Vehicle Seal Assembly With Electromagnetic Adhesive Bonding
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Solution Overview
Problem
Existing seal assemblies for vehicle doors and windows face challenges in bonding elastomeric and plastic materials without mechanical fastening, leading to increased costs and manufacturing time, and often fail to provide a water-tight seal.
Innovation Solution
A seal assembly using an elastomeric seal body with a mounting channel and a thermoplastic molded component bonded by an electromagnetic adhesive, comprising a resin and susceptor that softens upon exposure to electromagnetic energy, allowing direct mounting without mechanical fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mechanical fastening is used to bond elastomeric and plastic materials, then bonding strength is improved, but manufacturing cost and manufacturing time increase
Solution Approach 1:
The patent replaces mechanical fastening systems with an electromagnetic bonding system. The electromagnetic adhesive comprises a resin and a susceptor that, when exposed to electromagnetic energy, generates heat to melt the resin and bond the elastomeric seal body to the plastic molded component. This substitution eliminates the need for mechanical fasteners while achieving strong bonding between dissimilar materials.
Solution Approach 2:
The patent changes the physical state of the adhesive resin from solid to molten and back to solid through controlled heating and cooling. The susceptor absorbs electromagnetic energy, converting it to thermal energy that melts the resin, allowing the molded component to be pressed against the seal body. Upon cooling, the resin solidifies, creating a strong bond. This parameter change enables bonding without mechanical fastening.
2Strength
If mechanical fastening is used to bond elastomeric and plastic materials, then bonding strength is improved, but manufacturing time increases
Solution Approach 1:
The patent replaces time-consuming mechanical fastening operations with rapid electromagnetic bonding. The electromagnetic adhesive system allows for quick heating and bonding cycles, significantly reducing manufacturing time while maintaining strong bonds between the seal body and molded component.
Solution Approach 2:
The patent utilizes the phase transition of the adhesive resin from solid to liquid and back to solid to achieve rapid bonding. The susceptor enables quick heating to melt the resin, the components are pressed together during the molten phase, and rapid cooling solidifies the bond. This phase transition process is much faster than mechanical fastening operations.
3Device complexity
If electromagnetic adhesive with susceptor is used to bond seal body and molded component, then manufacturing cost is reduced, but bonding reliability may be affected
Solution Approach 1:
The patent employs a composite adhesive material consisting of a resin matrix combined with a susceptor material. The resin provides bonding capability while the susceptor enables electromagnetic energy absorption and conversion to heat. This composite structure ensures reliable bonding by combining the adhesive properties of the resin with the thermal generation capabilities of the susceptor, creating a dependable bonding system that is simpler than mechanical fastening.
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 enables cost-effective and time-efficient bonding of elastomeric and thermoplastic materials with a strong, water-tight seal, reducing manufacturing complexity and enhancing security.
Implementation Method 1
an electromagnetic adhesive disposed between the seal body and the molded component. The electromagnetic adhesive is comprised of a resin and a susceptor configured to be energized upon exposure to electromagnetic energy such that the susceptor softens the resin to directly mount the molded component to the seal body
Data Source
AI summary
A seal assembly is adapted to be coupled to a flange of a vehicle. The seal assembly includes a seal body extruded from an elastomeric material and having a base, a first leg, and a second leg collectively defining a mounting channel for receiving the flange of the vehicle. The seal assembly also includes at least one seal feature co-extruded with the seal body, extending from the body, and spaced from the mounting channel. The seal assembly further includes a molded component coupled to the seal body and molded from a thermoplastic material. The seal assembly further includes an electromagnetic adhesive disposed between the seal body and the molded component. The electromagnetic adhesive includes a resin and a susceptor configured to be energized upon exposure to electromagnetic energy such that the susceptor softens the resin to directly mount the molded component to the seal body.