Composite Components Profile Injection Molding Anchoring
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Solution Overview
Problem
Existing methods for producing composite components with injection-molded elements face challenges in achieving a secure, immovable hold on profiles, particularly due to shrinkage issues and complexity in production, leading to potential separation of plastic elements from metallic profiles.
Innovation Solution
The formation of intersecting longitudinal and peripheral lamellae on the profile, combined with positive-locking elements at their crossing points, ensures a form-fitting attachment of the injection-molded element, providing enhanced grip and stability without requiring the plastic to completely surround the profile, and allowing for material-saving and lightweight construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the plastic element is injected onto the hollow profile to achieve anchoring, then the plastic element is firmly gripped on the hollow profile, but the plastic element may separate from the profile due to shrinkage and lubricating anti-corrosion layer
Solution Approach 1:
The hollow profile is deformed at discrete points before injection molding to create deformation zones. This preliminary deformation creates mechanical interlocking features that prevent the plastic element from separating during subsequent injection and curing, addressing the shrinkage and lubrication separation issue before it can occur.
Solution Approach 2:
The hollow profile is deformed only at discrete points rather than uniformly, creating localized deformation zones that provide anchoring functionality where needed while maintaining the overall integrity and lubricating properties of the profile in other areas.
2Reliability
If the plastic element completely surrounds the profile to achieve secure anchoring, then the hold is stronger, but the material usage increases and lightweight construction is compromised
Solution Approach 1:
Instead of requiring the plastic element to completely surround the profile, the invention uses discrete deformation zones at specific points along the profile. These segmented deformation points provide sufficient anchoring hold while allowing the plastic element to be lighter and less material-intensive.
Solution Approach 2:
The plastic element does not need to completely surround the profile to achieve adequate anchoring. The discrete deformation zones provide sufficient mechanical interlocking with partial coverage, eliminating the need for excessive material usage while maintaining reliable hold strength.
3Reliability
If complex deformation methods are used to achieve anchoring, then the plastic element is firmly attached, but the production technology becomes very complex
Solution Approach 1:
The hollow profile is deformed at discrete points before injection molding, creating the anchoring features in advance. This preliminary action simplifies the overall production process by preparing the profile in a straightforward manner before the injection molding step, avoiding complex multi-stage deformation operations.
Solution Approach 2:
Instead of deforming the plastic element during or after injection molding to achieve anchoring, the invention inverts the approach by pre-deforming the hollow profile before injection. This reversal of the deformation timing simplifies the production technology while maintaining firm attachment.
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 ensures an immovable attachment of the injection-molded element on the profile, improving mechanical force distribution, resilience, and stability, while simplifying manufacturing and allowing for optical design flexibility of the composite component.
Implementation Method 1
The crossing of the lamellae, which are connected to one another in a materially joined manner at these crossing points
Implementation Method 2
In order to achieve anchoring of the plastic on the hollow profile, in particular in the case of a partial sheathing, it is deformed at discrete points
Implementation Method 3
a hollow profile is formed by means of fluid internal high pressure
Data Source
Figure 1
AI summary
The invention relates to a method for producing composite components (1) from a profile (2) and an injection moulded element (3), wherein the injection moulded element (3) is moulded onto the profile (2) such that the profile (2) is fully enclosed in the circumferential direction and at least one form enclosure element (7) is produced which is included. According to the invention, the injection moulded element (3) of the produced composite component (1) may be given a permanent hold on the profile (2), wherein the form enclosure element (7) lying between the ends (8,9) of the profile (2) has a limited shaping on the circumferential direction and the longitudinal direction.