WO2023175242A1 - Method for joining a metal component and a polymer component and a structure comprising said components - Google Patents

Method for joining a metal component and a polymer component and a structure comprising said components Download PDF

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Publication number
WO2023175242A1
WO2023175242A1 PCT/FI2023/050149 FI2023050149W WO2023175242A1 WO 2023175242 A1 WO2023175242 A1 WO 2023175242A1 FI 2023050149 W FI2023050149 W FI 2023050149W WO 2023175242 A1 WO2023175242 A1 WO 2023175242A1
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WO
WIPO (PCT)
Prior art keywords
polymer
component
joint
metallic
based component
Prior art date
Application number
PCT/FI2023/050149
Other languages
French (fr)
Inventor
Sean CONNOR
Prabilson KHADKA
Pedro VILACA
Original Assignee
Aalto University Foundation Sr
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Aalto University Foundation Sr filed Critical Aalto University Foundation Sr
Publication of WO2023175242A1 publication Critical patent/WO2023175242A1/en

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/56Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • B29C65/64Joining a non-plastics element to a plastics element, e.g. by force
    • B29C65/645Joining a non-plastics element to a plastics element, e.g. by force using friction or ultrasonic vibrations
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/12Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
    • B23K20/122Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
    • B23K20/1265Non-butt welded joints, e.g. overlap-joints, T-joints or spot welds
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/12Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
    • B23K20/122Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
    • B23K20/127Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding friction stir welding involving a mechanical connection
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/06Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding
    • B29C65/0681Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding created by a tool
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/44Joining a heated non plastics element to a plastics element
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/05Particular design of joint configurations
    • B29C66/10Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112Single lapped joints
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/05Particular design of joint configurations
    • B29C66/10Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112Single lapped joints
    • B29C66/1122Single lap to lap joints, i.e. overlap joints
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/05Particular design of joint configurations
    • B29C66/10Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114Single butt joints
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/05Particular design of joint configurations
    • B29C66/10Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114Single butt joints
    • B29C66/1142Single butt to butt joints
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/05Particular design of joint configurations
    • B29C66/20Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/24Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight
    • B29C66/244Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being non-straight, e.g. forming non-closed contours
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/05Particular design of joint configurations
    • B29C66/303Particular design of joint configurations the joint involving an anchoring effect
    • B29C66/3032Particular design of joint configurations the joint involving an anchoring effect making use of protusions or cavities belonging to at least one of the parts to be joined
    • B29C66/30321Particular design of joint configurations the joint involving an anchoring effect making use of protusions or cavities belonging to at least one of the parts to be joined making use of protusions belonging to at least one of the parts to be joined
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/40General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43Joining a relatively small portion of the surface of said articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/40General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43Joining a relatively small portion of the surface of said articles
    • B29C66/434Joining substantially flat articles for forming corner connections, fork connections or cross connections
    • B29C66/4344Joining substantially flat articles for forming fork connections, e.g. for making Y-shaped pieces
    • B29C66/43441Joining substantially flat articles for forming fork connections, e.g. for making Y-shaped pieces with two right angles, e.g. for making T-shaped pieces, H-shaped pieces
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/50General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/53Joining single elements to tubular articles, hollow articles or bars
    • B29C66/534Joining single elements to open ends of tubular or hollow articles or to the ends of bars
    • B29C66/5346Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially flat
    • B29C66/53461Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially flat joining substantially flat covers and/or substantially flat bottoms to open ends of container bodies
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/50General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/53Joining single elements to tubular articles, hollow articles or bars
    • B29C66/534Joining single elements to open ends of tubular or hollow articles or to the ends of bars
    • B29C66/5346Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially flat
    • B29C66/53461Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially flat joining substantially flat covers and/or substantially flat bottoms to open ends of container bodies
    • B29C66/53462Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially flat joining substantially flat covers and/or substantially flat bottoms to open ends of container bodies joining substantially flat covers and substantially flat bottoms to open ends of container bodies
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/74Joining plastics material to non-plastics material
    • B29C66/742Joining plastics material to non-plastics material to metals or their alloys
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/80General aspects of machine operations or constructions and parts thereof
    • B29C66/81General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81427General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth
    • B29C66/81429General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth comprising a single tooth
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/80General aspects of machine operations or constructions and parts thereof
    • B29C66/83General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/836Moving relative to and tangentially to the parts to be joined, e.g. transversely to the displacement of the parts to be joined, e.g. using a X-Y table
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00Materials to be soldered, welded or cut
    • B23K2103/30Organic material
    • B23K2103/42Plastics
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721Fibre-reinforced materials
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/74Joining plastics material to non-plastics material
    • B29C66/742Joining plastics material to non-plastics material to metals or their alloys
    • B29C66/7422Aluminium or alloys of aluminium

Definitions

  • the invention relates generally to j oining of components of different materials , and especially to j ointing metal components and polymer components together .
