Mechanical Interlock Over-Molding for Dissimilar Substrate Joining
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Solution Overview
Problem
Current methods for joining dissimilar materials, such as adhesives and mechanical fasteners, are labor-intensive and costly, and do not effectively achieve weight reduction and improved structural properties.
Innovation Solution
A mechanical coupling assembly is created by over-molding a polymeric secondary substrate onto a primary substrate with a mechanical interlock that spans the aperture, featuring a main body and head portion connected by a transition portion, allowing for uniform thickness and alignment, which reduces stress and enhances structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesives or bonding agents are used to join dissimilar materials, then the two components are attached together, but the assembly operation becomes complicated and cost intensive
Solution Approach 1:
The invention divides the joining system into distinct functional elements: a mechanical interlock component with interlocking features and a substrate with corresponding recesses. This segmentation allows each component to perform its specific function independently, eliminating the need for complex adhesive application procedures while maintaining strong joints.
Solution Approach 2:
The invention replaces the chemical bonding mechanism of adhesives with a mechanical interlocking system. The mechanical interlock features physically engage with the substrate recesses, providing a purely mechanical joining method that eliminates the complexity of adhesive application, curing, and quality control while achieving comparable or superior joining strength.
2Strength
If mechanical fasteners such as screws or rivets are used to join dissimilar materials, then the components are attached together, but labor intensive manufacturing techniques are required
Solution Approach 1:
The invention merges the fastening function and the structural component into a single integrated mechanical interlock feature. Instead of using separate fasteners that require assembly operations, the interlocking features are formed as integral parts of the substrate structure, allowing the joining function to be built-in during substrate manufacturing and eliminating subsequent fastening operations.
Solution Approach 2:
The mechanical interlock features and substrate recesses are pre-formed during substrate manufacturing before the actual joining operation. This preliminary action allows the joining components to be ready for immediate engagement, eliminating the need for on-site fastener installation and significantly improving manufacturing efficiency.
3Strength
If traditional joining methods are used, then dissimilar materials are connected, but weight reduction and improved structural properties are not achieved
Solution Approach 1:
The invention utilizes composite construction by combining the mechanical interlock component with the substrate structure to create an integrated joining system. This composite approach allows optimization of each component's material selection and geometry to achieve superior structural properties and weight efficiency compared to traditional joining methods that add separate fastener components.
Data Source
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AI summary
A mechanical coupling assembly (10) that includes a primary substrate (12) having at least one aperture (14) formed therein. A secondary substrate (22) includes at least one mechanical interlock (24) monolithically formed with the secondary substrate. The at least one mechanical interlock extends through the aperture. The mechanical interlock includes a main body (26) and a head portion (28) with a transition portion (30) connecting the main body and head portions. The main body includes a bore (32) formed longitudinally therein about a centerline of the aperture. The mechanical interlock joins the primary substrate and secondary substrate mechanically.