Vehicle Frame Joint Adhesive Assembly for Impact Resistance
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Solution Overview
Problem
Vehicle frame joints made of lightweight materials, such as plastics, tend to prematurely disengage during impacts due to their reduced weight, leading to potential structural instability and increased risk of injury to occupants.
Innovation Solution
A frame joint assembly is designed with an adaptor and a cavity connected by multiple adhesive layers and patches, including a first adhesive layer on the adaptor and a second adhesive layer on the cavity, which differ in chemistry, to enhance structural durability and prevent premature disengagement by providing resistance and controlled disengagement forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If lightweight materials such as plastics are used for vehicle frame joints, then weight reduction is achieved, but the joints tend to prematurely disengage during impacts due to reduced weight
Solution Approach 1:
The frame joint assembly uses a composite structure combining lightweight plastic materials with adhesive layers and metal reinforcement elements. The adaptor includes a plastic body with embedded metal inserts that provide anchoring points for adhesives, creating a composite joint that maintains lightweight properties while significantly improving impact resistance and preventing premature disengagement
Solution Approach 2:
The frame joint is divided into separate components: a first frame portion, an adaptor with core and shell, and a second frame portion. This segmentation allows each component to be optimized for its specific function - the plastic body for weight reduction, the metal inserts for strength, and the adhesive layers for bonding - while working together to solve the contradiction between lightweight design and impact resistance
2Strength
If adhesive layers are added to connect frame portions, then structural durability is enhanced, but device complexity increases
Solution Approach 1:
Instead of applying adhesive uniformly across the entire joint surface, the invention applies adhesive layers specifically at critical locations where bonding is most needed - between the adaptor and both frame portions. This localized application provides maximum structural durability while minimizing the overall complexity and number of adhesive layers required
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 significantly reduces the likelihood of premature axial disengagement, enhances structural durability, and minimizes operational noise, ensuring safer and more controlled disengagement of vehicle frame joints during collisions, particularly when using lightweight materials.
Implementation Method 1
an adhesive layer positioned between the adaptor and the cavity when the first frame portion is connected to the second frame portion
Implementation Method 2
provide occupants with relatively greater protection. Frame members are often connected with each other via frame joints, such that one or more of the frame members may be disengaged as needed and desirable during a collision event
Data Source
AI summary
In one or more embodiments, a vehicle frame joint assembly includes a first frame portion including an adaptor, a second frame portion defining a cavity to receive at least a portion of the adaptor, and a first adhesive layer positioned between the adaptor and the cavity when the first frame portion is connected to the second frame portion.