Adhesive Injection Joint for Vehicle Components
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Solution Overview
Problem
Conventional vehicle manufacturing methods often overlook non-conventional assembly techniques, such as adhesive fixation, due to traditional design approaches, which can limit the adoption of modern manufacturing technologies and customization in electric vehicles.
Innovation Solution
The use of a system and method that injects adhesive into a space between vehicle components, utilizing a joint assembly with a projection and insert to guide adhesive flow, allowing for automated assembly and improved bonding strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional welding fixation is used to join vehicle components, then structural strength and reliability are improved, but vehicle weight increases and assembly complexity increases
Solution Approach 1:
The patent replaces the mechanical welding system with a chemical adhesive bonding system. The adhesive formulation contains reactive groups that form chemical bonds with the substrate surfaces, substituting the mechanical/thermal welding process with a chemical bonding mechanism that achieves similar structural strength without the associated weight penalty of weld joints and filler materials.
Solution Approach 2:
The patent modifies the chemical parameters of the adhesive system by incorporating specific reactive groups (such as epoxy, carboxyl, or amine groups) that enhance bonding strength. By changing the chemical composition and reactivity parameters of the adhesive, the system achieves welding-equivalent strength while maintaining the weight advantages of adhesive bonding.
2Strength
If traditional welding fixation is used to join vehicle components, then structural strength is improved, but assembly time and manufacturing complexity increase
Solution Approach 1:
The patent replaces the multi-step welding process (positioning, clamping, welding, cooling, inspection) with a single-step adhesive bonding process. The adhesive is applied, positioned, and cures in one continuous operation, eliminating the sequential steps required for welding and significantly reducing assembly time while maintaining structural strength.
Solution Approach 2:
The adhesive system allows for preliminary positioning and adjustment during the open-time period before final curing. This enables components to be positioned and repositioned easily during assembly without the time-consuming adjustments required in welding, accelerating the overall assembly process while ensuring proper alignment and bond strength.
3Quantity of substance
If adhesive is injected freely into the joint space, then complete coverage is achieved, but adhesive flows away from the bonding interface reducing efficiency
Solution Approach 1:
The patent introduces a delivery system with flow control features (such as restricted channels, barriers, or controlled release mechanisms) that act as intermediaries between the adhesive reservoir and the bonding interface. These intermediaries regulate adhesive flow, ensuring complete coverage of the joint space while preventing excessive adhesive from flowing away from the bonding interface, thus reducing waste.
Solution Approach 2:
The patent implements spatially varying adhesive delivery characteristics, providing controlled flow in certain regions and restricted flow in other regions. The delivery system is designed with local flow control features that adapt adhesive distribution to the specific geometry of the joint space, ensuring adequate coverage where needed while preventing overflow and waste in other areas.
Data Source
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AI summary
A system for joining vehicle components is disclosed. The system comprises a first component comprising a projection and a second component comprising a hollow interior and an open end. A insert is provided, which is configured to be disposed within the hollow interior to form a cavity between the insert and the open end. The projection of the first component is configured to be received in the cavity and secured within the cavity with adhesive. The second component comprises a hole in a sidewall which is in communication with the cavity, through which adhesive can be introduced into the cavity. A joint between two components is also disclosed, along with a method of joining vehicle components.