Additive Projections for Metal-Plastic Composite Joints
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Solution Overview
Problem
Existing composite components for motor vehicles with plastic and metal portions face challenges in achieving strong, lightweight, and cost-effective connections with minimal weight and optimal sealing, particularly due to limitations in surface structuring methods like chemical etching or sandblasting which result in poor connection strength and increased weight.
Innovation Solution
The method involves creating projections on a metallic base region using additive manufacturing to anchor a plastic section, allowing for a strong and lightweight composite component with enhanced sealing, where the projections are formed from the same metallic material as the base region, facilitating recycling and integration with fiber-reinforced plastics for improved stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If chemical etching or sandblasting is used to structure the metal surface, then surface area is increased for bonding, but connection strength deteriorates and weight increases
Solution Approach 1:
The projections are created on the metal base region before the plastic section is molded onto it. This preliminary structuring of the surface with three-dimensional projections provides mechanical interlocking features that enhance connection strength without requiring heavy chemical etching or sandblasting processes, thereby avoiding increased component weight.
Solution Approach 2:
Instead of merely increasing surface area through two-dimensional surface texturing (etching or sandblasting), the invention creates three-dimensional projections that extend from the base region. This dimensional transition provides volumetric mechanical interlocking with the plastic, significantly enhancing connection strength without proportionally increasing weight.
2Reliability
If separate connection elements are used to join metal and plastic, then connection reliability is improved, but device complexity increases
Solution Approach 1:
The connection projections are integrated directly into the metal base region as a unified structure, eliminating the need for separate connection elements like clips, fasteners, or additional bonding components. This merging of the base region and connection features into a single piece maintains connection reliability while significantly reducing device complexity.
Solution Approach 2:
The metal base region serves multiple functions simultaneously: it provides structural support, corrosion resistance, and integrated connection features through its projections. This multi-functionality eliminates the need for separate specialized connection elements, reducing overall component complexity while maintaining reliable joining between metal and plastic sections.
3Adaptability or versatility
If different materials are used for base region and projections, then functional properties are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The projections are manufactured from the same metallic material as the base region, allowing both to be produced as a single integrated component through processes like additive manufacturing or stamping. This homogeneity simplifies manufacturing and reduces costs by eliminating material transitions, while the projection geometry itself provides the necessary functional differentiation for connection purposes.
4Area of stationary object
If traditional surface structuring methods are used, then bonding surface area is increased, but manufacturing precision deteriorates
Solution Approach 1:
The projections are formed as precise three-dimensional features during the initial manufacturing of the metal base region, before any bonding or surface treatment processes. This preliminary creation of connection features with exact geometries ensures high manufacturing precision, as the projections serve as built-in registration and alignment elements that guide the plastic molding process with accuracy.
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 enhances connection strength, reduces weight, and enables cost-effective series production of composite components with improved sealing and stability, while preventing galvanic corrosion and allowing for fluid transport through channels formed by the projections.
Implementation Method 1
creating the projections directly on the first base region by way of an additive manufacturing method
Implementation Method 2
the projections provided on the first base region are anchored in the second section in order to bring about the connection between the first section and the second section
Data Source
AI summary
A method for producing a composite component, which has a first section and a second section connected to the first section, the first section including a metallic material, the second section including a plastic, the first section having a first base region and projections provided on the first base region, and the projections provided on the first base region being anchored in the second section in order to bring about the connection between the first section and the second section, includes: manufacturing the first base region of the first section; creating the projections directly on the first base region by way of an additive manufacturing method; and connecting the second section to the first section.