Reinforced Structural Element With Multi-Surface Adhesive Bonding
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Solution Overview
Problem
Existing structural elements in vehicles with cavities face challenges in sealing, reinforcing, and damping due to their irregular shapes and narrow sizes, leading to issues with moisture ingress, corrosion, and noise transmission, while existing reinforcement systems lack efficient bonding surfaces.
Innovation Solution
A reinforced structural element system featuring a reinforcing element with side walls extending along a longitudinal axis, fastening elements, and an adhesive that connects the reinforcing element to the structural element, providing a larger bonding surface through a closed surface opposite the fastening element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If reinforcement elements are used to strengthen structural elements with cavities, then the strength and stiffness are improved, but the bonding surface area is insufficient leading to poor connection quality
Solution Approach 1:
The reinforcing element transitions from a conventional 2D plate-like structure to a 3D hollow structural form with multiple side walls extending along a longitudinal axis. This dimensional transformation creates multiple bonding surfaces (first side wall, second side wall, third side wall, and fourth side wall) that can be bonded to the structural element, significantly increasing the total bonding surface area and improving connection quality while maintaining strength enhancement.
Solution Approach 2:
The hollow interior of the reinforcing element allows it to be inserted into and nest within the cavity of the structural element. This nesting arrangement enables the reinforcing element to occupy the cavity space efficiently while providing extensive bonding surfaces along its side walls, solving the contradiction between needing sufficient bonding area and fitting within limited cavity space.
2Reliability
If sealing elements are used to seal cavities, then moisture ingress and corrosion are prevented, but irregular cavity shapes make proper sealing difficult
Solution Approach 1:
The reinforcing element serves multiple functions simultaneously: it reinforces the structural element, seals the cavity through its side walls that contact the cavity surfaces, and provides acoustic insulation. This multi-functionality eliminates the need for separate sealing elements, simplifying the overall system while effectively addressing irregular cavity shapes through the conformal bonding of its four side walls.
Solution Approach 2:
The side walls of the hollow reinforcing element act as flexible bonding surfaces that can conform to irregular cavity geometries. By bonding these side walls to the structural element using adhesive, the system achieves effective sealing of irregularly shaped cavities without requiring complex rigid sealing components.
3Reliability
If cavities are sealed and reinforced, then corrosion and noise transmission are reduced, but the weight increases
Solution Approach 1:
The hollow reinforcing element can be manufactured from composite materials such as fiber-reinforced plastics or aluminum alloys, which provide high strength-to-weight ratios. This allows the element to effectively reinforce the structural component and prevent corrosion while adding minimal weight compared to solid metal reinforcements.
Solution Approach 2:
The hollow thin-walled structure of the reinforcing element provides effective reinforcement and sealing with minimal material usage. The thin walls suffice to prevent corrosion and provide acoustic insulation while keeping the added weight low, unlike solid bulk reinforcements would require.
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
Enhances the connection between the reinforcement and structural elements, improving mechanical stability and noise damping while maintaining lightweight construction.
Implementation Method 1
an adhesive connects the reinforcing element and the structural element, wherein the adhesive connects at least the first side wall and the opposite side wall to the structural element
Data Source
Figure 1a~1b
Figure 2a~4
Figure 5a~5d
AI summary
A device for reinforcing a structural element in a motor vehicle comprises: a reinforcing element with a longitudinal axis, which can be arranged in a cavity of the structural element, wherein the reinforcing element comprises side walls which extend substantially in the direction of the longitudinal axis, wherein a fastening element for pre-fixing the reinforcing element to the structural element is arranged on a first side wall, and wherein a side wall opposite the first side wall has a closed surface for connection with the structural element at a location opposite the fastening element.