Metal-Polymer Joining with Offset Probe Extrusion Hooks
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Solution Overview
Problem
Current hybrid joining techniques fail to achieve strong and reliable connections between dissimilar materials like aluminium alloys and polymer-based components, particularly in high-performance industries such as aeronautics and automotive, due to differences in physical nature, leading to limitations in structural design and environmental compliance.
Innovation Solution
The THE-FSpW process uses a thin, rigid extrusion die plate with through-holes between metal and polymer components, where a rotating tool extrudes metal into the polymer under high pressure and temperature, activating adhesive, diffusion, and mechanical joining mechanisms, producing a non-axis-symmetrical high volume hook with enhanced resistance to peeling and torsion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional joining techniques (mechanical fastening or adhesive bonding) are used to join metal and polymer components, then the joining process is simple and well-established, but the joint strength and reliability are insufficient for high-performance applications
Solution Approach 1:
The invention utilizes phase transition of the polymer material through controlled heating to melt and subsequently solidify, creating a strong mechanical interlock. The heating element raises the polymer to its melting point, allowing the metal component to be inserted and form anchoring hooks, then cooling solidifies the polymer to lock the joint in place
Solution Approach 2:
The invention creates a composite joint structure combining metal and polymer materials with different physical properties. The metal component provides structural strength while the polymer provides bonding and damping, achieving superior joint performance that neither material could achieve alone
2Reliability
If the number of spot welds is increased to improve joint reliability, then the connection strength increases, but the productivity decreases and material consumption increases
Solution Approach 1:
The invention changes the fundamental joining parameters from mechanical fastening or adhesive bonding to direct thermomechanical extrusion. By controlling temperature, pressure, and extrusion force, a single highly reliable joint can be formed with superior strength compared to multiple conventional joints
3Weight of moving object
If hybrid joining of aluminium alloys and polymer components is implemented to achieve lightweight design, then weight reduction and energy efficiency improve, but the difficulty of achieving strong and chemically stable joining mechanisms increases
Solution Approach 1:
The invention replaces conventional mechanical fastening systems (screws, rivets) or chemical adhesive systems with a direct thermomechanical extrusion process. This substitution eliminates the need for separate fastening components or adhesive applications, simplifying the manufacturing process while achieving strong joints between dissimilar materials
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 process provides superior joint performance, reducing the number of spot welds required, increasing productivity, saving material, and enabling more environmentally friendly structural components with improved energy efficiency.
Implementation Method 1
a rotating tool extrudes metal into the polymer under high pressure and temperature
Implementation Method 2
activating adhesive, diffusion, and mechanical joining mechanisms
Implementation Method 3
activating adhesive, diffusion, and mechanical joining mechanisms
Data Source
AI summary
The invention concerns a method for joining a metal component and a polymer component, and a structure comprising said components. In the method, an extrusion die plate with a through hole is placed between the metal component and the polymer component. A probe is rotated and plunged across the thickness of the metal component and eventually through said through hole of the extrusion die plate, thereby extruding a part of the metal component through said through hole of the extrusion die plate into the polymer component. The probe has a rotation axis having an offset to the centre of the through hole during the rotating and plunging action.