Composite Surface Modification for Overmolding Interlock
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Solution Overview
Problem
Composite compression limiters made of polymeric materials with fibre reinforcement, such as glass and carbon fibres, do not chemically bond well with injection molded parts, leading to reduced pull-out force and increased loosening due to environmental extremes, vibration, and impact forces.
Innovation Solution
A process of modifying the surface of composite material base units by impressing surface geometries using a modifying unit, followed by overmolding with injection molded material to mechanically interlock the components, enhancing pull-out strength and resistance to torsional forces and creep.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If composite compression limiters are made of polymeric material with fibre reinforcement, then weight is reduced and load bearing capacity is maintained, but pull-out force is reduced due to lack of chemical bonding with injection molded parts
Solution Approach 1:
The surface geometry is impressed on the composite material base unit before the injection molding process. This preliminary action creates mechanical interlocking features that will engage with the injection molded material, ensuring strong bonding before the actual joining occurs.
Solution Approach 2:
The surface geometry acts as an intermediary between the composite compression limiter and the injection molded part. This intermediate structure provides mechanical interlocking that compensates for the lack of chemical bonding between dissimilar materials.
2Ease of manufacture
If composite material base units replace metal components, then cost and mass are reduced, but resistance to vibration and impact forces is worsened
Solution Approach 1:
The invention uses a composite structure combining the composite material base unit with injection molded material through mechanical interlocking. This composite joining method enhances the reliability of composite components to withstand vibration and impact forces while maintaining cost advantages.
Solution Approach 2:
The surface geometry includes protrusions and depressions that create curved, interlocking surfaces. These geometric features distribute stress more effectively during vibration and impact, improving the reliability of the joint.
3Strength
If surface geometry is impressed on composite material base unit, then pull-out strength is improved through mechanical interlocking, but manufacturing process complexity increases
Solution Approach 1:
The surface geometry impressing step is combined with the existing composite material manufacturing process. The geometry is created during or after composite material formation, merging the surface modification into the overall manufacturing flow rather than adding a completely separate complex process.
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 process significantly increases the pull-out force by up to 4200% and improves torsional resistance and thermal stability, while offering mass and cost savings by replacing metal components in automotive and construction parts.
Implementation Method 1
the surface geometry (203) of the composite material base unit (201) mechanically interlocks the composite material base unit (201) with the injection molded material
Implementation Method 2
heating the composite material base unit (201) to cure the surface (202) by a heating means before pressing, during pressing, after pressing, or combinations thereof
Implementation Method 3
overmolding the surface (202) with at least one surface geometry (203) of the composite material base unit (201) with an injection molded material
Data Source
AI summary
A process of modifying a surface of a composite material base unit includes: providing the composite material base unit; pressing at least one impression module of a modifying unit on the surface of the composite material base unit to form at least one surface geometry on the surface; optionally heating the surface of the composite material base unit by at least one or more of heating before pressing, during pressing, after pressing, or combinations thereof; the composite material base unit contains at least one or more of a resilient material, a covering material, or a combination thereof, the at least one impression module includes at least one protrusion, and/or at least one depression resulting in the surface geometry on the surface. Also herein is a process for preparing an interlocked composite material base unit and a process of utilizing the composite material base unit in automotive and construction.