Vehicle Body Bonding with Open Adhesive Channels and Shoulders
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Solution Overview
Problem
Existing methods for bonding body elements in motor vehicles are complex and costly, particularly when dealing with nested elements, as they require fluid-tightly closed spaces and precise production tolerances, making them difficult to handle and produce.
Innovation Solution
A system where a first body element with channels and shoulders is used, allowing an adhesive to be applied partially in the channels and partially on the shoulders, creating an open system that self-seals as the adhesive cools, eliminating the need for sealed spaces and enabling connection of elements with larger production tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If liquid adhesive is injected into a closed chamber to bond nested body elements, then bonding reliability is improved, but device complexity and production cost increase due to requirements for seals and tight tolerances
Solution Approach 1:
The invention extracts the requirement for fluid-tight closed chambers by using open channels on the body element surface. The adhesive is applied directly to these open channels and shoulders, eliminating the need for seals and closed cavity structures while maintaining bonding reliability through the adhesive's ability to self-distribute and self-seal during the bonding process.
Solution Approach 2:
The adhesive performs self-service functions by automatically distributing itself through capillary action in the channels and self-sealing at the shoulder regions without requiring external sealing mechanisms. This self-service capability eliminates the need for complex seal systems and tight tolerance control while ensuring reliable bonding.
2Reliability
If liquid adhesive is injected into a closed chamber to bond nested body elements, then bonding reliability is improved, but manufacturing cost increases due to tight production tolerances and seals
Solution Approach 1:
The invention removes the requirement for fluid-tight closed chambers and seals by using open channels and shoulders on the body element surface. This extraction of the closed chamber requirement eliminates the need for expensive seal components and tight tolerance manufacturing while maintaining bonding reliability through the adhesive's self-distributing and self-sealing properties.
Solution Approach 2:
The invention replaces expensive, precision-machined closed chambers with simple, open channels and shoulders that can be easily manufactured with standard tolerances. These simple geometric features serve as effective adhesive containment and distribution structures without requiring costly manufacturing processes or precision components.
3Ease of operation
If adhesive is applied as beads to bond body elements, then handling is simplified, but bonding capability is reduced for nested elements due to adhesive being scraped off
Solution Approach 1:
The invention segments the adhesive application area into distinct channels and shoulders on the body element surface. This segmentation allows the adhesive to be contained in specific zones where it can be easily applied and will not be scraped off during assembly, while still providing effective bonding for nested elements through the structured channel and shoulder geometry.
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 approach simplifies the bonding process, reduces production costs, and allows for the use of elements with greater tolerances, resulting in a more economical and versatile method for connecting body elements in motor vehicles.
Implementation Method 1
The adhesive is configured such that on cooling, it has a sharp transition between a non-hardened and a hardened state.
Implementation Method 2
The channels are dimensioned such that the adhesive flowing through the channels cools comparatively slowly. This is achieved in particular in that a surface area of the channels is configured so as to be relatively small in comparison with a volume of the channels.
Implementation Method 3
In contrast, in the region between the shoulder and the second body element, the adhesive cools comparatively more quickly. This is achieved in particular in that in this region, a surface area is designed relatively larger in comparison with a volume of this region.
Data Source
AI summary
A system of connected body elements for a motor vehicle includes a first body element and a second body element. The first body element has at least one duct on a surface, wherein a shoulder is formed next to the duct. The system furthermore includes an adhesive which is arranged at least partially in the duct and at least partially on the shoulder and adhesively bonds the first body element to the second body element. A connection region, directly adjoining the shoulder, of the surface of the first body element is free here from adhesive. A first space between shoulder and second body element and a second space between connection region and second body element are open towards each other.