Motor Vehicle Tailgate Reinforcement via Crimped Adhesive Bonding
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Solution Overview
Problem
The connection between the three components of a motor vehicle body component, typically a tailgate, is complex and requires simplification, particularly at circumferential opposing edges, where crimped and adhesive connections are used.
Innovation Solution
A vehicle body component comprising an inner, middle, and outer component connected via crimped and adhesive connections, where the components form intermediate spaces for precise positioning and bonding, with the middle component being a die-cast reinforcing element made of light metal, simplifying the assembly process and enhancing structural reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If three components (inner, middle, outer) are connected using both crimped connection and adhesive connection, then connection reliability is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The connection process is segmented into two distinct zones: a crimped connection zone at the end portion of the edge and an adhesive connection zone in the intermediate space. This segmentation allows each connection method to be applied optimally to its suitable location, improving overall reliability while maintaining manageable complexity through functional separation.
Solution Approach 2:
Different connection qualities are applied to different locations: the crimped connection provides mechanical interlocking at the edge end portion, while the adhesive connection provides bonding in the intermediate space. This local differentiation of connection methods optimizes the overall connection reliability without requiring uniform complex connections throughout.
2Reliability
If intermediate spaces are formed and filled with adhesive for bonding three components, then bonding reliability is improved, but manufacturing time and process complexity increase
Solution Approach 1:
The intermediate space is formed in advance during the crimping process itself, before adhesive application. This preliminary formation of the bonding cavity eliminates the need for separate space-creation steps and prepares the structure for immediate adhesive filling, reducing overall manufacturing time while ensuring reliable bonding.
Solution Approach 2:
The crimping process and intermediate space formation are merged into a single operation. The deformation of the edge end portion simultaneously creates the mechanical connection and forms the cavity for adhesive, combining two functions into one process step to reduce total assembly time.
3Weight of moving object
If light metal or light metal alloy is used for components, then weight is reduced, but manufacturing precision and connection reliability may be compromised
Solution Approach 1:
The connection parameters (crimp radius, adhesive amount, intermediate space dimensions) are specifically optimized for light metal materials. By adjusting these parameters, the connection process is adapted to the properties of light metals, ensuring manufacturing precision and connection reliability are maintained despite using lighter materials.
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 configuration simplifies the connection process, ensures reliable bonding, and provides enhanced structural reinforcement by using light metal alloys for the components, allowing for efficient assembly and improved durability of the tailgate.
Implementation Method 1
the inner component or the outer component is crimped at an end portion of an edge to form a cavity or intermediate space
Implementation Method 2
Adhesive is filled in the intermediate space... The three components are connected to one another at their edges by way of a crimped connection and adhesive connection
Data Source
AI summary
A motor vehicle includes a tailgate which has an inner panel, a reinforcing component and an outer panel. The inner component or the outer component is flanged on an end portion, forming a cavity or intermediate space. An adhesive is placed in the intermediate space. An end portion of the non-flanged component is arranged in the intermediate space. An intermediate space is formed between an inner surface of the inner component and an inner surface of the outer component and is filled with adhesive. The end portion of the middle component present in each case is arranged in the intermediate space.