  • the idea of the invention is to provide a new and improved concept to j oin metal to polymer .
  • the characteristic features of the structure according to the invention are presented in the characteri zing part of the first independent claim .
  • the characteristic features of the method according to the invention are presented in the characteri zing part of the second independent claim .
  • the metal-polymer j oining is based on j oining technique called a Through Slot Extrusion Joining with acronym TSEJ .
  • TSEJ is used in this document for simplicity reasons and for improving clarity .
  • TSEJ is a method to produce continuous j oints between a metallic component and a polymeric-based component in an overlap- j oint configuration .
  • the TSEJ method uses a rigid extrus ion die system which forms a continuous linear or non-linear slot through which the metallic component will be forced, or extruded, into the polymeric-based component .
  • the continuous linear or non-linear slot is the aperture , or slit , formed by the inner edges of the rigid extrusion die system .
  • the metallic component is forced by a rigid rotating tool , with a tool probe and a tool shoulder, into the polymeric-based component , through the continuous linear or non-linear slot of the rigid extrusion die system, when this rigid rotating tool is plunged in the metallic component and travels along the same path of the continuous linear or non-linear slot .
  • the portion of the metallic component being mechanically processed by the rigid rotating tool softens as result of the heat energy release during the bulk plastic deformation . Thi s heated and softened portion of the metallic component is then forced through the continuous linear or non-linear slot of the rigid extrusion die system into the polymer-based component .
  • the tool shoulder keeps the top surface of the metallic component closed, and the tool probe produces the bulk plastic deformation of the metallic component .
  • the local interaction between these components results in that the constrained polymeric-based component , reacts by forcing its way into the metallic component , forming a geometrical complex shape in the forced, or extruded, portion of the metallic component resulting in the formation of a hook or crab claws shape .
  • This hook or crab claws shape which is now filled with the polymeric-based component forms a strong mechanical interference , also known as clinching .
  • the j oining mechanisms of TSEJ result from this strong mechanical interference , with the additional contribution of the physical and chemical adhesive and diffusion phenomena at the contacting interface between the metallic component and the polymeric-based component .
  • the idea of the proposed solution is to provide a structure wherein the mentioned continuous TSEJ j oint is implemented in a structure compri sing a T-j oint between the metallic component and the polymer-based component .
  • An edge of the polymer-based component is in the T-j oint arranged perpendicularly against a planar surface of the metallic component .
  • the TSEJ j oining technique forms hooks of the metallic component and the hooks are penetrated in the structure inside the polymer-bases component .
  • An advantage of the disclosed solution i that the disclosed T-j oint has excellent mechanical strength properties and it can be implemented in a versatile manner in different structural pieces , elements , and components .
  • the structure comprises one or more metallic components , one or more polymer-based components , and at least one continuous j oint between them .
  • the structure further comprises at least one T-j oint wherein the metallic component and the polymer-based component are orientated perpendicularly relative to each other . Further, cross-section of the continuous j oint is located at the T-j oint and comprises hook configuration made of the metallic component and extruded into the polymer-based component .
  • the metal lic component is of lightweight metallic material .
  • the metall ic component is of aluminium or aluminium alloy material . According to an embodiment , the metall ic component is of magnesium or magnesium alloy material .
  • the polymer-based material may be for example polyether ether ketone PEEK, carbon fiber reinforced polymer CFRP, glas s fiber reinforced polymer, or thermoplastic structural polymer .
  • At least one edge surface of the at least one polymer-based component is fastened by means of metallic hooks or claws to a planar surface of the at least one plate-like metallic component .
  • the structure has onesided configuration with one metal lic component and one or more transverse polymer-based components . Then there is one or more T-j oints only on one side of the structure .
  • the structure has two- sided configuration with two spaced metallic components and one or more transverse polymer-based components . Then there are one or more T-j oints on two oppos ite sides of the structure .
