Reduced-Density Metal Core Laminate for Lightweight Stiff Structures
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Solution Overview
Problem
There is a need for lightweight, stiff, and cost-effective sheet materials compatible with existing metalworking infrastructure, as conventional composite materials are expensive and incompatible with high-volume metal forming processes like stamping.
Innovation Solution
A metal laminate comprising a reduced density metal core layer sandwiched between two continuous metal sheets, bonded metallurgically without oxides or adhesives, allowing for efficient press rolling and retention of core layer density, enabling lightweight and stiff structures suitable for deep drawing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional composite materials (carbon fiber, metal matrix composites) are used to reduce weight, then weight reduction is achieved, but manufacturing cost increases significantly
Solution Approach 1:
The patent uses a composite structure consisting of a reduced-density metal core layer (with through-holes or porous structure) sandwiched between two continuous metal sheets. This composite configuration achieves weight reduction similar to carbon fiber composites but uses metal materials that are compatible with conventional metalworking processes, thereby reducing manufacturing cost while maintaining structural performance
Solution Approach 2:
The core layer is designed with through-holes or porous structure to reduce its density and overall weight of the laminate. This porous configuration allows significant weight reduction while maintaining sufficient structural integrity, achieving comparable weight savings to carbon fiber composites but at lower material and manufacturing costs
2Weight of moving object
If conventional composite materials are used, then weight reduction is achieved, but compatibility with high-volume metal forming processes is lost
Solution Approach 1:
The patent creates a metal-based composite laminate that combines the weight benefits of composite materials with the formability of conventional metals. The metallurgical bonding between the continuous metal sheets and the reduced-density core layer produces a integrated structure that behaves like a single metal material, enabling compatibility with stamping, deep drawing, and other high-volume metal forming processes
Solution Approach 2:
The laminate is divided into three distinct layers (continuous metal sheet, reduced-density core layer, continuous metal sheet) that are metallurgically bonded together. This segmentation allows each layer to contribute specific properties (structural integrity from outer sheets, weight reduction from porous core) while the metallurgical bonding ensures they function as a unified, formable material
3Weight of moving object
If reduced-density core layer with through-holes is used, then weight reduction is achieved, but structural integrity may be compromised
Solution Approach 1:
The patent uses a composite sandwich structure where the reduced-density core layer is sandwiched between two continuous metal sheets. The outer continuous sheets provide structural integrity and load-bearing capacity, while the porous core provides weight reduction. This configuration allows the structure to maintain strength despite the reduced density of the core layer
Solution Approach 2:
Different regions of the laminate serve different functions: the continuous metal sheets provide structural strength and integrity, while the reduced-density core layer with through-holes provides weight reduction. This local differentiation of material properties allows the structure to achieve both strength and weight reduction simultaneously
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
The solution provides a lightweight, stiff, and formable laminate material with reduced manufacturing costs, maintaining structural integrity and compatibility with metalworking processes, offering superior mechanical properties and aesthetic surface patterns.
Implementation Method 1
a reduced density metal core layer disposed between the first continuous metal sheet and the second continuous metal sheet, the reduced density metal core layer comprising a core metal and having an average density that is less than the density of the core metal
Implementation Method 2
a planar metallurgical bond securing the first continuous metal sheet to the reduced density metal core layer; and a planar metallurgical bond securing the second continuous metal sheet to the reduced density metal core layer
Data Source
AI summary
A stiff, lightweight metal laminate includes a first continuous metal layer, a second continuous metal layer, and a reduced density metal core layer disposed between the first and second continuous metal layers. The reduced density metal core layer comprises a core metal and has an average density that is less than the density of the core metal. Planar metallurgical bonds secure the first and second continuous metal layers to the reduced density metal core layer. The metal laminate may be manufactured by press rolling the reduced density metal core layer sandwiched between the two continuous metal layers, after removing or overcoating the native oxide layer on each layer surface that contacts another layer in the metal laminate.