Composite-to-Metal Assembly Locking Mechanism
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Solution Overview
Problem
The existing methods for assembling composite structural parts with metal parts in mass production, such as in the automotive industry, are time-consuming and stressful for the composite parts, leading to uncertainty in durability and mechanical resistance due to stress concentrations.
Innovation Solution
A method involving pre-assembling composite structural parts with metal interface parts using complementary male/female connecting means and locking mechanisms that allow for interlocking and deformation by pressing, ensuring rapid assembly without stressing the composite parts, utilizing a single press stroke to maintain the assembled state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bonding or overmoulding is used to assemble composite structural part to metal interface part, then assembly is achieved, but assembly time is long and durability is uncertain
Solution Approach 1:
The assembly process is segmented into two distinct phases: a pre-assembly phase using complementary male/female connecting means for rapid positioning, and a final welding phase that provides durable connection. This segmentation allows the time-consuming welding to occur only once after quick pre-positioning, resolving the contradiction between speed and reliability.
Solution Approach 2:
The composite structural part and metal interface part are pre-equipped with complementary connecting means (male/female geometry) that enable rapid pre-assembly and positioning before the final welding operation. This preliminary action eliminates the need for time-consuming bonding or overmoulding while ensuring proper alignment for durable welding.
2Ease of manufacture
If conventional assembly methods are used, then assembly is achieved, but stress is applied to composite structural part causing damage
Solution Approach 1:
The metal interface part serves as an intermediary that receives all assembly stresses during pre-assembly and locking operations. The composite structural part only experiences the final welding stress, which is applied through the metal interface rather than directly to the composite material, protecting it from damage while maintaining ease of assembly.
Solution Approach 2:
The complementary male/female connecting means enable preliminary positioning and interlocking of parts without applying stress to the composite structure. The locking means are designed to deform and lock the assembly in place before welding, ensuring the composite part remains unstressed throughout the assembly process.
3Reliability
If locking means are deformed by pressing on composite structural part, then locking is achieved, but composite part is damaged
Solution Approach 1:
The metal interface part acts as an intermediary that absorbs all deformation and locking stresses. The locking means are configured so that pressing forces are applied exclusively to the metal interface part, which deforms to achieve locking while the composite structural part remains completely free from stress and damage.
Solution Approach 2:
The locking means are designed with localized deformation zones concentrated in the metal interface part. The composite structural part is specifically designed to avoid any deformation zones, ensuring that local quality differences protect the composite material while achieving reliable locking through metal deformation.
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 method enables quick and reliable assembly of composite and metal parts without stressing the composite structural parts, ensuring durability and mechanical resistance by using deformable locking means on the metal interface part, allowing for efficient production line assembly.
Implementation Method 1
a locking phase of said interlocking by deformation by pressing at least part of the locking means pre-equipping the interface part metallic
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
The method involves pre-assembling a composite structure part (1) and a metal interface part (2) by interlocking assembling male/female mating connectors such as tabs (41), lumens (42), studs (51), and matching apertures (52). The interlock is locked by deformation and pressing a portion of connection locks pre-equipping the metal part. The locks are passed from uncoupled condition to coupled condition corresponding to an active locking position, by deformation and simple pressing from a simple press stroke, during assembled condition of the parts by the mating connectors. The locks are lumen (61) and locking tabs (62). The composite structure part is a basin-shaped part forming a spare wheel bin, and the metal structure part is a frame of rolling stock and appears as an elongated body to be positioned along an edge of the basin. An independent claim is also included for an assembly to be elaborated.