  • the continuous j oint at the T-j oint has a linear configuration .
  • the continuous j oint at the T-j oint has a non-linear configuration .
  • the polymer-based component comprises a waved contact surface facing towards a planar mating surface of the metallic component .
  • the structure comprises at least two T-j oints at a distance from each other .
  • the structure comprises at least two T-j oints on opposite sides of the polymer- based component .
  • the structure further comprises : two metallic components at a distance from each other and serving as flanges in the structure ; and at least one polymer-based component fastened by means of the T- j oints between the mentioned flanges and serving as a web in the structure .
  • the structure comprises several polymer-based and spaced webs .
  • the spaced webs may be parallel or non-parallel .
  • the structure comprises only one web and is a beam .
  • the structure has I - shaped cross-section, whereby the structure is an I -beam .
  • width of the web may be greater than width of the flanges .
  • the structure has H- shaped cross-section, whereby the structure is a H-beam .
  • width of the flanges may be greater than width of the web between the flanges .
  • the structure comprises two polymeric-based webs at a transverse distance from each other .
  • the structure comprises three , four, five , or more polymeric-based webs at a transverse distance from each other .
  • the structure has a boxlike configuration .
  • the box may be closed or open .
  • the structure has a boxlike configuration with a closed shape and comprises a top panel , a bottom panel , and a side panel between the top panel and the bottom panel .
  • the top panel and the bottom panel both comprise the metallic components .
  • the side panel comprises at least one polymer-based component . Further, the top panel and the bottom panel are j oined to the side panel by means of the T-j oints .
  • the structure has a boxlike configuration with an open shape and comprises a top panel , a bottom panel , and a side panel between the top panel and the bottom panel .
  • the top panel and the bottom panel both comprise the metallic components .
  • the side panel comprises at least one polymer-based component and has at least one side opening. Further, the top panel and the bottom panel are joined to the side panel by means of the T- oints .
  • the structure has a boxlike configuration with an open shape and comprises one of the following panels formed of the metallic components: a top panel, a bottom panel.
  • the panel formed of the metallic component is joined to a side panel formed of the polymer- based component by means of the T-joint.
  • the structure has a boxlike configuration with rectangular shape.
  • the structure has a boxlike configuration with circular, oval or curved shape.
  • the side panel or web may have waved, tubular or rounded form.
  • the T-joint may surround a top panel or bottom panel of a box-like structure for example.
  • the continuous joint at the T-joint is a load bearing structural joint.
  • the closed joint geometry formed by the continuous joint is a fluid pressure tight joint.
  • the closed joint may be gas and liquid tight. This feature is advantageous for example when forming boxlike structures or cover elements.
  • the structure comprises an extrusion die plate structure between the metallic component and the polymer-based component. Further, the extrusion die plate structure comprises a slot with a path corresponding to the path of the continuous joint.
  • the structure comprises an extrusion die plate structure or extrusion die system during the j oining process but is removed from the final structure after the j oint in finished .
  • the disclosed solution relates also to a method for j oining one or more metallic components and one or more polymer-based components together by means of one or more j oints .
  • the method comprises : placing a metallic component and a polymeric-based component towards each other at a j oint area ; providing the j oint area with an extrusion die plate structure comprising a through opening; rotating and plunging a probe of a non-consumable tool across the thickness of the metallic component ; and extruding part of the metallic component through the opening of the extrusion die plate structure into the polymer-based component for forming hooks protruding into the polymeric- based component and forming a j oint between the metallic component and the polymer-based component .
  • the method further comprises : placing the polymeric-based component transversally in relation to the metallic component and forming thereby a T-shaped configuration at the j oint area ; and implementing an extrusion die plate structure compris ing a slot and providing the j oint with a continuous j oint path along the j oint whereby the j oint area comprises at least one T-j oint for the T-shaped configuration of the metallic component and the polymer-based component .
  • the method further comprises : arranging at least one polymer-based component between two metallic components ; orientating the polymer- based component transversally in relation to planar surfaces of the two metallic components ; and j oining the two metal lic components to opposing edge surfaces of the polymer-based component by means of the T-j oints .
  • the metal lic component and the polymer-based component may be orientated perpendicular in relation to each other .
  • the metallic component and the polymer-based component may be angled in relation to each other.
  • the angle may be 20 - 160°, typically 30°, 45° or 60°, or 120°, 135° or 150°, for example .
