynamic additional parts 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 features on the rear surface of the aesthetic piece must be kept to a minimum. 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. 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).

[0008] In the hybrid method used in the current technology, typically a 2-component Polyurethane adhesive consisting of two different components is used. Under normal conditions, the 2K adhesive has a curing time of approximately 45-60 minutes. During this time, the chemistry of the adhesive causes a phase separation between the two components. To prevent this separation, the 2K adhesive can be cured in a short time of 2-3 minutes using the "cure on demand" method with UV light.

[0009] UV curing is a process in which high-intensity ultraviolet light is used to instantly cure and dry coatings and adhesives. UV curing can be adapted to coating, printing, decoration, and the assembly of various products and materials. It can also be used outside the automotive industry in fields such as cosmetics, food, science, pharmaceuticals, medical, education, and art. Ultraviolet curing is a high-speed process. The curing process is carried out by polymerization rather than evaporation. The main advantage of UV curing lies in the speed it adds to production. By accelerating production, the time required for dust or other particles in the air to come into contact with the material is reduced, thereby significantly decreasing defects and errors. At this point, the quality of the finished product increases and provides more consistency. However, the biggest disadvantage of the mentioned method is the relatively high investment costs.

[0010] Patent application TR 2019 / 17673 - EP16717215.4 titled "Load-Resistant Spoiler Mechanism for a Vehicle" relates to a spoiler mechanism intended for a vehicle, which includes a spoiler with a folded position and first and second positioned positions. An actuator is configured to move the spoilers from the folded position and the first and second positioned positions in response to a command. A multi-connected arrangement is interconnected via pivot points. The multi-connected arrangement is functionally connected to the spoilers. In the first positioned position, at least three pivot points are aligned with each other in a plane, providing a geometrically locked first position. In the second positioned position, a connection of the multi-connected arrangement is leaned against another structure, providing a geometrically locked second position. Due to the low strength, high cost, and frequent occurrence of visual defects in the aforementioned joining methods, there is a necessity to develop a new method in this field.

[0011] 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, low cost, and maintains the stability of the parts during the curing process.

[0012] Brief Descrition Of The Invention

[0013] The primary purpose of the invention is to ensure the interconnection of spoiler components with high strength.

[0014] Another purpose of the invention is to provide both chemical and mechanical bonding of the parts.

[0015] A further purpose of the invention is to reduce investment costs.

[0016] Another purpose of the invention is to maintain the stability of the parts.

[0017] Another purpose of the invention is to eliminate the need for additional products such as fixtures and molds that ensure the stability of the parts.

[0018] To achieve the aforementioned purposes, the invention relates to a hybrid joining method developed for the automotive sector, specifically for interconnecting the aesthetic and support pieces, which are the main components of spoilers used in vehicles. This method involves applying adhesive from the PUR adhesive region created on the surface of the aforementioned aesthetic piece and performing welding through the ultrasonic welding region.

[0019] In order to realize all the advantages understood from the above and the detailed description below, the present invention brings numerous conveniences in terms of the mentioned features. 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 be conducted taking into account these figures and detailed explanations.

[0020] Brief description of the drawings

[0021] Figure la is a perspective view of a region related to the ultrasonic welding application of the aesthetic and support pieces.

[0022] Figure lb is a cross-sectional view of a region related to the ultrasonic welding application of the aesthetic and support pieces.

[0023] Figure lc is a view of the adhesive region.

[0024] Figure Id is a cross-sectional view of the adhesive and ultrasonic welding regions.

[0025] Reference numerals

[0026] 1. Aesthetic piece (shell)

[0027] 2. Support piece (carrier)

[0028] 3. Ultrasonic welding region

[0029] 4. PUR adhesive region

[0030] Detailed description of the Invention

[0031] The present detailed description explains the "hybrid joining method used for interconnecting vehicle spoiler components" to enhance the understanding of the subject matter without imposing any limiting effects.

[0032] 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). Various methods are employed to interconnect the aesthetic piece (1) and the support piece (2).

[0033] The subject of the invention, the hybrid joining method, encompasses both adhesive and ultrasonic welding processes. As shown in Figure Id, the aesthetic piece (1) and the support piece (2) are first interconnected using the adhesive method. The 2K adhesive used in the adhesive process is applied to the PUR adhesive region (4) created on the surface of the aesthetic piece (1), as seen in Figure lc, thereby bonding the two pieces together. Under normal conditions, the 2K adhesive has a curing time of approximately 45-60 minutes. During this time, the chemistry of the adhesive causes phase separation between the two components.

[0034] In the current technology, the 2K adhesive can be cured in a short time of 2-3 minutes using the "cure on demand" method with UV light; however, the investment costs for this system are very high. To reduce these costs and maintain the stability of the parts during the curing process, the present invention utilizes welding technology after the adhesive process.

[0035] As shown in Figures la and lb, an ultrasonic welding region (3) is created to interconnect the aesthetic piece (1) and the support piece (2). After applying the adhesive to the PUR adhesive region (4), welding technology is used to prevent phase separation between the two components due to the chemistry of the adhesive, ensure proper referencing of the components, and maintain dimensional stability. Additionally, the welding technology provides a mechanical connection.

[0036] In alternative applications of the invention, before using the PUR adhesive, plasma technology is applied to the surfaces where the adhesive will be applied to enhance the adhesion of the adhesive to the surface. This aims to increase the surface energy of the adhesive application areas, ensuring better adhesion without using the adhesive.

[0037] With the aforementioned hybrid joining method, the interconnection of the parts is achieved both mechanically and chemically with high strength, without the need for high- cost curing methods or additional investment costs such as fixtures and molds that ensure the stability of the parts after the adhesive process.

Claims

CLAIMS1. A hybrid joining method for interconnecting the aesthetic piece (1) and the support piece (2), which are the main components of spoilers used in vehicles within the automotive sector, characterized by applying adhesive to the PUR adhesive region (4) created on the surface of the aesthetic piece (1) and performing a welding method on the ultrasonic welding region (3).

2. The hybrid joining method according to claim 1, characterized by comprising the steps of:• Applying adhesive to the PUR adhesive region (4) created on the surface of the aesthetic piece (1),• Performing a welding process through the ultrasonic welding region (3) formed between the aesthetic piece (1) and the support piece (2),• 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) achieved by a hybrid joining method involving adhesive applied to the PUR adhesive region (4) created on the surface of the aesthetic piece (1) and welding applied through the ultrasonic welding region (3).

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 hybrid joining method.

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