Hybrid Vehicle Body Corrosion Prevention via CDC Coating
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Solution Overview
Problem
The challenge in producing a motor vehicle body in a hybrid design is the risk of corrosion and thermal expansion issues when connecting fiber composite components to metallic components, particularly due to the susceptibility of carbon fiber reinforced materials to electrochemical corrosion and differing thermal coefficients, which can lead to rigidity changes and crevice formation.
Innovation Solution
The method involves a cathodic dip coating (CDC) process for the metallic structure frame before connection to the fiber composite floor module, ensuring corrosion resistance and aligning individual parts of the multi-part floor module to compensate for tolerances, allowing for a secure and sealed integration without disassembly, using an integrally bonded, force-fitting, or form-fitting connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If fiber composite components are connected to metallic components, then lightweight hybrid design is achieved, but corrosion occurs due to electrochemical contact
Solution Approach 1:
A corrosion protection layer is applied as an intermediary between the carbon fiber reinforced plastic floor module and the metallic bodyshell structure. This intermediate layer prevents direct electrochemical contact between the dissimilar materials, eliminating galvanic corrosion while maintaining the lightweight hybrid design benefits.
Solution Approach 2:
A thin film corrosion protection layer is applied to the metallic structure frame before connection to the fiber composite floor module. This thin protective barrier provides sufficient corrosion resistance while minimizing additional weight and complexity.
2Weight of moving object
If fiber composite components are connected to metallic components, then hybrid design is achieved, but thermal expansion differences cause rigidity changes and crevice formation
Solution Approach 1:
The metallic structure frame undergoes cathodic dip coating (CDC) treatment before connection to the fiber composite floor module. This preliminary surface treatment not only provides corrosion protection but also creates a controlled interface that accommodates thermal expansion differences, preventing subsequent dimensional instability and crevice formation.
3Reliability
If additional insulation layers are applied to prevent corrosion, then corrosion resistance is improved, but production complexity and cost increase
Solution Approach 1:
The corrosion protection function is merged with the existing cathodic dip coating (CDC) process used for the metallic structure frame. By integrating corrosion protection into the existing surface treatment process rather than adding separate insulation layers, the solution maintains reliability while avoiding increased production complexity and cost.
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 approach prevents corrosion and thermal expansion-related issues, ensuring a durable, sealed, and cost-effective hybrid bodyshell structure with improved tolerance compensation and reduced production complexity.
Implementation Method 1
A layer may be formed on the metallic component by the CDC process
Data Source
AI summary
A method is provided for producing a motor vehicle body in a hybrid design. The motor vehicle body (2) has a bodyshell structure (1) and a floor module (4). The bodyshell structure (1) has a structure frame (3), and the floor module (4) is a fiber composite component. The method includes passing the structure frame (3) through a CDC process before connecting the floor module (4) to the structure frame (3).