Metal-Composite Bonding via Protruding Features
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Solution Overview
Problem
Bonding metal and composite materials is challenging, especially in small form factor devices where achieving a strong bond while minimizing joint size is difficult due to space constraints.
Innovation Solution
Creating a layer stack with a metal layer featuring protruding features, such as flanges or wire bonds, and molding a non-metal layer over these features to facilitate a strong bond between the metal and composite materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional bonding methods are used to bond metal and composite materials, then bond strength can be achieved, but joint size becomes large and occupies excessive space
Solution Approach 1:
The bonding interface is segmented into multiple discrete protruding features (ribs, flanges, or other geometric shapes) distributed across the metal substrate surface. Each protruding feature acts as an independent bonding element that the composite material can mechanically interlock with, thereby achieving strong bonding through multiple small contact points rather than a single large joint area.
Solution Approach 2:
The protruding features extend in the vertical dimension (perpendicular to the substrate surface), creating three-dimensional bonding interfaces. This vertical dimension allows the composite material to wrap around or interlock with the protrusions, significantly increasing the effective bonding surface area and mechanical interlocking strength without increasing the horizontal footprint of the joint.
2Volume of moving object
If joint size is reduced to meet space constraints, then space efficiency improves, but bond strength between metal and composite materials decreases
Solution Approach 1:
Instead of uniformly distributing bonding capacity across a large area, the bonding strength is concentrated at specific local locations where protruding features are strategically positioned. These localized high-strength bonding points provide sufficient overall bond strength while keeping the total joint area minimal, as the protrusions create intense local mechanical interlocking effects.
Solution Approach 2:
The solution employs a hybrid bonding mechanism that combines mechanical interlocking (through protruding features made of metal or other materials) with the composite material's inherent properties. The protruding features may be made from materials optimized for bonding to the composite, creating a composite-like layered structure at the bonding interface that maximizes strength within minimal space.
Data Source
AI summary
Apparatus, systems and methods for forming a structure that includes a metal and a composite material are disclosed. According to one aspect, a layer stack includes a metal layer with a first surface, the first surface including at least one protruding feature. The layer stack also includes a non-metal layer molded to the first surface of the metal layer, wherein the non-metal layer is molded over and/or around the at least one protruding feature.