Multi-Layer Composite Unit With Segmented Connecting Elements
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Solution Overview
Problem
Existing multi-layer composite structures face challenges in withstanding large lateral forces and thermal expansion differences between metal and plastic components, leading to distortion, particularly in high-temperature applications and large-area connections.
Innovation Solution
Incorporating separate connecting elements that are positively embedded in the liquid plastic layer and directly connected to the metal component, forming form-fitting 'undercut' connections to resist lateral forces and thermal influences, with the connecting elements being made of sheet metal or metal foil and connected via laser welding, and optionally supplemented with adhesive bonding across large areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mechanical or chemical roughening is used to create form fit or chemical adhesion between metal and plastic, then adhesion strength is improved, but the connection cannot withstand large lateral forces and thermal expansion differences, leading to distortion
Solution Approach 1:
The patent divides the connection system into multiple independent connecting elements distributed across the interface between metal and plastic layers. Each connecting element acts as an independent load-bearing unit, preventing stress concentration and reducing overall distortion while maintaining strong adhesion through distributed bonding points.
Solution Approach 2:
The patent creates a composite connection structure combining metal connecting elements with both plastic and adhesive materials. This multi-material approach leverages the strengths of each material: metal provides structural integrity, plastic provides form-fit connection, and adhesive provides bonding strength, collectively resisting both lateral forces and thermal expansion differences.
2Area of stationary object
If large-area connections are made between metal and plastic layers, then bonding area is increased, but thermal expansion differences cause bimetal effect and distortion in high-temperature ranges
Solution Approach 1:
The patent segments the large-area connection into multiple smaller connecting elements distributed across the bonding interface. This segmentation allows each element to independently accommodate thermal expansion without creating cumulative distortion across the entire assembly, while still providing extensive bonding coverage through the distributed arrangement.
Solution Approach 2:
The patent modifies the connection architecture by introducing discrete connecting elements with specific geometric parameters (spacing, size, distribution pattern) that optimize thermal performance. These parameter changes allow the connection to maintain integrity across temperature ranges by accommodating expansion through the distributed element geometry rather than continuous bonding.
3Stability of the object's composition
If separate connecting elements are added between layers to resist lateral forces, then distortion resistance is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple functions into the connecting elements: they provide mechanical form-fit connection through their geometry, chemical adhesion through adhesive application, and structural reinforcement against lateral forces. This consolidation achieves high distortion resistance without proportionally increasing complexity, as each element performs multiple functions simultaneously.
Solution Approach 2:
The connecting elements are designed as universal components that serve multiple purposes: mechanical anchoring, adhesive substrate, thermal expansion accommodation, and lateral force resistance. This multi-functionality reduces the need for separate specialized components, thereby limiting the increase in overall device complexity while achieving comprehensive distortion resistance.
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 design achieves a robust, distortion-resistant connection that minimizes warping between layers due to thermal expansion differences and mechanical forces, ensuring stability under various loading conditions.
Implementation Method 1
the metal connection element is connected to the metal component on the connection part by a welding process, in particular by laser welding
Implementation Method 2
caused by thermal influences to avoid distortion between the layers
Data Source
Figure 1~4
AI summary
The multilayer composite unit consists of at least one prefabricated component (1) forming a first layer (1) and provided with a distinctive outer surface, and at least one further layer (2) applied to the component (1) in liquid form, preferably made of a flowable plastic, wherein these layers are firmly bonded together. According to the invention, separate connecting elements (3) are provided between the layers (1, 2), on the one hand being positively embedded in the liquid-applied layer (2) and on the other hand being directly connected to the component (1).