Composite Part Metal Plate Insertion Welding
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Solution Overview
Problem
Composite parts with reinforced fibers and metal plates face insufficient binding forces when connected to metal parts, leading to potential detachment under external forces due to discontinuities at the fiber-metal boundary and damage to adhesive layers.
Innovation Solution
A composite part design featuring a metal plate covered by a reinforced fiber layer with a connecting hole that exposes the metal plate, allowing for increased contact surfaces and improved welding, along with a resin impregnation process to enhance bonding between the metal and fiber layers, thereby increasing the part's resistance to impact forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal plate is affixed to the composite material using adhesive, then the metal plate can be connected to the composite part, but the binding force is insufficient to withstand impact forces due to discontinuity at the fiber-metal boundary
Solution Approach 1:
The patent combines multiple connection methods (adhesive bonding and mechanical insertion) into a unified structure. The metal plate is both adhesively bonded to the composite material and mechanically inserted through the through-hole, creating a hybrid connection that leverages the advantages of both methods to achieve sufficient binding force and impact resistance
Solution Approach 2:
The invention uses a composite connection structure combining adhesive material and metal plate insertion. This composite approach creates a multi-layered connection system where the adhesive provides distributed bonding and the inserted metal plate provides mechanical anchoring, together achieving superior strength and reliability
2Ease of operation
If a welding tab is created by inserting a metal plate into the composite part, then the metal plate can be welded to metal parts, but the adhesive layer may be damaged under external force causing detachment
Solution Approach 1:
The patent divides the connection function into separate zones: the through-hole creates a dedicated welding access path through the composite material, while the adhesive layer provides distributed bonding in surrounding areas. This segmentation allows welding operations to occur through the hole without compromising the adhesive bonding, and the adhesive continues to provide backup binding force even under external loads
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
The design significantly enhances the binding force between the composite and metal parts, preventing detachment under external forces and ensuring a stable connection through increased contact areas and improved welding capabilities.
Implementation Method 1
a resin impregnating the reinforced fiber layer and integrally adhering the first plate and the reinforced fiber layer
Data Source
AI summary
Disclosed is a composite part with an inserted metal plate, the composite part including: a first metal plate; a sheet of reinforced fiber layer folded around the metal plate; a first connection hole disposed in the reinforced fiber layer and exposing a section of the metal plate; and a resin impregnating the reinforced fiber layer and integrally adhering the first plate and the reinforced fiber layer.