Polymer Assembly Pad with Embedded Metal Insert for High-Temperature Welding
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Solution Overview
Problem
The challenge is to develop a method for assembling large polymer parts with metal body structures that can withstand high temperatures, such as those encountered during corrosion treatments, while maintaining compatibility with both polymer and metal components, and allowing for the use of existing assembly techniques like metal-to-metal welding.
Innovation Solution
A polymer part design incorporating metal pellets integrated into the assembly zones, which are overmolded to create a secure connection with the metal structure, enabling secure welding and accommodating differential expansion, thus facilitating assembly and high-temperature resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If polymer parts are assembled directly to metal structures without metal inserts, then assembly simplicity is maintained, but the assembly cannot withstand high temperatures during corrosion treatments
Solution Approach 1:
The invention creates a composite assembly structure combining polymer material, metal inserts, and adhesive layers. The metal inserts are embedded within the polymer part, forming a hybrid structure that leverages the temperature resistance of metal while maintaining the polymer's formability and weight advantages. This composite approach allows the assembly to withstand high temperatures during corrosion treatments like cataphoresis.
Solution Approach 2:
The invention introduces metal inserts as intermediary elements between the polymer part and the metal support structure. These inserts serve as mediators that can be welded to the support structure, providing a reliable connection that bridges the polymer and metal components. The adhesive layer between the insert and polymer provides additional bonding, creating a multi-layer intermediary system that ensures strong attachment.
2Temperature
If metal inserts are integrated into polymer parts, then high-temperature resistance is achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The metal inserts are prepared and positioned in advance during the polymer molding process. The inserts are placed in the mold cavities before the polymer material is injected, allowing them to be precisely positioned and integrated into the final part geometry. This preliminary action ensures proper alignment and reduces post-manufacturing adjustments.
Solution Approach 2:
The invention merges multiple manufacturing operations into a single integrated process. The metal inserts are embedded during the polymer injection molding operation, and the adhesive is applied in the same or immediately subsequent step, before the part is removed from the mold. This combining of operations reduces the number of separate manufacturing steps and tooling requirements.
3Weight of moving object
If polymer parts replace stamped sheet metal parts, then vehicle weight is reduced, but compatibility with existing metal assembly techniques is lost
Solution Approach 1:
The metal inserts act as intermediaries that enable the use of existing metal assembly techniques. The inserts can be welded to the metal support structure using conventional welding processes, allowing the polymer part to be integrated into the vehicle assembly line that was originally designed for metal-to-metal welding. This intermediary approach maintains compatibility with established manufacturing capabilities.
Solution Approach 2:
The metal inserts provide multi-functionality by serving both as structural connection elements and as interfaces for existing assembly techniques. The same insert design can accommodate different joining methods (welding, adhesive bonding), and the polymer parts with these inserts can replace various metal components across different vehicle applications, enhancing versatility.
4Weight of moving object
If the polymer part is made thinner to reduce weight, then weight reduction is achieved, but the structural integrity at assembly points is compromised
Solution Approach 1:
The invention creates a composite structure at the assembly points where metal inserts are embedded within the polymer matrix. This local composite construction provides enhanced strength and stiffness at the critical connection points while allowing the rest of the polymer part to remain thin and lightweight. The metal insert carries the mechanical loads, while the polymer provides form and lightweight structure.
Solution Approach 2:
The invention applies different material properties to different regions of the part. The assembly areas contain metal inserts for strength and temperature resistance, while the main body of the polymer part remains thin and lightweight. This local differentiation of material quality allows weight reduction in non-critical areas while maintaining strength where needed.
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 allows for the successful assembly of polymer parts with metal structures, enabling them to withstand high temperatures and maintain structural integrity, while allowing for the use of existing assembly techniques, thus enhancing the integration of polymer parts into vehicle body structures.
Implementation Method 1
The part and the support structure having different coefficients of thermal expansion, in that the part undergoes expansion to a greater extent than the support structure when subjected to a temperature increase
Data Source
Figure 1~2
Figure 3~6b
AI summary
The invention relates to a molded part (1) made of polymer material, the part comprising at least one portion of a flat assembly zone (5) intended to be joined to a support structure. The portion of the flat assembly zone (5) comprises a metal pad (20, 8) integrated within the thickness of the portion of the flat assembly zone (5) so as to cover the circumference of the pad (20, 8) with the polymer material of the molded part (1), and so as to leave a central portion of each of the two faces of the pad (20, 8) exposed.