Metal Composite Material Embedded Functional Structure
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Solution Overview
Problem
Metal composite materials, particularly steel composite materials with embedded functional structures, face increased mechanical stress and degradation during processing due to local elevations or bulges formed by functional structures applied to metal substrates, which can lead to reduced performance or destruction of the functional structures.
Innovation Solution
A method involving a layered structure with recessed sections in the metal substrate to match the thickness of functional structures, allowing for even embedding and reducing mechanical stress by ensuring the layer structure has a consistent thickness before and after pressing, with optional protective layers for added protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If functional structures are applied to a metal substrate, then the functional structures are embedded in the metal composite material, but local elevations or bulges are formed which increase mechanical stresses during further processing
Solution Approach 1:
Recessed sections are formed in the metal substrate before the functional structures are applied. This preliminary action creates a contour-adapted embedding that prevents local elevations from forming, thereby eliminating the source of mechanical stresses during subsequent processing while maintaining the functional integrity of the embedded structures
Solution Approach 2:
The metal substrate is given different local geometries through the recessed sections, which are specifically tailored to match the contour of the functional structures. This local adaptation ensures that each functional structure is embedded in a customized recess, preventing stress concentrations at interfaces while maintaining overall structural reliability
2Reliability
If functional structures are applied to a metal substrate, then the functional structures are embedded in the metal composite material, but the functional structures are exposed to increased degradation and can be destroyed or have reduced performance
Solution Approach 1:
The recessed sections are pre-formed in the metal substrate to create a protective cavity that accommodates the functional structures. This preliminary preparation ensures that during subsequent processing steps, the functional structures are shielded from mechanical degradation forces, preventing destruction and maintaining performance stability
Solution Approach 2:
The recessed sections act as protective cushions that absorb and distribute mechanical stresses before they can reach the functional structures. By providing this protective geometry in advance, the functional structures are shielded from harmful mechanical forces during processing, reducing degradation risks
Data Source
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AI summary
The present invention relates to a method for producing a metal composite material (1) with an embedded functional structure (2), in which a build-up of layers (3) comprising a number of layers (4, 5, 6) which are arranged one on top of the other in the vertical direction (Y) is produced and pressed, wherein the build-up of layers (3) is produced by the following steps: providing a lower layer (4) comprising a metal substrate, arranging at least in certain portions over the lower layer (4) in the vertical direction (Y) an intermediate layer (5), which is in contact with the lower layer (4), and arranging one or more functional structures (2) respectively in a portion (3a) of the build-up of layers (3). In order to reduce the risk of increased degradation, the invention proposes that, before the pressing, the build-up of layers (3) has the same thickness in the respective portion (3a) with the functional structure (2), at least in a subportion or over the entire longitudinal and/or transverse extent of the portion with the functional structure, as in the remaining build-up of layers (3). The invention also relates to a metal composite material (1) with an embedded functional structure (2) that is produced by such a method.