Hybrid Metal-Plastic Component Sealing Against Thermal Microcracks
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Solution Overview
Problem
Existing hybrid components with metal conductor tracks overmolded with plastic face issues with inadequate leaktightness due to thermal expansion differences, leading to microcracks and potential leaks or corrosion.
Innovation Solution
The surface of the metal component is processed using a laser to introduce nano- and/or microstructures, followed by mounting a shrink tube or applying a sealing material like an elastomer or varnish, which is then overmolded with plastic, enhancing the interfacial contact and sealing effect.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the metal component surface is left unprocessed, then the manufacturing process is simpler, but microcracks arise between plastic and metal due to different coefficients of expansion
Solution Approach 1:
The laser processing fundamentally changes the physical parameters of the metal component surface, including surface area, surface roughness, and mechanical interlocking capability. By increasing the surface area and creating microstructures, the laser treatment modifies the interface properties between metal and plastic, enabling the sealing layer to accommodate thermal expansion differences without forming microcracks.
2Reliability
If the metal component surface is processed with laser to increase surface area, then the sealing effect and leaktightness are significantly improved, but the manufacturing process becomes more complex
Solution Approach 1:
Traditional mechanical surface treatment methods (such as machining, grinding, or chemical etching) are replaced with laser technology. The laser beam provides a contactless, highly precise, and controllable method for creating microstructures and increasing surface area. This substitution reduces the need for multiple mechanical processing steps, tool changes, and post-processing operations, thereby simplifying the overall manufacturing process despite the added laser equipment.
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
This process significantly increases the leaktightness and longevity of the seal between the metal and plastic components, minimizing stress concentrations and notch effects while maintaining a homogeneous stress distribution.
Implementation Method 1
processing a surface region (13) of the metal component (11), especially by exposing it to a laser beam, such that nano- and/or microstructures are introduced into that surface region (13)
Implementation Method 2
mounting and shrinking a shrink tube onto the processed surface region of the metal component
Data Source
AI summary
A hybrid component has least one metal component, which has been overmolded with plastic at least in regions. A process for producing the hybrid component comprises processing a surface region of the metal component with a laser beam, and mounting and shrinking a shrink tube onto the processed surface region of the metal component or applying a sealing material to the processed surface region of the metal.