Vehicle Reinforcement Insert Structure for Stronger Adhesive Bonding
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Solution Overview
Problem
Existing reinforcement elements for vehicle structural components lack sufficient mechanical stability, especially in crash-relevant structures, and have limited bonding surface area for adhesives, making them difficult to manufacture and install effectively.
Innovation Solution
A reinforcing element comprising a carrier with elongated openings and insert elements, bonded using different adhesives, where the insert elements are directly bonded to both the carrier and the structural element, providing increased mechanical stability and bonding surface area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If reinforcement elements are used to strengthen structural elements in vehicles, then mechanical stability is improved, but bonding surface area for adhesives is limited
Solution Approach 1:
The reinforcement element is divided into a carrier component and multiple insert elements. The carrier provides the main structural reinforcement, while the insert elements are positioned within elongated openings of the carrier and extend into the structural element. This segmentation increases the total bonding surface area by distributing adhesive application across multiple components (carrier outer surface and insert element surfaces) rather than relying on a single monolithic structure.
Solution Approach 2:
The insert elements are nested within the carrier structure, specifically positioned inside elongated openings of the carrier that extend into the structural element. This nested configuration allows the insert elements to protrude into the structural element while being supported by the carrier, thereby increasing the bonding interface area without significantly increasing the overall volume of the reinforcement element.
2Strength
If reinforcement elements are used to strengthen structural elements in vehicles, then mechanical stability is improved, but manufacturing complexity increases
Solution Approach 1:
The reinforcement element is divided into a carrier component and multiple insert elements. The carrier provides the main structural reinforcement, while the insert elements are positioned within elongated openings of the carrier and extend into the structural element. This segmentation increases the total bonding surface area by distributing adhesive application across multiple components (carrier outer surface and insert element surfaces) rather than relying on a single monolithic structure.
Solution Approach 2:
The insert elements are nested within the carrier structure, specifically positioned inside elongated openings of the carrier that extend into the structural element. This nested configuration allows the insert elements to protrude into the structural element while being supported by the carrier, thereby increasing the bonding interface area without significantly increasing the overall volume of the reinforcement element.
3Strength
If reinforcement elements are used to strengthen structural elements in vehicles, then mechanical stability is improved, but installation difficulty increases
Solution Approach 1:
The reinforcement element is divided into a carrier component and multiple insert elements. The carrier provides the main structural reinforcement, while the insert elements are positioned within elongated openings of the carrier and extend into the structural element. This segmentation increases the total bonding surface area by distributing adhesive application across multiple components (carrier outer surface and insert element surfaces) rather than relying on a single monolithic structure.
Solution Approach 2:
The insert elements are nested within the carrier structure, specifically positioned inside elongated openings of the carrier that extend into the structural element. This nested configuration allows the insert elements to protrude into the structural element while being supported by the carrier, thereby increasing the bonding interface area without significantly increasing the overall volume of the reinforcement element.
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 solution enhances mechanical stability and bonding strength, allowing for improved reinforcement of vehicle structures while being cost-effective and easy to install, with the option to choose materials and adhesives based on specific requirements.
Implementation Method 1
a first adhesive (18), which can be arranged on an outer surface of the carrier and on a first group of first sections of the insert element and which is configured to bond the carrier and the insert element within the structural element
Implementation Method 2
a second adhesive (19), which can be arranged on a second group of first sections of the insert element and which is configured to bond the insert element within the carrier
Data Source
Figure 1~2
Figure 3a~3c
Figure 4~5
AI summary
A reinforcement element for reinforcing structural elements in vehicles comprises, in the first instance, a carrier with a longitudinal axis. The carrier here has at least one elongate opening, which runs in the direction of the longitudinal axis. The reinforcement element also comprises at least one insert element with a longitudinal axis, said insert element being designed to be arranged in the elongate opening of the carrier. The insert element here has a plurality of first portions and a plurality of second portions. The first portions here are located parallel to a first plane, the longitudinal axis of the insert element being located in said first plane. The second portions here are located parallel to a second plane, the longitudinal axis of the insert element being located in the second plane. The reinforcement element also comprises a first adhesive, which can be arranged on an outer side of the carrier, and on a first group of first portions of the insert element, and which is designed to bond the carrier and the insert element adhesively in the structural element. The reinforcement element also comprises a second adhesive, which can be arranged on a second group of first portions of the insert element and which is designed to bond the insert element adhesively in the carrier.