Vehicle Body Reinforcement Member for Electrocoat-Compatible Bonding
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Solution Overview
Problem
The challenge in vehicle body design is to provide structural reinforcement that does not interfere with the electrocoat process, ensuring proper anticorrosion coating on inner surfaces while maintaining structural integrity and preventing corrosion, especially in hollow cross-sectional members.
Innovation Solution
A structural reinforcement member is positioned within the vehicle body's hollow members with a gap between the reinforcement and the inner surface, comprising an outer section, an inner section, and a tension web, where the adhesive expands to fill the gap and bond with the inner surface during the electrocoat process, allowing for effective anticorrosion coating and enhanced structural stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a reinforcement member is inserted into the hollow structural member to provide structural reinforcement, then the structural integrity is improved, but the electrocoat process is blocked and anticorrosion coating cannot be applied to the inner surface
Solution Approach 1:
The reinforcement member is divided into multiple discrete reinforcement elements positioned at specific locations within the hollow structural member, rather than using a single continuous reinforcement. This segmentation allows electrocoat fluid to flow around and coat the inner surfaces between the reinforcement elements, maintaining both structural integrity and coating completeness
Solution Approach 2:
A temporary spacer or positioning fixture is used during the electrocoat process to maintain a gap between the reinforcement member and the inner wall of the hollow structural member. This intermediary element allows the electrocoat fluid to access the inner surface, after which the spacer is removed and the reinforcement member is permanently secured
2Stability of the object's composition
If the reinforcement member is positioned close to the inner surface to maximize structural support, then the structural stability is improved, but the electrocoat fluid cannot reach the inner surface for proper coating
Solution Approach 1:
The reinforcement member is pre-positioned with built-in positioning features such as protrusions or guides that maintain a predetermined optimal distance from the inner wall before the electrocoat process. This preliminary positioning ensures that the electrocoat fluid can uniformly access the inner surface while the reinforcement remains in the optimal location for structural stability
Solution Approach 2:
The distance between the reinforcement member and the inner wall is optimized to a specific parameter range that allows sufficient electrocoat fluid flow while maintaining structural effectiveness. This parameter is controlled through precision manufacturing of the reinforcement member dimensions and positioning features
3Force
If an expandable adhesive is applied to the reinforcement member to bond it to the structural member walls, then the bonding strength is improved, but the adhesive prevents electrocoat application to the inner surface
Solution Approach 1:
The adhesive is applied in a periodic or staged manner: first a preliminary adhesive layer is applied to allow positioning, then the electrocoat process is performed, and finally the adhesive is activated (through heat, pressure, or chemical reaction) to achieve full bonding strength. This periodic application sequence ensures both coating access and bonding performance
Solution Approach 2:
A temporary release film or barrier layer is applied to portions of the reinforcement member that should remain uncoated, allowing the electrocoat fluid to access other areas. The release film is then removed after coating, providing a clean separation between coated and uncoated regions while maintaining bonding integrity
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 solution ensures proper anticorrosion coating on inner surfaces and enhances the structural integrity of the vehicle body by maintaining a gap for the electrocoat process while providing reinforcement through the expansion of the adhesive, thus preventing corrosion and improving structural stability during impacts.
Implementation Method 1
An adhesive is secured to the reinforcement member. The adhesive is activatable to expand toward the inner surface of the structural member to define a joint between the reinforcement member and the structural member and to at least partially fill the gap.
Implementation Method 2
The vehicle body generally undergoes an electrocoat process in which the vehicle body is passed through a bath of anticorrosion fluid whereby an anticorrosion coating is deposited onto the vehicle body by electrolysis.
Data Source
AI summary
A vehicle body includes a structural member having an inner surface defining an elongated cavity. The structural member includes an outer panel member joined to an inner panel member. A tension web secured in the cavity separates the outer and inner panel members. A reinforcement member is positioned in the cavity of the structural member. The reinforcement member contacts the transverse web and a gap is provided between the reinforcement member and the inner surface of the structural member. The reinforcement member including a base member having a plurality of bumpers extended in a width direction of the reinforcement member. The plurality of bumpers face one of the inner surface and the tension web. An adhesive secured to the reinforcement member is activatable to expand toward the inner surface to define a joint between the reinforcement member and the structural member and to at least partially fill the gap.