Vehicle Sill Profile Assembly With Integrated End Interlock
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Solution Overview
Problem
Existing motor vehicle components, such as sills, require numerous connection points for assembly, making the process complex and costly due to the need for large-area gluing, riveting, or welding of multiple profiles.
Innovation Solution
A motor vehicle component comprising two profiles with a connecting surface, where one profile is positively connected to the other using a separate connecting means, such as adhesive, and a component-integrated connection system, allowing for a simplified and cost-effective joining process by reducing the number of connection points and improving connection quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If large-area gluing, riveting, or welding is used to connect profiles, then connection strength is improved, but the number of connection points and process complexity increase
Solution Approach 1:
The patent combines form-fitting connection and friction-based connection into a single integrated connecting surface. The first profile receives the second profile at an angle (e.g., 45 degrees), creating both geometric interlocking and surface friction simultaneously, eliminating the need for separate connection mechanisms while maintaining high connection strength
Solution Approach 2:
The connecting surface is divided into two functional zones: a form-fitting connection zone that provides geometric interlocking and a friction-based connection zone that provides surface resistance. This segmentation allows each zone to optimize its specific function while working together to achieve strong connections with simplified process
2Reliability
If multiple connection points are used to join profiles, then connection reliability is improved, but manufacturing cost and assembly time increase
Solution Approach 1:
The form-fitting connection design allows the profiles to self-align and self-connect through geometric interlocking at the angled receiving surface. The components guide themselves into proper position during assembly, eliminating the need for multiple precision alignment steps and reducing assembly time while maintaining connection reliability
3Device complexity
If form-fitting connection is used at one end of connecting surface, then number of connecting elements is reduced, but connection quality must be maintained
Solution Approach 1:
The patent changes the connection mechanism from discrete connecting elements to a continuous friction-based connection along the angled surface. By transforming the connection parameter from point-based (rivets/welds) to surface-based (friction), the system reduces the number of connecting elements while maintaining or improving connection quality through distributed stress distribution
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 solution enables a more efficient and cost-effective assembly of motor vehicle components by ensuring a strong, reliable connection over a significant portion of the profiles' length, reducing the need for additional connection means and enhancing bond quality through controlled adhesive distribution and guided movement during assembly.
Implementation Method 1
at least one connecting means, which is preferably a separate element, in addition to the two profiles, for example an adhesive, in order to glue the two connecting surfaces together
Data Source
Figure 1a~1b
Figure 1c~2
Figure 3a~3f
AI summary
A motor vehicle component, in particular a sill, comprising a first profile (1) and a second profile (2), wherein the first profile (1) and the second profile (2) each have a connecting surface (3), wherein the first and the second profile (1, 2) are joined to each other at their connecting surfaces (3) by means of at least one connecting means (4), wherein the first profile and the second profile are positively connected to each other at one end (5) of the connecting surface (3) and a method for manufacturing such a motor vehicle component.