Motor Vehicle Sill Bonding with Grooved Adhesive Surfaces
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Solution Overview
Problem
Existing methods for producing large-area bonds in motor vehicle components, such as sills, are unreliable due to uneven adhesive distribution, leading to non-crosslinked areas and air pockets, which result in poorer strength properties than predicted by simulations.
Innovation Solution
A motor vehicle component comprising a first and second profile with adhesive surfaces, where at least one profile has grooves on its adhesive surface, ensuring that the adhesive only covers the areas without grooves, thereby avoiding air pockets and ensuring a reproducible bonding network.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If large adhesive surfaces are used to bond profiles together, then the bonding area is increased, but air pockets and non-crosslinked areas occur due to uneven adhesive distribution
Solution Approach 1:
The adhesive surface is segmented into multiple smaller adhesive surfaces by introducing grooves that divide the continuous bonding area into discrete zones. This segmentation prevents air pockets and non-crosslinked areas by ensuring uniform adhesive distribution across each smaller surface, while the collective area of these segmented surfaces maintains the overall bonding area requirement.
2Reliability
If grooves are introduced on adhesive surfaces to prevent air pockets, then bonding reliability is improved, but the continuous adhesive surface is disrupted
Solution Approach 1:
The adhesive surface is segmented into multiple smaller adhesive surfaces by introducing grooves that divide the continuous bonding area into discrete zones. This segmentation prevents air pockets and non-crosslinked areas by ensuring uniform adhesive distribution across each smaller surface, while the collective area of these segmented surfaces maintains the overall bonding area requirement.
3Area of stationary object
If adhesive is applied to large areas, then more bonding surface is available, but manufacturing precision decreases due to uneven adhesive distribution
Solution Approach 1:
The adhesive surface is segmented into multiple smaller adhesive surfaces by introducing grooves that divide the continuous bonding area into discrete zones. This segmentation prevents air pockets and non-crosslinked areas by ensuring uniform adhesive distribution across each smaller surface, while the collective area of these segmented surfaces maintains the overall bonding area requirement.
Solution Approach 2:
Different regions of the adhesive surface are given different properties through the introduction of grooves. The grooved areas prevent adhesive accumulation and air pocket formation, while the non-grooved areas maintain bonding capability. This local differentiation ensures uniform adhesive distribution and consistent bonding quality across the entire adhesive surface.
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 allows for more accurate prediction of operational strength and crash behavior, as the bonding process is more controlled and reliable, reducing the likelihood of air pockets and non-crosslinked areas.
Implementation Method 1
the first and the second profile are glued to one another at their adhesive surfaces by an adhesive
Data Source
Figure 1a~1c
Figure 2~5
Figure 6
AI summary
A motor vehicle component, in particular a sill, comprising a first profile (1) and a second profile (2), wherein the first profile (1) and the second profile (2) each have an adhesive surface (3), wherein the first and the second profile (1, 2) are bonded together at their adhesive surfaces (3) by an adhesive (4), wherein the adhesive surface (3) of the first profile (1) and/or the adhesive surface (3) of the second profile (2) has at least one groove (5), wherein the adhesive (4) completely covers the respective adhesive surface (3) in those areas where no groove (5) is formed and does not cover it in those areas where a groove (5) is formed, and a method for manufacturing such a motor vehicle component.