Multi-Layer Body Panel Bonding With Adhesive Groove Structures
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Solution Overview
Problem
Existing bonding processes for multi-layered components in automotive parts are inefficient, requiring multiple steps, complex machinery, excessive adhesive use, and labor-intensive operations, which affect manufacturing costs and product quality.
Innovation Solution
A bonding process involving pre-machining elements to create grooves for adhesive distribution, using temporary fasteners, and applying adhesive beads that overflow into these grooves to ensure homogeneous bonding, facilitated by simple machinery and tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional bonding processes are used for multi-layered components, then bonding can be achieved, but the process requires multiple steps, complex machinery, excessive adhesive use, and labor-intensive operations
Solution Approach 1:
The patent combines multiple bonding operations into a single multi-layer bonding process where three elements are bonded simultaneously in one operation. The bonding device integrates multiple adhesive application systems and compression mechanisms that work together to bond layers 1, 2, and 3 in a single step, eliminating the need for sequential bonding operations and complex machinery setups.
Solution Approach 2:
The patent applies adhesive to the elements before stacking and bonding them together. Adhesive layers are pre-applied to specific surfaces of the elements, and then the elements are stacked and compressed in a single operation. This preliminary adhesive application simplifies the bonding process by eliminating the need for complex in-process adhesive delivery systems.
2Manufacturing precision
If traditional bonding processes are used, then bonding can be achieved, but excessive adhesive is used and distribution is poor
Solution Approach 1:
The patent applies adhesive selectively to specific local areas of the elements rather than uniformly across entire surfaces. Adhesive is applied to specific bonding zones where contact between layers is required, ensuring precise local adhesion while minimizing overall adhesive consumption. This localized application improves distribution uniformity and reduces waste.
Solution Approach 2:
The patent applies adhesive in controlled amounts that are sufficient for bonding but not excessive. The adhesive quantity is optimized to achieve complete bonding without over-application, which would cause spillage and waste. The bonding pressure and adhesive amount are calibrated to work together efficiently.
3Ease of manufacture
If multiple bonding steps are used, then bonding can be achieved, but the time spent on each step increases manufacturing cost
Solution Approach 1:
The patent merges multiple bonding steps into a single multi-layer bonding operation. Three elements are bonded together in one continuous process step rather than requiring separate bonding operations for each layer interface. This consolidation significantly reduces process time and associated manufacturing costs.
Solution Approach 2:
The bonding process operates continuously in a single operation without interruption between bonding different layer interfaces. The compression and adhesive curing processes occur simultaneously for all layers, maintaining continuous useful action throughout the bonding operation and eliminating idle time between 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
Reduces manufacturing costs and improves adhesive distribution, resulting in higher quality bonded products with fewer steps and less adhesive usage.
Implementation Method 1
at least one bead of adhesive 4 is applied to at least one of said elements 1; 2, 2’, 2’’...; 3, particularly at the level of the aforementioned groove(s) 6; the said glue bead(s) 4 are sufficiently compressed by bringing the elements 1; 2, 2’, 2’’...; 3 to be glued together so that the said glue bead(s) 4 spread out and overflow from the molded, or even machined, groove-type structures 6 and structurally link the two external elements 1 and internal elements 3
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to a method for bonding together at least three panel elements (1, 2, 3), and is characterised in that: - at least one moulding step is carried out before the bonding step or even machining step on at least two of the three elements (1, 2, 3) above, respectively on at least n-1 of the n elements (1, 2, 3) above so as to create at least one machined groove structure (6) into which one or more beads of adhesive (4) can be injected; - at least one bead of adhesive (4) is applied to at least one of the elements (1, 2, 3); - the bead(s) of adhesive (4) are sufficiently crushed by bringing together the elements (1, 2, 3) to be bonded in order to bind the two outer (1) and inner (3) elements and the intermediate element(s) (2) to form the desired structure.