Multi-Material Vehicle Frame With Uncoated Bonding Zones
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Solution Overview
Problem
Current mass production methods for vehicle structural design, primarily relying on stamped metal and spot welding, fail to achieve significant weight reduction necessary for improved fuel economy, as they are limited by material grade and section size.
Innovation Solution
A multi-material assembly method involving a coated high-strength steel frame member with strategically uncoated portions and a dissimilar reinforcement member, bonded using an adhesive, allowing for the integration of materials with different properties to form a lightweight yet strong vehicle frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If stamped metal and spot welding are used for mass production, then manufacturing efficiency is improved, but weight reduction is insufficient
Solution Approach 1:
The patent applies composite materials by combining coated high-strength steel frame members with dissimilar reinforcement members (such as aluminum or plastic) through adhesive bonding. This multi-material approach enables significant weight reduction while maintaining structural integrity, overcoming the limitation of traditional single-material stamped steel construction.
2Reliability
If coating is applied to the frame member, then corrosion resistance is improved, but adhesive bonding is prevented
Solution Approach 1:
The patent applies local quality by providing coating on specific portions of the frame member while leaving other portions uncoated. Specifically, the coating is applied to the outer surface for corrosion protection, but strategic uncoated areas are created at bonding surfaces to enable direct adhesive bonding with reinforcement members. This resolves the contradiction by having different surface treatments in different locations based on functional requirements.
3Strength
If material gauge and section size are increased to achieve performance requirements, then structural strength is improved, but vehicle weight increases
Solution Approach 1:
The patent uses composite materials to achieve high structural strength without increasing weight. By combining coated high-strength steel frame members with dissimilar reinforcement members bonded through adhesives, the assembly achieves enhanced structural performance while the reinforcement members can be made from lighter materials, avoiding the need to increase material gauge or section size.
4Weight of moving object
If dissimilar materials are used for reinforcement, then weight reduction is achieved, but bonding compatibility is reduced
Solution Approach 1:
The patent applies local quality by creating uncoated portions at specific locations where bonding is required. This allows direct adhesive bonding between the steel frame member and dissimilar reinforcement materials without the coating barrier, while other coated portions maintain corrosion protection. The selective coating removal enables bonding compatibility with dissimilar materials.
Solution Approach 2:
The patent uses adhesive as an intermediary substance between the coated frame member and dissimilar reinforcement member. The adhesive bridges the interface between incompatible materials, enabling strong bonding while allowing each material to maintain its inherent properties. This mediator resolves the bonding compatibility issue between dissimilar materials.
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 enables consistent adhesive bonding and increased strength, enabling weight reduction without compromising structural integrity, thus enhancing fuel efficiency by reducing vehicle weight.
Implementation Method 1
an adhesive positioned between the first foot and the first uncoated portion that bonds the reinforcement member to the elongated frame member
Implementation Method 2
The elongated frame member comprises a coated high strength steel stamping. The coating may comprise a metal, a metal alloy, or an e-coating.
Implementation Method 3
hot-stamping the high strength steel blank to form an elongated frame member including a first leg and a second leg
Data Source
AI summary
A multi-material assembly is provided, as well as methods of making a multi-material assembly. The multi-material assembly includes a first coated structural component and a second structural component. The first coated structural component includes a first uncoated portion, and an adhesive is positioned between the second structural component and the first uncoated portion that secures the first coated structural component to the second structural component.