Adhesive Cup Insert Fastening for Motor Vehicle Lamps
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Solution Overview
Problem
The existing methods for fastening cup-shaped housings in motor vehicle body openings, such as rear lamps, require complex geometry and large welding lugs to avoid cracking, complicating the design and increasing production difficulties due to the need for sufficient size and sealing.
Innovation Solution
A motor vehicle design featuring a body with body openings where a cup-shaped insert is fastened to a body wall with a peripheral or partially peripheral angled flange, using an adhesive layer and an expandable seal between the flange portion of the cup-shaped insert and the body wall, which simplifies the fastening process and allows for narrow radii, reducing the complexity of the body flange geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a welded connection is used to fasten the cup-shaped housing to the body flange, then the fastening strength is improved, but the device complexity increases due to the requirement of large welding lugs and complicated body flange geometry
Solution Approach 1:
The patent replaces the welded mechanical connection system with an adhesive bonding system. Instead of requiring welding lugs and complex body flange geometry for welding, the invention uses an adhesive layer applied between the cup-shaped insert flange and the body flange, thereby eliminating the need for complicated mechanical fastening features while achieving sufficient fastening strength.
Solution Approach 2:
The invention changes the fastening parameter from mechanical welding (requiring large lugs and complex geometry) to chemical adhesive bonding. This parameter change allows the body flange to have a constant, simplified geometry without large welding lugs, while the adhesive provides the necessary bonding strength through its material properties rather than mechanical interlocking.
2Reliability
If a seal is provided between the cup-shaped housing and the body wall, then the sealing performance is improved, but the manufacturing precision requirements increase due to the need for precise fit and positioning
Solution Approach 1:
The patent changes the sealing approach from requiring precise mechanical fit and positioning to using an expandable seal material that actively adapts to the intermediate space. The seal material's expansion parameter (when heated) compensates for dimensional variations and positioning tolerances, achieving reliable sealing without stringent manufacturing precision requirements.
Solution Approach 2:
The invention introduces a dynamic sealing mechanism where the seal material changes its physical state from a non-expanded to an expanded state in response to temperature changes. This dynamic adaptation allows the seal to automatically adjust to the intermediate space dimensions, maintaining effective sealing despite variations in manufacturing tolerances or assembly positioning.
3Ease of manufacture
If an angled flange portion is used on the cup-shaped insert, then the ease of manufacture is improved by allowing adhesive application, but the fastening area is reduced compared to larger welding lugs
Solution Approach 1:
The patent replaces the mechanical fastening system (relying on large area welding lugs for strength) with an adhesive bonding system. The angled flange portion provides a surface for adhesive application, and the bonding strength comes from the adhesive's chemical bonding capability rather than the mechanical contact area, allowing a smaller fastening area to achieve equivalent or superior fastening strength.
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 simplifies the fastening process of cup-shaped housings, reduces the risk of cracking, and allows for a more streamlined design by using an adhesive and expandable seal, ensuring secure attachment while maintaining design aesthetics.
Implementation Method 1
An adhesive or an adhesive layer is applied between the outer surface of the fastening portion of the flange portion of the cup-shaped insert and the inner surface of the body wall
Implementation Method 2
The seal is advantageously composed of a material which expands from a predetermined temperature T and sealingly fills the intermediate space
Implementation Method 3
An expandable seal is arranged in the intermediate space between the outer surface of the angled flange portion of the cup-shaped insert and the inner surface of the body wall
Data Source
AI summary
A motor vehicle has a body, wherein the body has body openings, in which auxiliary devices such as lamps, turn indicators, or the like are arranged. A body wall surrounds the body opening and has a body flange formed at the particular body opening, to which body wall a cup-shaped insert is fastened, wherein the particular auxiliary device is fastened to the cup-shaped insert. The cup-shaped insert has a peripheral or partially peripheral, bent flange segment having a fastening segment, which extends parallel to an inner surface of the body wall surrounding the body opening. A glue or an adhesive layer is applied between the outer surface of the fastening segment of the flange segment of the cup-shaped insert and the inner surface of the body wall. A seal is arranged in an intermediate space between a flange segment of the cup-shaped insert and the body wall.