Vehicle Joint Assembly with Expandable Structural Foam

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Solution Overview

Problem

Existing vehicle joint assemblies lack robust mechanical features to accommodate assembly variations, requiring additional mechanical fastening steps to secure components, which can lead to inefficiencies and inconsistencies.

Innovation Solution

A vehicle joint assembly utilizing an expandable material, such as epoxy-based structural foam, within a housing system that expands when heated, securely attaching vehicle components without mechanical fastening by constraining its expansion with ledges and ratchet steps, allowing for secure contact surfaces between components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional mechanical fastening methods are used to secure vehicle components, then assembly robustness is improved, but assembly complexity and time increase

Engineering Contradiction:

Improveassembly robustnessVSAvoidfastening complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces traditional mechanical fastening systems with a thermal expansion-based securing mechanism. The expandable material is injected into a cavity and heated, causing it to expand and mechanically secure the vehicle component through thermal expansion rather than requiring separate mechanical fasteners, thereby reducing fastening complexity while maintaining assembly robustness

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent utilizes changes in the physical state of the expandable material through temperature parameter changes. The material transitions from a low-volume injected state to a high-volume expanded state when heated, enabling the cavity to be filled and the component to be secured without additional mechanical fastening steps

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If additional mechanical fastening steps are added to accommodate assembly variations, then assembly precision is improved, but manufacturing efficiency decreases

Engineering Contradiction:

Improveassembly precisionVSAvoidmanufacturing efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The expandable material performs multiple functions automatically: it fills the cavity, accommodates assembly variations through its expansion, and secures the component all in one operation. The material self-adjusts to accommodate variations in assembly dimensions, eliminating the need for additional fastening steps and improving both precision and efficiency

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent employs phase transition of the expandable material from a liquid or semi-liquid injected state to a solid expanded state through heating. This phase transition enables the material to adapt to assembly variations and secure the component in a single integrated step, improving assembly precision without sacrificing manufacturing efficiency

Inventive Principle:

Principle #36Phase transitions

3Adaptability or versatility

If conventional bushings with mechanical features are used, then adaptability to assembly variations is improved, but mechanical robustness decreases

Engineering Contradiction:

Improveadaptability to assembly variationsVSAvoidmechanical robustness

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The patent uses composite material construction where the expandable material is combined with the housing structure. The expandable material provides both adaptability to assembly variations and mechanical robustness through its expanded state, creating a composite system that achieves both flexibility and strength simultaneously

Inventive Principle:

Principle #40Composite 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 solution eliminates the need for additional mechanical fastening steps, providing a robust and efficient attachment method that ensures consistent assembly by using heat-induced expansion to secure vehicle components, enhancing manufacturing robustness and reducing assembly variability.

Implementation Method 1

The expandable material may be configured to expand when subjected to heat from a paint oven of a vehicle assembly process

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

A temperature of the heat applied to the expandable material may be between 43 degrees Celsius and 205 degrees Celsius

Methodology Applied

Scientific EffectHeating: Heating

Data Source

PatentUS10106204B2Vehicle joint assembly with expandable structural material

Publication Date: 2018.10.23 FORD GLOBAL TECH LLC

AI summary

A vehicle joint assembly may include a lower housing, an upper housing, an expandable material, first and second vehicle components, and a fastener. The lower housing may define a first cavity. The upper housing may define a second cavity and may be sized for partial disposal within the lower housing. The expandable material may be disposed within the second cavity. The first and second vehicle components may each include contact surfaces. The fastener may extend through through-holes defined by the lower and upper housings to secure the first and second vehicle components to one another. Subjecting the expandable material to heat may move the upper housing to contact one of the contact surfaces. The expandable material may be configured to expand when subjected to heat from a paint oven of a vehicle assembly process.