Textured Laminate Piercing Mechanism for Stiffness
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Solution Overview
Problem
There is a growing need for structural materials that are lighter, stiffer, and cheaper to produce, while existing methods for laminating composite materials with metal substrates do not effectively achieve all three qualities simultaneously.
Innovation Solution
A laminate is created by combining harder lamina with softer lamina, where the harder lamina has textured surfaces with pointed structures that pierce and lock into the softer material, forming a strong and stiff composite through clinching, allowing for the use of materials like metal and plastic.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional lamination methods are used to join composite materials with metal substrates, then structural integrity is achieved, but the laminate becomes heavier and more expensive
Solution Approach 1:
The bonding interface is segmented into multiple discrete piercing structures distributed across the laminate surface, rather than using continuous adhesive layers or mechanical fasteners. This segmentation allows for reduced material usage and weight while maintaining bond strength through distributed load paths.
Solution Approach 2:
The patent replaces traditional mechanical bonding systems (adhesives, fasteners, rivets) with a piercing-based mechanical interlocking system. The piercing structures create direct physical penetration and interlocking between layers, eliminating the need for additional bonding materials and reducing overall laminate weight.
2Ease of manufacture
If traditional lamination methods are used, then structural integrity is achieved, but manufacturing cost increases
Solution Approach 1:
The piercing structures are integrated directly into the laminate manufacturing process, combining the bonding function with the structural material itself. This merging eliminates separate bonding operations, additional materials, and complex assembly steps, thereby reducing manufacturing cost while maintaining bond strength.
Solution Approach 2:
The piercing structures are designed to self-lock and self-bond during the lamination process without requiring additional fastening operations or adhesive application. The structures perform multiple functions (structural support, bonding, and load transfer) simultaneously, simplifying manufacturing and reducing costs.
3Weight of moving object
If lighter materials are used to reduce weight, then cost-effectiveness improves, but stiffness and strength may be compromised
Solution Approach 1:
The patent employs composite construction with alternating harder and softer layers, where the harder layers provide stiffness and structural support while the softer layers provide ductility and bonding. This composite architecture achieves high stiffness-to-weight ratio by strategically positioning materials based on their mechanical properties.
Solution Approach 2:
The laminate structure exhibits local quality variations with harder, stiffer layers positioned where structural support is needed and softer, more ductile layers positioned where flexibility and bonding are required. This spatial differentiation of material properties optimizes both stiffness and weight performance.
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 results in a laminate with exceptional stiffness and cost-effectiveness, suitable for various applications, by creating a locked-laminate structure that imparts high resistance to bending and pull-apart forces.
Implementation Method 1
Each such harder lamina has at least one face surface textured such that a myriad of pointed, nail-like, piercing structures rise therefrom. The textured lamina is not perforated. One or more of the textured lamina(s) are forced against at least one pierceable lamina so that it is thereby pierced and preferably penetrated through such that the pointed tips of the piercing structures are co-clinched against each other and thereby locking the three lamina together.
Data Source
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Figure 11~13
AI summary
A process is provided for making stiff, lightweight laminate materials. At least one sheet of textured lamina having raised pointed structures is forced against a softer plain lamina so as to embed the structures therein. The pointed structures raised from grooves carved into the surface of the sheet material by means of a set of teeth carried on a knife element. The pointed structures may pierce through the softer lamina such that the protruding tips may be bent over or clinched to prevent their easy withdrawal. Two such texturized lamina may be used to sandwich and pierce through the softer lamina and are co-clinched by the other. In this way a light and stiff laminate is created.