Multi-Component Adhesive Assembly to Prevent Air Inclusions
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Solution Overview
Problem
In contemporary automobile construction, the bonding of complex geometries in multi-component assemblies is challenging due to the risk of air inclusions and incomplete bonding, particularly with fibre-reinforced plastics, where traditional cold joining techniques and gluing methods struggle with process reliability.
Innovation Solution
A two-stage adhesive bonding process is employed, where a cavity is formed between components, and adhesive is introduced through strategically positioned openings to create reliable adhesive connections, reducing the risk of air inclusions by forming the first adhesive connection on a side remote from the attachment point and subsequently forming the second connection within the cavity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional gluing methods are used for complex geometries, then bonding can be achieved, but air inclusions and incomplete bonding occur reducing process reliability
Solution Approach 1:
The bonding process is segmented into multiple stages: first bonding two components together, then bonding the third component to the assembly. This segmentation allows air to be systematically removed from each bonding interface separately, preventing air inclusions that would occur if all components were bonded simultaneously.
Solution Approach 2:
The method performs preliminary bonding of the first and second components before bonding the third component. This preliminary action creates a stable base assembly with air already removed from the first interface, enabling subsequent bonding without air inclusion risks.
2Productivity
If multiple components are bonded simultaneously, then assembly time is reduced, but geometrically complex glue seams increase difficulty of process-reliable bonding
Solution Approach 1:
The bonding operation is divided into sequential stages rather than simultaneous execution. The first adhesive connection is created between components 2 and 3, then the second adhesive connection is created between components 1 and 2. This segmentation maintains bonding quality while achieving efficient production through optimized sequencing.
Solution Approach 2:
The method performs preliminary preparation by positioning all three components in their predetermined arrangement before bonding begins. This preliminary action enables the subsequent sequential bonding to proceed efficiently without requiring repositioning or realignment, maintaining high productivity.
3Reliability
If adhesive is introduced through multiple openings, then complete bonding is achieved, but device complexity increases
Solution Approach 1:
The second component serves multiple functions: it provides structural support in the assembly and simultaneously serves as the access point for introducing adhesive into both bonding interfaces. By making the second component multi-functional, the design avoids adding separate access openings while achieving complete bonding.
Solution Approach 2:
The method merges the adhesive introduction function with the structural component function. The second component's opening is used for both introducing adhesive to bond with the first component and introducing adhesive to bond with the third component, combining multiple functions into a single structural element.
Data Source
Figure 1~2
Figure 3a~3f
AI summary
The invention relates to a method for producing an assembly (10') comprising at least three components (11, 12, 13), said method having the steps of: - producing an intermediate assembly (10) from a first component (11), a second component (12) and a third component (13), wherein the three components (11, 12, 13) are arranged in a predefined position relative to each other, - producing a first adhesive connection (19) between the second component (12) and the third component (13), and - producing a second adhesive connection (21) between the first component (11) and the second component (12).