Arcuate Composite Panel Bonding for Vehicle Chassis
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing vehicle chassis structures with composite panels bonded to tubular frameworks face challenges in achieving reliable and strong adhesive bonds, particularly when using 3D digital tube bending methods that result in circular-section tubular elements, where the bond must be along the arc of the tube outer surface, affecting mechanical strength and cost-effectiveness.
Innovation Solution
A vehicle chassis design featuring a framework of interconnected tubular-section metallic members with composite panels adhesively bonded using an arcuate formation integral with the panel's edge, where a layer of adhesive is applied along a partial angular extent of the arcuate section, ensuring a strong and reliable bond by maintaining a controlled spacing and adhesive distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is applied along the complete arc of the tube outer surface, then the bond strength between panel and tube is maximized, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent applies adhesive only along a portion of the arcuate formation rather than the complete arc, achieving sufficient bond strength without the complexity and cost of complete arc bonding. The adhesive is applied to create a bond that is adequate for the structural requirements while simplifying the manufacturing process.
Solution Approach 2:
The arcuate formation is integrated into the composite panel at the edge to match the external profile of the tubular member, creating a localized bonding zone. This local integration allows the panel to conform to the tube shape where needed while maintaining a simpler overall manufacturing approach.
2Strength
If composite panels are made relatively thick to provide required mechanical properties, then the structural integrity is improved, but the weight of the chassis increases
Solution Approach 1:
The patent uses composite panels with arcuate formations that are integrated with tubular members. The composite material provides the required mechanical properties and structural integrity while the arcuate integration with the tubular framework optimizes the weight-strength ratio, creating a lightweight yet rigid chassis structure.
3Ease of manufacture
If 3D digital tube bending methods are used to form circular-section tubular elements, then manufacturing cost is reduced, but the adhesive bond reliability is compromised
Solution Approach 1:
The patent incorporates an arcuate formation in the composite panel that matches the external profile of the circular-section tubular member. This curved integration allows the use of cost-effective 3D digital tube bending methods to create circular tubes while providing a reliable adhesive bonding surface through the arcuate panel feature.
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 design enhances the mechanical strength and reliability of the adhesive bond between the composite panels and tubular members, reducing manufacturing costs while maintaining the lightweight and rigid characteristics of the chassis, with improved crashworthiness and torsional rigidity.
Implementation Method 1
at least one bond between a composite panel and a metallic member is formed by an arcuate formation integral with and extending from an edge of a planar section of the composite panel and fitting around an exterior of the metallic member, and a layer of adhesive along the gap therebetween
Data Source
AI summary
A chassis and a method of forming the chassis comprising assembling a framework of interconnected tubular-section metallic members and a plurality of composite panels, each panel being adhesively bonded to a plurality of the metallic members, wherein at least one bond between a composite panel and a metallic member is formed by an arcuate formation integral with and extending from an edge of a planar section of the composite panel and fitting around an exterior of the metallic member, and providing a layer of adhesive along the gap there between extending substantially from the edge of the planar section across a part of but less than the complete angular extent of the arcuate section.