3D Metal-Polymer Lattice Composite for Fluid-Sealed Auto Parts
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Solution Overview
Problem
Existing composite materials used in automotive parts, such as metal-plastic hybrids, face challenges in sealability against fluids, brittleness, and stiffness, limiting their weight reduction and environmental impact benefits.
Innovation Solution
A method involving 3D-printing a metal lattice and introducing a polymer into the lattice structure, optimizing the metal volume percentage and pore diameter to enhance sealability, stiffness, and ductility, while reducing weight by up to 30% and increasing stiffness by 10% compared to solid metal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a 3D-lattice metal structure is used for weight reduction, then weight decreases and design freedom increases, but sealability against fluids deteriorates and brittleness increases
Solution Approach 1:
The patent applies composite materials by combining metal 3D-lattice structure with polymer materials to create a hybrid structure that achieves both weight reduction and improved sealability. The polymer fills the lattice pores to provide fluid sealing while the metal framework maintains structural integrity and stiffness.
2Weight of moving object
If a 3D-lattice metal structure is used for weight reduction, then weight decreases, but local strength and ductility deteriorate
Solution Approach 1:
The composite structure combines the high strength-to-weight ratio of metal lattices with the ductility and toughness of polymers. The polymer matrix distributes and absorbs local stresses, preventing stress concentration at lattice nodes and improving overall local strength and ductility.
3Force
If metal volume percentage is increased to improve stiffness, then stiffness increases, but weight reduction benefit decreases
Solution Approach 1:
The patent optimizes the metal volume percentage parameter within specific ranges (10-80 vol.%, preferably 20-65 vol.%, most preferably 30-60 vol.%) to achieve the best balance between stiffness and weight reduction. This parameter optimization allows maximum weight savings while maintaining required structural stiffness.
Data Source
AI summary
The present disclosure relates to a method of producing a compound material comprising at least one metal and at least one polymer, a compound material comprising at least one metal and at least one polymer, comprising a 3D-lattice of the at least one metal and a polymer introduced into the 3D-lattice, a component for a vehicle comprising the compound material and a vehicle comprising the component.