Dashboard Support Embossing for Hybrid Adhesive Bonding
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Solution Overview
Problem
Existing dashboard supports in motor vehicles face challenges in meeting high load requirements while allowing for adhesive connections between support parts and are not suitable for hybrid material compositions, particularly when one part is metal and the other is plastic.
Innovation Solution
A dashboard support design featuring a first support part with an embossing as a negative structure that serves as a contact seat for the second support part, enabling adhesive bonding and reinforcing the connection area, allowing for hybrid material combinations and improved rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a longitudinal cutout is made in one support part to enable connection, then the other support part can be inserted and welded, but adhesive connection between hybrid materials (metal and plastic) becomes impossible
Solution Approach 1:
A connector element made of thermoplastic material serves as an intermediary between the metal first support part and the plastic second support part. The connector is bonded to the metal support part via adhesive in a first bonding operation, then the plastic support part is inserted and bonded to the connector in a second bonding operation, enabling hybrid material connection
Solution Approach 2:
The connection between support parts is segmented into multiple bonding operations: first bonding the connector to the metal support part, then bonding the plastic support part to the connector. This segmentation allows each bonding operation to use material-appropriate adhesives and parameters
2Stability of the object's composition
If support parts are connected using traditional mechanical connectors, then structural integrity is maintained, but hybrid material adhesive bonding is not enabled
Solution Approach 1:
The thermoplastic connector acts as a mediator that interfaces with both metal and plastic support parts through adhesive bonding, replacing traditional mechanical connectors and enabling hybrid material connections while maintaining structural integrity
Solution Approach 2:
The solution employs a composite connection system combining thermoplastic connector material with adhesive materials suitable for both metal and plastic substrates, creating a multi-material assembly that maintains structural integrity across hybrid material interfaces
3Force
If the second support part has larger diameter and thicker wall thickness to withstand loads, then load bearing capacity increases, but manufacturing complexity and cost increase
Solution Approach 1:
The connector element provides localized reinforcement at the bonding interface between support parts, allowing the second support part to maintain standard dimensions while achieving enhanced load bearing capacity through the strengthened connection zone
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
The design enhances rigidity and tolerance compensation, supports hybrid material use, and provides a vibration-reducing effect, while allowing for adhesive connections between support parts.
Implementation Method 1
an embossing which is designed as a negative structure with respect to the first support part (2) and which reinforces this section of the first support part (2) in the manner of a bead
Implementation Method 2
the other support part (3) can immerse its lateral surface (6b) according to the width of the longitudinal cutout (5). The result is that the first support part (2) then rests with the joints of its longitudinal cutout (5) on the lateral surface (6b) of the second support part (3) in its connecting portion (6) and can be welded to it on the outside
Data Source
AI summary
A dashboard support for a motor vehicle with at least two support parts which follow the longitudinal extent of the dashboard support and are arranged to overlap one another with their mutually facing end portions. A first support part, in its overlapping portion, has a contact seat against which the second support part rests with its connecting portion provided by the overlapping arrangement with its lateral surface and is materially bonded to the first support part. The contact seat of the first support part is provided by an embossing which is designed as a negative structure in relation to the first support part.