Sandwich Component Manufacturing via Coil-Wound Adhesive Bonding
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Solution Overview
Problem
The existing methods for producing sandwich components in vehicle bodies are inefficient due to the complexity and accuracy requirements of the preparatory work for mechanical forming, which involves multiple steps and can lead to material tearing and increased costs.
Innovation Solution
A method where a layer of adhesive is applied to a cold strip, followed by a functional layer, and then rolled into a coil, allowing for efficient processing without the need for repeated positioning and using existing guide devices, with options for thermal or photoinitiator-activated adhesives for curing, and a carbon-containing adhesive for diffusion bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is applied to flat metal sheets and components are moved and positioned multiple times for common forming, then sandwich components can be produced with high joining strength, but the production process becomes complex and time-consuming
Solution Approach 1:
The adhesive is applied to the metal sheets before they are wound into coils, and the sheets are pre-positioned relative to each other in the coil structure. This preliminary positioning eliminates the need for repeated moving and repositioning during the forming process, reducing production time while maintaining joining strength
Solution Approach 2:
The adhesive application, sheet positioning, and coil winding operations are merged into a single integrated process. By combining these steps, the patent eliminates multiple separate handling operations, thereby improving productivity without compromising the strength of the sandwich component
2Ease of manufacture
If multiple positioning and moving steps are performed to assemble bonded blanks, then sandwich components can be formed, but the risk of material tearing increases
Solution Approach 1:
The metal sheets are pre-assembled into a bonded blank structure while in coil form, with adhesive already applied and sheets pre-positioned. This preliminary assembly in coil form maintains material integrity by avoiding repeated handling and positioning steps that could cause tearing, while still enabling subsequent forming operations
3Manufacturing precision
If flat metal sheets are coated with adhesive and brought into correct relative position multiple times, then sandwich components can be produced, but the number of production steps increases
Solution Approach 1:
The metal sheets are pre-positioned relative to each other with adhesive applied before being wound into coils. This preliminary positioning establishes the correct relative geometry once, and the coil structure maintains this positioning throughout storage and transport, eliminating the need for repeated positioning operations and reducing process complexity while maintaining manufacturing precision
Solution Approach 2:
The adhesive-coated metal sheets are nested together in a specific sequence within the coil structure, with each sheet positioned relative to the others. This nested arrangement in the coil form preserves the correct relative positioning without requiring complex handling equipment or multiple positioning steps during production
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 method simplifies the production process, reduces material handling, and enhances the mechanical forming properties of the sandwich components, achieving high-strength connections and efficient energy use while maintaining rigidity and crash behavior.
Implementation Method 1
a layer of adhesive (8) is applied to a cold strip (1)
Implementation Method 2
the adhesive (8) is a thermally activatable adhesive... the adhesive being heated above the activation temperature of the adhesive
Implementation Method 3
the adhesive additionally contains photoinitiators in a known manner, which decompose into radicals when short-wave light is irradiated
Implementation Method 4
the cold strip (1) connected to the functional layer (14)... is converted into the desired three-dimensional shape of the sandwich component (26) by a known mechanical forming process
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3b
AI summary
The method comprises cooling a cold strip (1) after rolling and recrystallisation annealing, subjecting an adhesive layer on the cooled cold strip, subjecting a function layer (14) on the adhesive layer, rolling the cold strip with the adhesive layer and function layer to a coil and/or rolling the coils and mechanical forming the cold strips with the adhesive layer and function layer to a sandwich component (26). The cold strip is received by cold rolling, recrystallisation annealing and cooling. The adhesive of the adhesive layer is a thermally activatable adhesive. The method comprises cooling a cold strip (1) after rolling and recrystallisation annealing, subjecting an adhesive layer on the cooled cold strip, subjecting a function layer (14) on the adhesive layer, rolling the cold strip with the adhesive layer and function layer to a coil and/or rolling the coils and mechanical forming the cold strips with the adhesive layer and function layer to a sandwich component (26). The cold strip is received by cold rolling, recrystallisation annealing and cooling. The adhesive of the adhesive layer is a thermally activatable adhesive and the cold strip is heated with the function layer subjected on the cold strip before rolling to a coil for hardening the adhesive over activating temperature of the adhesive. The hardening of the adhesive is activated through thermal energy released during forming process in such a way that the function layer is movable during the forming process relative to the cold strip. The adhesive of the adhesive layer is an organic adhesive. The cold strip is subjected with the function layer before rolling to a coil in such a way that carbon contained in the adhesive forms a diffusion layer between the cold strip and the function layer, where the diffusion layer connects the cold strip and the function layer to each other. The cold strip unrolls with the function layer of the coil and a pressure forming process, a deep drawing process or a stretch drawing process is carried out in order to transport the flat cold strop together with the function layer into a spatial form of the sandwich component. The function layer is subjected solely in part section on the first side of the cold strip. The cold strip is equipped on both sides with a layer of adhesive and the function layer is subjected on both sides of the cold strip. The function layer contains stainless steel, aluminum or titanium that overlays after subjecting of the adhesive layer with the cold strip. An independent claim is included for a cold strip coil.