Metal-Composite Assembly via Surface Coupling Form
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Solution Overview
Problem
Existing methods for assembling metal and composite parts, particularly under shear and torsion loads, are complex, costly, and not compatible with mass production, as they require extensive interfaces and multiple pins that can bend and lead to decoupling.
Innovation Solution
A method involving forming a coupling form on the metal part with patterns that penetrate into the composite part during stamping, over-molding with a locking layer to prevent displacement, and optionally using an adhesive layer for stabilization, allowing for a more economical and torsion-resistant connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If Z-pins are used to connect metal and composite parts, then resistance to delamination is improved, but device complexity and mass increase due to requiring a thick composite part or multiple fine pins
Solution Approach 1:
The invention extracts the connection function from the composite part thickness and relocates it to the metal part surface through protruding elements. Instead of inserting pins through the entire composite structure, the protruding elements are formed directly on the metal part and engage with the composite part's surface layer, simplifying the assembly process while maintaining delamination resistance.
Solution Approach 2:
The protruding elements are formed on the metal part before assembly with the composite part. This preliminary formation of connection elements allows for integrated manufacturing of the metal component with built-in connection features, eliminating the need for separate pin insertion operations and reducing assembly complexity.
2Strength
If multiple fine pins are used to improve delamination resistance, then connection strength is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The invention merges the connection function with the metal part itself by forming protruding elements directly on its surface. This integration eliminates the need for separate pins as distinct components, reducing the number of parts and simplifying manufacturing while maintaining connection strength through the integrated protruding features.
Solution Approach 2:
The protruding elements serve multiple functions: they provide mechanical connection between metal and composite parts, resist delamination, and can be integrated into the metal part's manufacturing process. This multi-functionality reduces the need for specialized connection components and simplifies the overall assembly.
3Ease of manufacture
If a thick composite part is used to accommodate Z-pins, then pin insertion is facilitated, but device mass and complexity increase
Solution Approach 1:
Instead of making the composite part thick to accommodate pin insertion, the invention inverts the approach by forming the connection elements on the metal part side. The protruding elements engage with the composite part's surface without requiring excessive composite thickness, thereby reducing device mass while facilitating connection.
4Force
If pins extend between two metal parts, then load transfer is improved, but device mass increases
Solution Approach 1:
The invention extracts the load transfer function from extended metal parts and concentrates it at the interface through protruding elements. By forming connection features directly on the metal part surface that engage with the composite part, load transfer is achieved at the interface without requiring extended metal structures, thereby reducing device mass.
Data Source
AI summary
An assembly includes a first part made of composite material including a polymer matrix and a second part made of metal. The two parts are assembled by opposite or assembly faces along an interface subjected to shear loads. The first part is made of a composite having continuous reinforcing fibers in a thermoplastic matrix. The second part includes, on its assembly face, a coupling form having a plurality of patterns. Each pattern has a closed contour in a plane parallel to the assembly face of the second part and extends along a direction normal to the assembly face of the second part. A method for making such an assembly is also provided.