Hierarchical Surface Structure for Durable Gas-Tight Bonding
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Solution Overview
Problem
Existing composite components in motor vehicles, particularly in the engine compartment, face challenges in maintaining high strength and permanent gas-tightness under temperature and load changes, as well as media exposure, due to temporary gas-tightness caused by shrinkage stresses and lack of durable adhesive connections.
Innovation Solution
A composite component is created with a microstructure overlaid by a nanostructure on both contact surfaces, using electromagnetic radiation such as laser processing with ultra-short pulses under inert gas, ensuring strong and tight connections through partial encapsulation and shared thermal expansion coefficients, and optionally using adhesives with adhesion promoters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If macroscopic structures with undercuts are used to enable positive fit with plastic material, then initial gas-tightness can be achieved, but the gas-tightness is temporary and cannot withstand temperature and load changes
Solution Approach 1:
The surface structure is segmented into multiple hierarchical levels: macroscopic structures (10 μm to 1 mm) providing positive fit, microscopic structures (1 μm to 10 μm) increasing surface area, and nanoscopic structures (1 nm to 1 μm) creating chemical bonding sites. This multi-scale segmentation allows each level to contribute differently to the overall connection strength and gas-tightness durability.
Solution Approach 2:
The invention creates a composite surface structure combining multiple length scales and material properties. The hierarchical composite structure integrates mechanical interlocking (macro), physical adsorption (micro), and chemical bonding (nano) mechanisms, resulting in a connection that maintains gas-tightness under varying temperature and load conditions.
2Strength
If adhesive connection is used to connect components, then bonding strength can be improved, but the connection lacks permanent gas-tightness under environmental stress
Solution Approach 1:
The invention merges multiple connection mechanisms into a unified surface structure: mechanical interlocking through macroscopic undercuts, physical adsorption through increased surface area from microstructures, and chemical bonding through nanoscopic structures. This combination creates a connection that is both strong and permanently gas-tight under environmental stress.
Solution Approach 2:
Different regions of the surface structure provide different functions: macroscopic structures provide mechanical interlocking in load-bearing areas, while nanoscopic structures provide chemical bonding sites in areas requiring gas-tightness. This local differentiation of surface properties optimizes both strength and sealing performance.
3Strength
If laser radiation is used to produce surface structure, then connection strength can be enhanced, but the process requires precise control of multiple parameters
Solution Approach 1:
The laser processing uses periodic pulsed radiation to create the hierarchical surface structure. By controlling the pulse frequency, duration, and intensity, the process systematically creates macro, micro, and nano structures in sequence, making the complex structuring process controllable and repeatable.
Solution Approach 2:
The invention utilizes changes in laser parameters (wavelength, pulse duration, power density) to selectively create different structural levels. By adjusting these parameters, the same laser system can produce macroscopic undercuts, microscopic roughness, and nanoscopic features, simplifying the overall process while achieving complex surface morphology.
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 solution achieves reliable and permanent gas-tight connections capable of withstanding temperature and load fluctuations, enhancing the durability and performance of components like fuel injection valves and housing covers by forming strong adhesive forces and chemical sealing.
Implementation Method 1
it is provided that the first contact surface is provided with a surface structure by means of a laser beam
Implementation Method 2
the radiation wavelength of the electromagnetic radiation used, in particular the laser radiation, is selected from a value range between approximately 10 nm and approximately 11 μm
Implementation Method 3
it is further preferred if an ultra-short pulse laser is used for this purpose
Data Source
Figure 1~3
AI summary
The invention relates to a component composite, particularly for motor vehicle applications, comprising a first component (1) having a first contact surface (3), wherein the first contact surface (3) has a surface structure (6) having a microstructure (7) that is superimposed with a nanostructure (10), and at least a second component (4) having a second contact surface (5). According to the invention, a medium, particularly an adhesive layer (12), is arranged between the two contact surfaces (3, 5) of the two components (1, 4) for bonded connection.