Composite Subassembly Bonding via Molded Dimensional Control Features
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Solution Overview
Problem
The existing methods for bonding composite materials in motor vehicle assemblies require tight molding tolerances and complex tooling, leading to laborious and precise processes, which can result in weakening of the structural parts and increased costs due to variability in dimensional tolerance and aesthetic issues.
Innovation Solution
The use of composite molded subassemblies with molded-in dimensional control features, such as cross-car and fore-aft locating features, allows for adjustable bonding interfaces and reduced processing steps, enabling more accurate and repeatable assembly while minimizing fiber stress and improving surface finish.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If tight molding tolerances are used for bonding composite materials, then assembly precision is improved, but device complexity and manufacturing cost increase due to complex tooling and post-molding operations
Solution Approach 1:
Dimensional control features are integrated directly into the molding process itself, performing the dimensional control action beforehand rather than requiring separate post-molding operations. This eliminates the need for complex tooling and surface preparation steps while maintaining tight assembly tolerances.
Solution Approach 2:
The patent combines multiple functions into the molding process: dimensional control features, bonding surfaces, and locating features are all integrated into the molding step. This merging eliminates separate tooling operations and reduces manufacturing complexity while maintaining precision.
2Manufacturing precision
If tight molding tolerances are used for bonding composite materials, then assembly precision is improved, but labor and processing time increase due to laborious handling and precise bonding processes
Solution Approach 1:
The molding process itself performs dimensional control and surface preparation in advance, eliminating the need for laborious post-molding handling and precise manual bonding operations. This reduces processing time while maintaining assembly precision.
Solution Approach 2:
The molding process automatically creates the dimensional control features and bonding surfaces without requiring separate manual operations. The part serves its own dimensional control needs through integrated features, reducing labor requirements.
3Strength
If complex post-molding operations are used for surface preparation and bonding, then bonding strength is improved, but reliability decreases due to fiber stress and potential weakening of structural parts
Solution Approach 1:
The molding process creates optimally prepared bonding surfaces and dimensional control features in advance, eliminating the need for post-molding surface preparation that can induce fiber stress. This maintains bonding strength while preserving structural integrity.
Data Source
AI summary
An assembly of mating subassemblies having dimensional control features for a motor vehicle is provided. The assembly includes a composite molded first subassembly having a first set of molded-in dimensional control features. The assembly also includes an injection molded second subassembly having a second set of molded-in dimensional control features. The first and second sets of dimensional control features are integrally formed on their respective subassemblies to permit contact between the first and second sets of control features when the subassemblies are assembled together.