Metal-Composite Assembly Using Interlocking Teeth and Fiber Retention
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Solution Overview
Problem
Current methods for assembling metal parts with composite materials, such as those described in documents FR3021899, US7802799, DE102013205745, and US2013/149501, face challenges including long manufacturing times, high costs due to injection operations, and insufficient mechanical strength for high-stress applications.
Innovation Solution
A method involving the formation of teeth on a metal part's contact face with interstitial spaces for fiber retention, where the composite material's fibers penetrate and are retained by the teeth's extremal protrusions, and optional heating and cooling steps for consolidation, eliminating the need for additional materials or surface preparation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If injection molding operation is used to create a locking layer, then assembly strength is improved, but manufacturing time and cost increase significantly
Solution Approach 1:
The patent extracts the essential function of mechanical interlocking from the complex injection molding process. Instead of using a full injection molding operation to create a locking layer, the invention uses simple protrusions directly formed on the metal part surface that can be created through basic forming operations, thereby removing the time-consuming injection molding step while maintaining the interlocking function.
Solution Approach 2:
The patent replaces the expensive and time-consuming injection molding process with a simpler, more economical forming operation that creates protrusions on the metal part. This simpler approach achieves the same mechanical interlocking function without the high costs and long cycle times associated with injection molding.
2Strength
If injection molding operation is used to create a locking layer, then assembly strength is improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent extracts the essential function of mechanical interlocking from the complex injection molding process. Instead of using a full injection molding operation to create a locking layer, the invention uses simple protrusions directly formed on the metal part surface that can be created through basic forming operations, thereby removing the time-consuming injection molding step while maintaining the interlocking function.
Solution Approach 2:
The patent replaces the expensive and time-consuming injection molding process with a simpler, more economical forming operation that creates protrusions on the metal part. This simpler approach achieves the same mechanical interlocking function without the high costs and long cycle times associated with injection molding.
3Ease of manufacture
If traditional assembly methods are used, then manufacturing process is simple, but mechanical strength is insufficient for high-stress applications
Solution Approach 1:
The patent segments the contact surface into multiple protrusions distributed across the interface between metal and composite parts. This segmentation creates multiple interlocking points that collectively provide high mechanical strength, while each individual protrusion remains simple to manufacture. The segmented approach allows the assembly to withstand high stresses without requiring complex manufacturing processes.
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 method provides a strong, cost-effective assembly with enhanced mechanical strength, comparable to or exceeding traditional methods like gluing or riveting, while reducing weight and eliminating the need for intermediate elements.
Implementation Method 1
a heating step of the second part, carried out before the pressing step
Implementation Method 2
a cooling step carried out after the mechanical pressing step, specifically intended to allow the consolidation of the assembly
Data Source
Figure 1a~1b
Figure 2~3
Figure 4~5
AI summary
The invention relates to a method for assembling a first, metal part (10) and a second part (11) made of a composite material comprising at least one matrix (12) and fibres (13) arranged inside the matrix (12). The method comprises at least: - a step of forming the first part (10), consisting of producing a plurality of teeth (16) projecting from a contact surface (101) of the first part (10), two adjacent teeth (16) being separated from one another by an interstitial space, the teeth (16) having an extremal protrusion; and - a step of pressing the second part (11) against the first part (10), so that the fibres (13) of the composite material can penetrate into the interstitial space defined between adjacent teeth (16) and so that the fibres (13) are held by the extremal protrusions of the teeth.