Interlocking Sill Profiles to Reduce Vehicle Joining Points
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Solution Overview
Problem
Existing motor vehicle components, such as sills, require numerous connecting points for bonding, riveting, or welding, making the joining process complex and costly.
Innovation Solution
A motor vehicle component comprising interlocking profiles with a connector member, such as an adhesive or mechanical fastener, that connects the profiles over a significant length, allowing for a simplified and cost-effective joining method by reducing the need for supplemental connections and enhancing the quality of the bond through targeted adhesive application and interlocking mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If profiles are connected using large-area adhesive bonding, riveting, or welding, then the profiles can be reliably joined, but a large number of connecting points are required, increasing complexity and cost
Solution Approach 1:
The connector member integrates multiple connection functions into a single component. It combines mechanical interlocking features (protrusions and recesses) with adhesive bonding surfaces, eliminating the need for separate mechanical fasteners and reducing the number of connecting points while maintaining connection reliability
Solution Approach 2:
The connector member serves multiple functions simultaneously: it provides mechanical interlocking through protrusions and recesses, offers adhesive bonding surfaces for chemical bonding, and creates a unified connection structure. This multi-functionality reduces the overall complexity of the connection system
2Strength
If multiple connecting points are used to join profiles, then the connection is secure, but the manufacturing process becomes more complex and expensive
Solution Approach 1:
The connector member merges mechanical interlocking and adhesive bonding into a single integrated component. The protrusions and recesses provide immediate mechanical strength, while the adhesive bonding surfaces enhance the connection, achieving strong joints with simpler manufacturing processes
Solution Approach 2:
The mechanical interlocking features (protrusions and recesses) are pre-formed during the extrusion process of the connector member itself. This preliminary action ensures proper alignment and provides initial mechanical strength before adhesive bonding, simplifying the overall manufacturing process
3Manufacturing precision
If profiles are connected over a large area, then the bond quality is high, but the number of connecting points increases, reducing production efficiency
Solution Approach 1:
The connector member is segmented into distinct functional zones: mechanical interlocking regions with protrusions and recesses, and adhesive bonding regions with bonding surfaces. This segmentation allows each zone to perform its specific function effectively, maintaining high bond quality while reducing the overall number of connecting points needed
Solution Approach 2:
Different regions of the connector member have different local qualities optimized for specific functions. The protrusions and recesses provide mechanical interlocking in critical areas, while the bonding surfaces provide adhesive attachment in other areas. This local optimization maintains high bond quality with fewer connecting points, improving production efficiency
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 interlocking connection method simplifies the joining process, reduces the number of connecting points, and enhances the bond quality by ensuring a strong and reliable attachment of the profiles over their length, thereby improving the efficiency and cost-effectiveness of motor vehicle component production.
Implementation Method 1
at least one connecting element such as an adhesive, which is preferably a separate element or component relative to the first profile and the second profile, is used to adhesively bond the two connecting surfaces together
Data Source
AI summary
A motor vehicle component, in particular, a sill, and a method for producing such a motor vehicle component. The motor vehicle component includes a first profile having a first connecting surface; a second profile having a second connecting surface that is connected to the first connecting surface; and at least one connector member operable to form, at an end of the first connecting surface and at one end of the second connecting surface, an interlocking connection between the first profile and the second profile.