Beam-Node Adhesive Assembly for Stronger Lightweight Joints
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Solution Overview
Problem
Traditional methods for joining beams and nodes in automotive vehicle structures, such as welding, bolting, and adhesive bonding, are time-consuming, costly, and may not provide sufficient strength and durability, while also adding weight and impacting fuel efficiency.
Innovation Solution
A method and assembly for manufacturing a joined assembly of beams and nodes, involving fitting and datuming the components with apertures, using a mechanical fastener to temporarily hold them in place, and injecting a structural adhesive into a cylindrical interface between the beam and node, which cures to form a strong bond.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding or bolting is used to join beams and nodes, then joint strength is achieved, but manufacturing time and cost increase
Solution Approach 1:
The patent replaces traditional mechanical joining methods (welding, bolting) with adhesive bonding. The adhesive is injected into the cylindrical interface between beam and node, cured to form a strong bond, eliminating the need for welding or bolting operations. This substitution reduces manufacturing time and cost while maintaining joint strength.
2Loss of time
If adhesive bonding is used to join beams and nodes, then manufacturing time is reduced, but joint strength and durability may be insufficient
Solution Approach 1:
The patent applies preliminary action by pre-coating the beam and node surfaces with adhesive before assembly. The surfaces are prepared in advance with adhesive coating, ensuring proper bonding when components are joined. This preliminary preparation ensures sufficient joint strength and durability while maintaining the time efficiency of adhesive bonding.
3Strength
If traditional joining methods are used, then joint strength is achieved, but vehicle weight increases
Solution Approach 1:
The patent substitutes heavy mechanical fastening systems (welding equipment, bolting hardware) with lightweight adhesive bonding. The adhesive forms strong joints without requiring additional heavy fasteners or structural reinforcements, thereby reducing overall vehicle weight while maintaining joint strength.
4Strength
If traditional joining methods are used, then joint strength is achieved, but additional coating and paint shop processes are required
Solution Approach 1:
The patent merges the joining function and coating function into a single adhesive bonding process. The adhesive serves dual purposes: it provides structural joint strength and simultaneously acts as a protective coating that eliminates the need for separate painting or coating operations. This consolidation reduces process complexity and eliminates additional manufacturing steps.
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 provides a cost-effective and efficient way to achieve strong and durable joints between beams and nodes, reducing weight and improving fuel efficiency, while eliminating the need for post-joining coatings and paint shop processes.
Implementation Method 1
final joining of the beam and the node by curing the structural adhesive
Data Source
AI summary
An assembly and a method are provided for manufacturing a joined assembly. A method for manufacturing includes fitting together and datuming a beam and a node, wherein at least one of the beam and the node is formed with an aperture, and wherein a cylindrical interface is formed between the beam and node. Further, the method includes advancing a mechanical fastener through the aperture to temporarily hold the beam and the node in an engagement. Also, the method includes injecting a structural adhesive into the cylindrical interface between the beam and the node. The method includes final joining the beam and the node by curing the structural adhesive.