  • the disclosed solution :
  • Figure 1 shows schematically steps of using through- slot extrusion joining TSEJ in manufacture of a multi-material structural system with T-joint design
  • Figure 2 comprises subfigures 2a - 2e and shows schematically a structure with a T-joint design implementing single-side TSEJ joining process along a linear path
  • Figure 3 shows schematically some dif ferent crosssections of hook-type j oints formed by means of the TSEJ process for T-j oints ,
  • Figure 4 comprises subfigures 4a - 4c and shows schematically use of the TSEJ process for producing a T- j oint between a planar metallic component and a wavy polymer-based component ,
  • Figure 5 comprises subfigures 5a and 5b and shows schematically use of the TSEJ j oining technique for producing a beam-like single-web structure with a double sided T- j oint design
  • Figure 6 comprises subfigures 6a - 6d and shows schematically a beam-like s ingle-web structure with a wavy polymer-based web fastened between two metallic flanges ,
  • Figure 7 comprises subfigures 7a - 7c and shows schematically a double-web structure with two polymeric- based webs fastened between two metallic flanges ,
  • Figure 8 comprises subfigures 8a - 8c and shows schematically a triple-web structure with three polymeric- based webs fastened between two metallic flanges ,
  • Figure 9 comprises subfigures 9a - 9c and shows schematically an open box-shaped structure in Figure 9b and its production in Figures 9a and 9c,
  • Figure 10 comprises subfigures 10 a - 10 c and shows schematically a closed box-shaped structure in different angles of view
  • Figure 11 comprises subfigures I l a - 11 c and shows schematically an alternative open box-shaped structure
  • Figure 12 comprises subfigures 12 a - 12 c and shows in Figure 12a picture of a cross-section of a T-j oint and Figures lb and 12c are pictures showing top and bottom views of the same .
  • Figure 1 discloses a sequence via through-slot extrusion joining (TSEJ) of manufacturing of a multi-material structural system with T-joint design, in single-side, along a linear path: Step i) the exploded perspective of the components; Step ii) the tool (5) is positioned above a pre hole (8) and the multi-component extrusion die (3) is closed to form the extrusion slot (4) ; Step iii) the start position of the manufacturing system, with the components clamped and the tool (5) ready to travel with rotation implement the joining process on the T-joint design; Step iv) the perspective upon extraction of the tool (5) but before extraction of the multicomponent extrusion die; Step v) the perspective upon extraction of the multicomponent extrusion die (3) .
  • TSEJ through-slot extrusion joining
  • Figure 2 discloses a perspective on the T-joint design, in single-side, along a linear path, with an exemplary embodiment of a joint cross-sectional structure depicting in Detail a, the extruded metallic plate (1) into the shape of a hook or crab (6) acting as a joining mechanism for the T-joint design.
  • the multicomponent extrusion die (3) At the top with the multicomponent extrusion die (3) and at the bottom, without the multicomponent extrusion die (3) .
  • Figure 3 discloses exemplary embodiments of structures formed with TSEJ.
  • the crab claw-like structure can develop asymmetrically (A) ; with long and thin structures (B) ; short and thick (C) ; or short and symmetric rounded claws (D) .
  • the tool geometry (5a, 5b) determines the form of these structures.
  • Figure 4 discloses implementation of the T-joint design, in single-side, along a non-linear waved joining path ( 7 ) .
  • Figure 5 discloses simultaneous implementation in double side, with one flange, of the T-joint design along a linear joining path (7) . This results in a I- or H- shape beam with the two flanges made of lightweight metallic material and the web made of polymer-based material.
  • Figure 6 discloses simultaneous implementation in double-side, with one flange, of the T-joint design along a non-linear joining path (7) . This results in a I- or H- shape beam with the two flanges made of lightweight metallic material and the web made of polymer-based material.
  • Figure 7 discloses implementation in double-side, with two-spaced webs, of the T-joint design along a linear joining path (7) . This results in two flanges made of lightweight metallic material and a double-web made of polymer- based material.
  • Figure 8 discloses implementation in double-side, with three-spaced webs, of the T-joint design along a linear joining path (7) . This results in two flanges made of lightweight metallic material and a triple-web made of polymer- based material.
  • Figure 9 discloses implementation in an open boxshaped flange structural system, with the T-joint design applied in single-side along a square non-linear joining path (7) . This results in an open box-shape structural system with one end flanges made of lightweight metallic material and the box-shape web made of polymer-based material.
