Metal-Composite Assembly Using Retention Teeth for Strong Joining
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Solution Overview
Problem
Existing methods for assembling metal parts with composite materials are time-consuming and costly due to the need for injection operations and lack sufficient mechanical strength to withstand significant forces.
Innovation Solution
A method involving the production of teeth on the metal part's contact face with interstitial spaces for fiber retention, where the composite part is pressed against the metal part to allow fiber penetration and consolidation, potentially with heating and cooling steps to enhance the assembly's mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an injection operation is performed to create a locking layer for assembling metal part with composite part, then the assembly can be achieved, but the manufacturing time increases and manufacturing costs increase
Solution Approach 1:
The patent extracts the essential function of fiber retention from the complex injection molding process. Instead of injecting a locking layer to trap fibers, the invention uses simple protrusions with retention zones that passively hold fibers during assembly, eliminating the time-consuming injection operation while maintaining assembly feasibility
Solution Approach 2:
The protrusions with retention zones are designed to automatically capture and hold composite fibers during the assembly process without requiring additional operations. The fibers self-align and are retained by the retention zones, making the assembly process self-sufficient without needing injection molding or other complex procedures
2Ease of manufacture
If a locking layer is used to assemble metal part with composite part, then the assembly can be achieved, but the mechanical strength is insufficient for withstanding significant forces
Solution Approach 1:
The retention zones are designed with curved surfaces that conform to the geometry of composite fibers. This curvature allows the retention zones to effectively capture and hold fibers under load, distributing forces evenly and significantly improving the mechanical strength of the assembly compared to flat locking layers
Solution Approach 2:
The invention creates a true composite assembly by allowing composite fibers to physically interlock with the metal protrusions. The fibers penetrate between protrusions and are retained by the retention zones, creating a hybrid structure that combines the strength of metal with the tensile properties of composite materials
3Ease of manufacture
If additional materials like locking layer are used for assembly, then the assembly can be achieved, but the device complexity increases
Solution Approach 1:
The invention extracts the essential assembly function from the complex locking layer system. Instead of adding a separate locking layer material, the retention function is integrated directly into the metal part through protrusions with retention zones, eliminating the need for additional materials and reducing overall assembly complexity
Solution Approach 2:
The retention function is merged with the structural protrusions themselves. The same metal features that provide mechanical connection also provide fiber retention through integrated retention zones, eliminating the need for separate locking layers or additional assembly components
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, eliminating the need for additional materials or surface preparation, and allows direct connection between metal and composite parts without intermediate elements, achieving strength comparable to bonding or riveting.
Implementation Method 1
a step of heating the second part that is performed before the pressing step
Implementation Method 2
a cooling step that is performed after the mechanical pressing step, in particular intended to allow the consolidation of the assembly
Data Source
AI summary
The invention relates to a method for assembling a first metal part with a second part made of a composite material comprising at least one matrix and fibers arranged inside the matrix. The method comprises at least:a step of forming the first part, consisting in producing a plurality of teeth projecting from a contact face of the first part, two adjacent teeth being separated from each other by an interstitial space, the teeth having an end protuberance; anda step of pressing the second part against the first part,in such a way that the fibers of the composite material can penetrate inside the interstitial space defined between adjacent teeth and that the fibers are retained by the end protuberances of the teeth.