Solid Adhesive Coated Torsion Bar for Vehicle Stabilizer

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Solution Overview

Problem

The existing methods for producing motor vehicle stabilisers with fiber-composite torsion bars and metallic limbs result in extensive adhesive erosion due to liquid adhesives, leading to interruptions and debris issues in production, which are problematic for DIN-certified facilities.

Innovation Solution

A torsion bar coated with a solid adhesive coating and a protective layer, where the adhesive is activated upon partial removal of the protective layer during assembly, eliminating liquid adhesive erosion and enabling a quicker, interruption-free production process. The adhesive coating is preferably a multi-component adhesive activated by mechanical bursting, heat, or solvents, and the protective layer is form-stable, ensuring a secure and clean assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If liquid adhesive is applied during the press-on process, then the adhesive serves as a lubricant and provides corrosion protection, but extensive adhesive erosion occurs that interrupts production and creates debris

Engineering Contradiction:

Improveease of manufactureVSAvoidproductivity

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The adhesive is changed from liquid state to solid state (adhesive coating), fundamentally altering its physical parameter. This eliminates the erosion problem while maintaining the bonding function, as the solid coating does not generate debris during the press-on process

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The adhesive coating is applied and dried in advance before the press-on process. The protective layer is then applied over the adhesive coating. This preliminary preparation eliminates the need for liquid adhesive application during production, preventing erosion and enabling continuous manufacturing

Inventive Principle:

Principle #10Preliminary action

Solution Approach 3:

A protective layer is introduced as an intermediary between the adhesive coating and the external environment. This protective layer prevents damage to the adhesive coating during storage and transport, and is removed or breached during the press-on process to expose the adhesive for bonding

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If liquid adhesive is used to fill material-free space during press-on, then adhesive bond is created, but adhesive erosion generates debris problematic for DIN-certified production

Engineering Contradiction:

ImprovereliabilityVSAvoidadhesive erosion

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The adhesive is transformed from liquid to solid coating form, changing its physical state parameter. This eliminates the harmful erosion effect while preserving the bonding function, as the solid coating remains stable during the press-on process

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The protective layer, which initially seems to add complexity, actually protects the adhesive coating from erosion and damage. During press-on, the protective layer is removed or breached to expose the adhesive, converting the protective function into active bonding function

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 approach prevents debris erosion, allows for DIN-certifiable production, and ensures a secure, form-fitting connection between the torsion bar and stabiliser limbs, resulting in a simpler, more economical, and operationally safer manufacturing process with reduced component weight.

Implementation Method 1

the adhesive component can be activated by means of a mechanical bursting of the microcapsule

Methodology Applied

Scientific EffectMechanical bursting of microcapsules: Fracture Mechanics

Implementation Method 2

the adhesive component can be activated by means of a mechanical bursting of the microcapsule, the input of heat, solvents, and/or moisture

Methodology Applied

Scientific EffectHeat activation: Heating

Implementation Method 3

the adhesive component can be activated by means of a mechanical bursting of the microcapsule, the input of heat, solvents, and/or moisture

Methodology Applied

Scientific EffectSolvent activation: Solvation

Implementation Method 4

the adhesive component can be activated by means of a mechanical bursting of the microcapsule, the input of heat, solvents, and/or moisture

Methodology Applied

Scientific EffectMoisture activation: Absorption (physical)

Data Source

PatentUS11046144B2Torsion bar for a stabiliser of a motor vehicle, and stabiliser and method for producing a stabiliser

Publication Date: 2021.06.29 AUDI AG

AI summary

A torsion bar for a stabiliser of a motor vehicle, on the axial ends of which a respective stabiliser limb can be rotationally fixed. In the region of the axial ends thereof, the torsion bar is coated with an adhesive coating and a protective layer covering the adhesive coating, wherein the adhesive coating is designed as a solid adhesive coating that can be activated after at least partial removal of the protective layer.