  • Figure 10 discloses implementation in a closed boxshaped flange structural system, with the T-joint design applied in double-side along a square non-linear joining path (7) . This results in a closed box-shape structural system with two end flanges made of lightweight metallic material and the box-shape web made of polymer-based material .
  • Figure 11 discloses implementation in an open boxshaped flanged structural system, with the T-joint design applied in double-side along a square non-linear joining path (7) . This results in an open box-shape structural sys- tem with two end flanges made of lightweight metallic material and the open box-shape web made of polymer-based material .
  • Figure 12 discloses a real-world T-joint design made between a metallic component (1) and a polymer based component (2) with a removable extrusion die system (3) .
  • the top image is a cross-section with the extruded hook/crab joining mechanism (6) , and the lower images are the top and bottom side of the finished component.
  • TSEJ is a method to produce continuous joints between a metallic component (1) and a polymer-based component (2) in an overlap- j oint configuration.
  • the TSEJ method uses a rigid extrusion die system (3) which forms a continuous slot (4) through which the metallic component (1) will be forced, or extruded, into the polymer-based component (2) .
  • the continuous slot (4) is the aperture, or slit, formed by the inner edges of the rigid extrusion die system (3) .
  • the metallic component (1) is forced by a rigid rotating tool (5) , with a tool probe (5a) and a tool shoulder (5b) , into the polymer-based component (2) , through the continuous slot (4) of the rigid extrusion die system (3) , when this rigid rotating tool (5) is plunged in the metallic component (1) and travels along the same path of the continuous slot (4) .
  • the portion of the metallic component (1) being mechanically processed by the rigid rotating tool (5) softens as result of the heat energy release during the bulk plastic deformation. This heated and softened portion of the metallic component (1) is then forced through the continuous slot (4) of the rigid extrusion die system (3) into the polymer- based component (2) .
  • the tool shoulder (5b) keeps the top surface of the metallic component (1) closed, and the tool probe (5a) produces the bulk plastic deformation of the metallic component (1) .
  • the local interaction between these components results in that the constrained polymer-based component (2) , reacts by forcing its way into the metallic component (1) , forming a geometrical complex shape in the forced, or extruded, portion of the metallic component (1) resulting in the formation of a hook or crab claws shape (6) .
  • the process evolutes in a quasi-conserva- tion of volume, so no significant voids are formed in the joining zone.
  • the hook or crab claws shape (6) which is filled with the polymer-based component (2) forms a strong mechanical interference, also known as clinching.
  • the joining mechanisms of TSEJ result from this strong mechanical interference, with the additional contribution of the physical and chemical adhesive and diffusion phenomena at the contacting interface between the metallic component (1) and the polymer-based component (2) .
  • the TSEJ cycle develops along the following sequence :
  • the metallic component (1) , the polymer-based component (2) with the rigid extrusion die system (3) in between, are brought together and clamped in overlap- j oint, or T-joint configuration;
  • a pre-hole (8) may be opened in the metallic component (1) at the start position of the TSEJ joint (7) .
  • This pre-hole (8) can be cylindrical or conical.
  • This prehole (8) can be blind or through.
  • This pre-hole (8) can be larger, smaller, or equal to the diameter of the tool probe (5a) ;
  • the tool probe (5a) of the rigid rotating tool (5) is plunged at the start position of the TSEJ joint (7) until the tool shoulder (5b) contacts the top surface of the metallic component (1) ; -Upon a given dwell time, that can be equal to zero seconds or more, the rigid rotating tool (5) travels along the path of the continuous slot (4) , with constant or variable travel speed;
  • the rigid rotating tool (5) is extracted from the metallic component ( 1 ) ;
  • the hook or crab claws shape (6) formed by the metallic component (1) in interaction with the polymer-based component (2) can have the following configurations:
  • the width of the continuous slot (4) is greater than zero, and it can be constant or variable.
  • the continuous slot (4) can follow a one-dimensional, two-dimensional, or three-dimensional path.
  • the rigid extrusion die system (3) can be made of one (e.g., monolithic die (3a) ) , or more components (e.g. strips (3b) ) , which define an inner continuous slot (4) . After the TSEJ cycle is completed, if the rigid extrusion die system (3) if made of multiple components, it may be kept, within the joint, or it may be extracted.
