Adhesive Bonding Recesses for Nested Motor Vehicle Elements
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Solution Overview
Problem
Existing methods for connecting elements in motor vehicles, such as extrusion profiles and castings, are complex and restrictive, particularly when dealing with nested elements, as adhesive beads can be easily displaced during assembly, making it difficult to achieve efficient and cost-effective bonding.
Innovation Solution
Applying adhesive only when the elements are in their intended position, allowing for efficient arrangement and connection of elements with recesses designed to maintain the adhesive in place, enabling the use of various geometries and materials, and using pre-fixing techniques like riveting or welding before adhesive introduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive beads are applied to the first element before assembly, then the elements can be bonded together, but the adhesive bead can be wiped off when the second element is attached, making it no longer in the desired position
Solution Approach 1:
The recess is formed on the first element before assembly, and the adhesive is applied to the recess after the elements are positioned. This preliminary preparation of the recess structure allows the adhesive to be retained in the correct position without being wiped off during assembly, resolving the contradiction between bonding reliability and assembly ease
Solution Approach 2:
The recess acts as an intermediary structure that holds the adhesive in place. By providing this intermediate holding structure, the adhesive is protected from being displaced during the assembly process, ensuring both reliable bonding and easy assembly operations
2Productivity
If adhesive is applied before element arrangement, then bonding can occur, but it is difficult to bond nested elements and the process is time-consuming
Solution Approach 1:
The recess is pre-formed on the first element, but the adhesive is only applied after the elements are arranged in their intended positions. This allows nested elements to be properly positioned first, then the adhesive is applied to bond them, improving both productivity and adaptability to different geometries
Solution Approach 2:
Instead of applying adhesive first and then assembling elements, the method inverts the sequence by positioning elements first and then applying adhesive to the recess. This inversion enables proper bonding of nested elements and reduces assembly time, addressing both productivity and geometry adaptability requirements
3Ease of operation
If each element is individually coated with adhesive before positioning, then bonding can occur, but it requires individual coating of each element which is time-consuming
Solution Approach 1:
Instead of individually coating each element with adhesive, the method merges the coating operation into a single step where adhesive is applied to the recess after all elements are positioned. This combining of operations eliminates the need for separate coating steps for each element, improving ease of operation and reducing total assembly time
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 method simplifies the connection process, allows for universal application across different element geometries and materials, and enhances the tensile load by using optimized recess geometries and adhesives, resulting in a more efficient and cost-effective bonding solution.
Implementation Method 1
an adhesive is introduced into a space between the first element and the second element
Data Source
Figure 1
Figure 2~3
Figure 4a~4c
AI summary
A system of connected elements for a motor vehicle comprises: a first element which has at least one depression on a surface; a second element which is arranged on the first element in such a manner that a surface of the second element and the depression of the first element form a cavity; a filling opening which forms an access to the cavity; and an adhesive which at least partially fills the cavity and thereby adhesively bonds the first element to the second element.