Metal-Composite Transition Structure for Fiber-Safe Joining

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Solution Overview

Problem

Traditional methods for joining composite components made of continuous fiber materials to metal components often damage the reinforcing fibers and result in weaker joints, as mechanical fasteners can break the continuous fibers, creating points of weakness.

Innovation Solution

A transition structure is developed, featuring a metallic portion with embedded fiber tows and a binding material matrix, where channels in the metallic portion securely hold the fibers and prevent crushing, allowing for metal-to-metal contact and reinforcing the joint with a resin that binds the fibers and metal, preventing galvanic corrosion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional mechanical fastening methods are used to join composite components to metal components, then the joining process is simple and fast, but the continuous fibers are damaged and the joint strength is reduced

Engineering Contradiction:

Improvejoining speedVSAvoidjoint strength

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The invention divides the joining process into two distinct stages: first, mechanical fastening is used to quickly assemble the components; second, adhesive is applied to restore and enhance the bond strength. This segmentation allows each method to perform its optimal function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mechanical fastener is installed first to provide immediate structural integrity and alignment, creating a preliminary bond that holds the components in position. This preliminary action enables subsequent adhesive application to occur in a stable configuration, maximizing the final joint strength.

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If mechanical fasteners are driven through continuous fiber materials, then the components can be joined quickly, but the fibers are broken creating points of weakness

Engineering Contradiction:

Improvejoining easeVSAvoidfiber integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The invention applies adhesive material around the mechanical fastener and within the fiber material before the fibers can be fully compromised. This adhesive cushioning protects the fiber ends and distributes stress away from the fiber break points, preventing catastrophic failure while maintaining manufacturing simplicity.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The invention creates a hybrid joint system combining mechanical fastening elements with adhesive bonding, forming a composite joining structure. This composite approach leverages the immediate structural support of mechanical fasteners while the adhesive restores fiber continuity and eliminates stress concentration points.

Inventive Principle:

Principle #40Composite materials

3Strength

If adhesive and mechanical fastening are combined to join composite to metal, then the joint strength is improved, but the manufacturing process becomes more complex

Engineering Contradiction:

Improvejoint strengthVSAvoidjoining process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The mechanical fastener serves a dual function: it provides immediate structural support during assembly and creates channels or pathways that facilitate adhesive distribution. The fastener itself helps deliver the adhesive to critical areas, reducing the need for separate complex delivery systems.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The invention merges the mechanical fastening and adhesive bonding processes into a single integrated operation where both methods work simultaneously or in immediate sequence. This consolidation reduces the number of separate manufacturing steps and simplifies the overall process while maintaining enhanced joint strength.

Inventive Principle:

Principle #5Merging (Combining)

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 solution enhances the strength and durability of the joint by preventing fiber damage and creating a robust mechanical bond between the composite and metal components, improving the load-sharing capability and reducing stress concentrations.

Implementation Method 1

a binding material forming a matrix surrounding the fiber portion embedded within the metallic portion

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Data Source

PatentUS11511367B2Hybrid structures for joining of metals and continuous fiber materials

Publication Date: 2022.11.29 HONDA MOTOR CO LTD

AI summary

A transition structure includes a metallic portion, a fiber portion including a plurality of tows embedded within the metallic portion and extending out from the metallic portion forming a fabric, and a binding material forming a matrix surrounding the fiber portion embedded within the metallic portion. The fiber portion may be attached to or form part of a composite vehicle component. The transition structure may join a metallic component and a composite component. The transition structure may be manufactured by creating first channels within a layer of a metallic substrate, inserting fiber tows into the first channels, placing a first metallic layer over the metallic substrate and the fiber tows, consolidating the metallic layer to the metallic substrate, and binding the fiber tows within a resin. Prior to binding, additional layers of channels and fiber tows may be consolidated onto the first metallic layer.