Metal Insert Projections for Composite Fiber Separation

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Solution Overview

Problem

Composite material parts in motor vehicle assemblies face challenges in assembly and attachment of components due to difficulties in integrating metal inserts without damaging the reinforcing fibers, such as through screwing, welding, or gluing.

Innovation Solution

A metal insert with shaped projections that penetrate and bend through the reinforcing ply, allowing for the separation of fibers without degradation, enabling secure attachment and integration with the composite material without damaging it, and facilitating robotic handling or welding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If metal inserts are integrated into composite material parts using conventional methods (screwing, welding, or gluing), then attachment capability is improved, but the reinforcing fibers are damaged or degraded

Engineering Contradiction:

Improveattachment capabilityVSAvoidfiber integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

Metal inserts with shaped projections are placed onto the composite material sheet before molding. The projections are pre-formed to penetrate and bend through the reinforcing fibers during the molding process, establishing secure attachment points before the composite fully cures. This preliminary positioning ensures fibers are separated rather than cut or damaged during subsequent assembly operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The shaped projections on metal inserts act as intermediaries between the metal insert and the composite material. These projections penetrate the fiber matrix and bend to create mechanical interlocking, mediating the connection between dissimilar materials (metal and composite) without requiring direct welding, screwing, or gluing that would damage the fibers.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If conventional attachment methods are used on composite parts, then component integration is achieved, but assembly complexity increases

Engineering Contradiction:

Improvecomponent integrationVSAvoidassembly complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The metal insert integration is merged with the composite molding process itself. Inserts with shaped projections are placed on the composite sheet before molding, combining the insert attachment and composite formation into a single manufacturing step. This eliminates separate post-molding attachment operations and reduces overall assembly complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The shaped projections on metal inserts serve multiple functions: they penetrate and separate fibers during molding, provide mechanical interlocking for secure attachment, and enable subsequent welding or magnetic handling. This multi-functionality reduces the need for separate attachment mechanisms and simplifies assembly operations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If metal inserts are added to composite parts after molding, then attachment capability is improved, but manufacturing time increases

Engineering Contradiction:

Improveattachment capabilityVSAvoidmanufacturing efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

Metal inserts are pre-positioned on composite material sheets before the molding process. This preliminary placement allows inserts to be integrated during the molding cycle itself, rather than requiring separate post-molding attachment operations. The shaped projections are already in place to penetrate and lock into the fiber matrix as the composite cures.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The insert attachment process is merged with the composite molding process. Inserts are placed on the sheet prior to molding, and their shaped projections become integrated into the composite structure during curing. This combination eliminates sequential operations and reduces total manufacturing time.

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

Enables easy integration of metal inserts into composite material parts, enhancing assembly efficiency and allowing for secure attachment methods like screwing, welding, or suction, while maintaining the integrity of the reinforcing fibers, particularly beneficial for motor vehicle components.

Implementation Method 1

the projections are shaped to pass through the reinforcing layer, in order to bend on the opposite side of the reinforcing layer, by plastic deformation

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Data Source

PatentEP2922689B1Assembly of a metal insert and a sheet of composite material and part obtained by moulding such a sheet

Publication Date: 2019.01.09 COMPAGNIE PLASTIC OMNIUM SA

Figure 1~2
Figure 3a~4

AI summary

The assembly (10) consists of at least one metal insert (14A, 14B, 14C) and one reinforcing sheet (12). The reinforcing sheet (12) contains reinforcing fibres longer than or equal in length to one centimetre. The metal insert (14A, 14B, 14C) comprises protrusions (22) shaped to traverse the sheet (12), passing between the reinforcing fibres, and to fold by plastic deformation, enclosing the reinforcing fibres when said protrusions are subjected to a longitudinal compression force.