Hybrid Metal-Plastic Structure Mechanical Interlock
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing hybrid structures face challenges in creating a strong, cost-effective mechanical bond between dissimilar materials, such as metals and plastics, which is crucial for automotive applications where safety and weight reduction are paramount.
Innovation Solution
A hybrid structure is developed where a thermoplastic second component is moulded to encapsulate a pre-formed first component, creating a reinforcing portion within the interior and a locking portion on the exterior, forming a mechanical interlock without adhesives, allowing for complex geometries and weight reduction while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mechanical connection or chemical treatment is used to bond dissimilar materials, then bonding strength is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent replaces complex mechanical connection systems (fasteners, welds) and chemical treatment processes with a simplified mechanical interlocking system. The L-shaped profile with integrated flange and web creates inherent mechanical interlocking with the plastic insert, eliminating the need for separate bonding operations while maintaining strong connections between dissimilar materials.
Solution Approach 2:
The patent employs composite construction by integrating a metal L-shaped profile with a plastic insert to create a hybrid component. This composite approach allows each material to contribute its superior properties (metal for structural strength, plastic for corrosion resistance and complex geometry) while the integrated design simplifies manufacturing compared to traditional multi-step bonding processes.
2Weight of moving object
If hybrid structures with multiple materials are used, then weight is reduced, but bonding reliability between dissimilar materials deteriorates
Solution Approach 1:
The patent implements nesting by placing the plastic insert inside the hollow cavity of the L-shaped profile, with the insert's flange and web interlocking with the profile's corresponding features. This nested configuration creates a reliable mechanical bond between dissimilar materials while maintaining weight reduction benefits, as the integrated structure acts as a unified load-bearing component.
3Ease of manufacture
If traditional bonding methods are used, then manufacturing process is simple, but adaptability to complex geometries deteriorates
Solution Approach 1:
The L-shaped profile is pre-formed with integrated flange and web features designed to mechanically interlock with the plastic insert. This preliminary action of creating the interlocking geometry in the metal component enables subsequent easy integration with the plastic insert through a single molding or assembly operation, achieving both manufacturing simplicity and complex geometry adaptability.
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 solution provides a strong, cost-effective mechanical bond between dissimilar materials, enabling significant weight reduction while maintaining structural integrity and allowing for complex geometries, thus addressing the challenges of bonding in hybrid structures.
Implementation Method 1
a thermoplastic second component moulded to the first component, the second component comprising a reinforcing portion for structurally reinforcement of the first component
Data Source
AI summary
The invention relates to a hybrid structure comprising a first component having a base and an upstanding wall extending from the base, the first component having an interior enclosed between the upstanding wall and the base, and a thermoplastic second component moulded to the first component, the second component comprising a reinforcing portion for structurally reinforcing the first component, the reinforcing portion extending in a longitudinal direction of the first component and located in the interior of the first component, the thermoplastic second component further comprising a locking portion that extends adjacently over at least part of an exterior of the first component, wherein the reinforcing portion and the locking portion are integrally formed, thus interlocking the first component in the thermoplastic second component. The invention relates as well to a method for manufacturing such a hybrid structure, and to a vehicle comprising such a hybrid structure.