Over the last few years bonding has become an established method in the traditional steel-based vehicle construction. Over the years a lot of papers have been presented outlining the advantages which are related to the use of adhesive for structural and semi-structural applications in vehicle body constructions. Mainly single component, thermal crosslinking adhesives based on epoxies, polyurethane and synthetic rubber are in use. The cure takes place together with the cure of the e-coat in existing ovens. Beside hem-flange and anti-flutter applications structural bonding to replace spot welds or in synergy with spot welding have become important. As weight reduction of the vehicle together with improved safety performance and a cost efficient production are nowadays important issues the use of different Materials than steel will increase in the future. It is very likely that the future car will be a hybrid construction of different materials, steel, lightweight alloys e.g. aluminum and plastics. A rather good example illustrating the opportunities of new body concepts is the Chrysler Composite Concept Vehicle (CCV). The body consists of joined to a structural steel perimeter frame that supports the power train and suspension while supplying additional torsional bending strength. The resulting weight of 95 kg is significantly lower than the weight of similar steel-based body which is between app. 150 and 200 kg.
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