Laser Structured Metal-Plastic Composite for Gas-Tight Sealing
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Solution Overview
Problem
Existing composite components with metal and plastic combinations are not reliably gas-tight, especially under temperature and load changes or exposure to media, due to inadequate adhesion between the materials.
Innovation Solution
The surface of one component is structured using electromagnetic radiation to create a nanostructure that overlays a microstructure, enhancing adhesion and achieving a robust, gas-tight connection through partial overmolding, with preferred use of ultra-short pulse lasers and inert gases to prevent oxidation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metallic flat gasket with a laser-structured surface is used to achieve gas-tightness, then initial gas-tightness can be achieved, but the gas-tightness is temporary and fails under temperature and load changes or media influence
Solution Approach 1:
The patent transitions from a single-level microstructure to a hierarchical structure combining microstructure (1-100 μm) and nanostructure (1-100 nm) dimensions. This multi-dimensional surface structuring creates increased surface area and mechanical interlocking capability, enabling stable adhesion of elastomeric material under temperature and load changes
Solution Approach 2:
The patent creates a composite surface structure combining metal substrate, microstructure elements, and nanostructure elements. This composite hierarchical structure provides both mechanical interlocking at the micro level and enhanced surface area for chemical bonding at the nano level, achieving reliable and stable adhesion
2Strength
If electromagnetic radiation is used to structure the surface with nanostructure overlaying microstructure, then adhesion between components is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The surface structure is created in advance using electromagnetic radiation before the actual joining process. The microstructure and nanostructure are pre-formed on the component surface, enabling subsequent elastomeric material application or thermal bonding to achieve strong adhesion without requiring complex real-time processing during assembly
Solution Approach 2:
The patent replaces traditional mechanical surface preparation methods (such as mechanical grinding or chemical etching) with electromagnetic radiation (laser) to create the hierarchical surface structure. This substitution provides more precise control over the microstructure and nanostructure geometry while maintaining adhesion strength
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 approach results in a composite component that maintains gas-tightness and strength even under temperature fluctuations and media exposure, suitable for thermoplastic or thermosetting plastics, and is applicable in various applications such as fuel injection systems and electrical connectors.
Implementation Method 1
structuring the surface of the first component (1) before joining the two components (1, 4) to one another using electromagnetic radiation in such a way that a surface structure (6) results that has a nanostructure (10) in addition to a microstructure (7)
Implementation Method 2
it being further preferred if the surface structure is produced under the influence of a process medium to increase the efficiency and/or for passivation. Process gas, in particular inert gas, is advantageously used in this case. The process gas is very particularly preferably helium or argon, which prevents the formation of an oxide layer on the first component
Data Source
Figure 1~3
AI summary
The invention relates to a component composite (2), in particular for motor vehicle applications, comprising a first component (1) comprising a first contact surface (3) and at least a second component (4) comprising a second contact surface (5) that abuts against the first contact surface (3), wherein the first contact surface (3) has a surface structure (6) that is produced using electromagnetic radiation. According to the invention, the surface structure (6) comprises a microstructure (7) that is overlaid by a nanostructure (10). The invention further relates to a method for manufacturing a component composite (2).