Steel-Light Metal Side Sill Bonding With an Open Curing Region
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Solution Overview
Problem
Existing methods for producing a side sill for a passenger vehicle body are inefficient and costly, particularly in forming a strong and cost-effective connection between a steel support element and a light metal insert part.
Innovation Solution
A side sill design featuring a steel support element with an open region allowing direct access for heat to cure an adhesive bond seam between the steel and a light metal insert part, which is partially surrounded by the steel, enabling a strong and cost-effective connection without costly joining techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the insert part is completely surrounded by the support element, then the structural integrity is improved, but the bond seam cannot be effectively cured by heat or air
Solution Approach 1:
The support element is designed to only partially surround the insert part, leaving an open region that provides just enough access for heat and air to cure the bond seam effectively, rather than completely surrounding it which would prevent curing
2Strength
If costly joining techniques are used, then the connection strength between steel support element and light metal insert part is improved, but the production cost increases
Solution Approach 1:
The patent replaces costly mechanical joining techniques (such as riveting or welding) with a bonding system using adhesive and thermal curing, achieving comparable or superior connection strength at lower production cost
Solution Approach 2:
The patent changes the physical-chemical parameters of the bond seam by using temperature-controlled curing of adhesive, transforming the bonding process from mechanical to thermal-chemical, which reduces production costs while maintaining connection strength
3Device complexity
If the bond seam is not accessible to heat or air, then the structural design is simplified, but the adhesive cannot be cured completely
Solution Approach 1:
The support element provides partial surrounding of the insert part, creating an open region that allows sufficient heat and air access for complete adhesive curing, while maintaining overall structural simplicity
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 bond seam is effectively cured, allowing for a robust and efficient structural connection that absorbs accident energy, reduces production costs, and enhances accident resistance while avoiding costly joining methods.
Implementation Method 1
the bond seam is accessible to heat or air, in particular via the open region, from which heat can be transferred to the bond seam, i.e., to the adhesive, whereby, for example, the bond seam, i.e., the adhesive, can be cured particularly advantageously
Implementation Method 2
the bond seam or the adhesive can be cured particularly advantageously and in particular completely, so that the bond seam has a structural or load-bearing function
Data Source
AI summary
A side sill for a body of a passenger vehicle includes a support element made of steel, and at least one insert part made of a light metal, which is directly bonded to the support element by the formation of at least one bonded seam and is surrounded, at least in part, on the outer peripheral side by the support element. As a result, when the side sill is in the fully manufactured state, the carrier element has an open region in which the insert part is arranged without an overlap with respect to the support element, wherein the bonded seam directly adjoins the open region.