Elastomeric Bonding Interface for Composite-to-Metal Impact Joints
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Solution Overview
Problem
Existing methods for bonding composite and metal materials in haul truck trays lack sufficient shear strength, tensile strength, and flexibility to withstand repeated high-impact shocks, leading to potential detachment and operational safety issues.
Innovation Solution
A system utilizing an elastomeric material to create an adhesive bond between dissimilar or similar materials, such as carbon fiber and steel, by filling the gaps between these materials, thereby enhancing the shear strength, tensile strength, and flexibility of the bonded assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If existing bonding methods are used to join composite and metal materials, then the bonding process is simple, but the shear strength and tensile strength are insufficient to withstand high-impact shocks
Solution Approach 1:
An elastomeric material is introduced as an intermediary substance between the composite material and metal material to create a bonding interface. This elastomeric layer fills gaps and provides mechanical interlocking, significantly enhancing shear strength and tensile strength of the bond while accommodating thermal expansion differences and impact forces between the dissimilar materials.
Solution Approach 2:
The bonding system uses a composite approach by combining the elastomeric material with the composite and metal materials. The elastomeric material acts as a bonding matrix that adheres to both material types, creating a tri-material composite structure that leverages the advantages of each material for superior bond strength and impact resistance.
2Strength
If rigid bonding materials are used, then shear strength is improved, but flexibility and energy absorption capability deteriorate
Solution Approach 1:
The elastomeric material's physical parameters are optimized to achieve a balance between strength and flexibility. By selecting elastomeric materials with specific durometer ranges, elongation properties, and hardness values, the bonding system achieves both high shear strength and the flexibility needed to absorb impact energy and accommodate thermal expansion without rigid fracturing.
3Strength
If gaps between materials are left unfilled, then manufacturing complexity is reduced, but bonding strength and structural integrity deteriorate
Solution Approach 1:
The elastomeric material is applied specifically in the gap regions between the composite and metal materials, providing localized bonding and structural support where needed. This targeted application approach ensures that gaps are filled only in critical areas, maintaining bonding strength while minimizing unnecessary material usage and manufacturing complexity in non-critical regions.
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 elastomeric bonding system significantly improves the shear strength, tensile strength, and flexibility of the bonded materials, ensuring they function as a single unit under high-impact conditions, thereby enhancing the operational efficiency and safety of haul trucks.
Implementation Method 1
an elastomeric material substantially filling at least a portion of the height and length of the gap between the first material and the second material
Implementation Method 2
The elastomeric bonding system significantly improves the shear strength, tensile strength, and flexibility of the bonded materials
Data Source
AI summary
Embodiments herein provides a system for creating an adhesive bond using elastomeric material. The system includes the steps of (i) a first material, the first material having a first material length and a first material width, (ii) a second material, the second material having a second material length and a second material width, (iii) a gap between the first material and the second material, (iv) an elastomeric material substantially filling at least a portion of the height and length of the gap between the first material and the second material. The gap includes a height and a length. The height being substantially equal to a distance between the first material and the second material and the length being substantially orthogonal to the height and defined by a degree of overlap between the first and second materials.