  • the rigid extrusion die system (3) can be fully, or partially, embedded in the metallic component (1) , or in the polymer-based component (2) , or partially embedded in both the metallic component (1) and the polymer-based component (2 ) .
  • the surface of the polymer-based component (2) , facing the joining domain, can be flat, or have one or more shallow grooves, to mate with the fully, or partially embedded rigid extrusion die system (3) .
  • the surface of the metallic component (1) facing the joining domain, can be flat, or have one or more shallow grooves, to mate with the fully, or partially embedded rigid extrusion die system (3) .
  • the rigid extrusion die system (3) is made of high- strength material compared with the strength of the metallic component (1) and the polymer-based component (2) .
  • the rigid extrusion die system (3) is made with minimum thickness, as long as it provides rigidity effect to act as rigid, i.e. non-def ormable, extrusion die.
  • the joint configuration between the overlapping metallic component (1) and the polymer-based component (2) forms a T-joint design.
  • the rigid extrusion die system (3) is positioned parallel, under and in contact with the metallic component (1) , while the polymer-based component (2) is positioned perpendicular to the metallic component (1) .
  • TSEJ the TSEJ joint (7) length is longer than zero, with no maximum length.
  • a TSEJ joint (7) can include zones of overlap and/or intersection with previous TSEJ joint (7) processed zones.
  • the rigid rotating tool (5) can be made in one single component or made of multicomponent assembled together, namely a tool probe (5a) and a tool shoulder (5b) .
  • T-joint design with a linear joint enables to get a T-shape structural beam, i.e., a load-bearing system, with the one flange made of lightweight metallic material and the one web made of polymer-based material.
  • the web can be planar, joining the multilateral components with a linear T-joint design.
  • the web can be non-planar (e.g., waved) joining the multilateral components with a non-linear T-joint design.
  • T-joint design enables to get a I- or H-shape structural beam, i.e., a load-bearing system, with two flanges made of lightweight metallic material and one web made of polymer-based material with a shape that can be planar or non-planar, e.g., a waved shape.
  • T-joint design enables to get a multi-web-shape structural beams, i.e., a load-bearing system, with the two flanges made of lightweight metallic material and two, or more, webs made of polymer-based material, with a shape that can be planar or non-planar, e.g., a waved shape.
  • the TSEJ manufacturing of the T-joint design in I- shape, H-shape, and multi-web-shape structural beams can be made in sequence or simultaneously.
  • the TSEJ manufacturing of the T-joint design enables other complex-shape structural beams such as closed and open box-shaped flanged structural system, with the T-joint design applied in single or double-side along non-linear joining path (7) .
  • the end flange (s) are made of lightweight metallic material and the open or closed box-shape web made of polymer-based material.
  • the length of the tool probe (5a) and the plunged position of the rigid rotating tool (5) during the manufacturing of the TSEJ joint (7) is such that the tip of the tool probe (5a) can be positioned above, below, or at the level of the rigid extrusion die system (3) .
  • the parameters controlling the process TSEJ are the following :

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Abstract

A structure and method for joining of components of different materials, especially joining a metal component and a polymer component. The solution comprises a through slot extrusion joining of metal to polymer-based component along linear or non-linear path with a continuous extrusion in one continuous linear action of the tool, or in continuous linear action of the tool. The joint is implemented for forming a T-joint.

Description

Method for joining a metal component and a polymer component and a structure comprising said components
Background of the invention
The invention relates generally to j oining of components of different materials , and especially to j ointing metal components and polymer components together .
Thereby, a structure and a method implementing such j oining technique are disclosed .
The obj ect of the invention is described in more detail in the preambles of independent claims of the application .
There is a continuously growing need for lightweight design in several industries , mainly in the field of transportation . This need has led to the usage of alternative lighter materials and new solutions . New obstacles arise in search of more lean and efficient designs . One of these obstacles is the need to j oin different types of engineering materials via dissimilar material j oining ( DMJ) methods . Achieving satisfactory physical and chemical performance is difficult in DMJ due to fundamental differences in the physical and chemical properties of the base components . It has been especially challenging for making j oints between metallic and polymeric components . Some techniques and arrangement have been developed for this purpose . However, it has been found that there are drawbacks in the current solutions which limits their usage for industrial scale production .
Brief description of the invention
The idea of the invention is to provide a new and improved concept to j oin metal to polymer .
The characteristic features of the structure according to the invention are presented in the characteri zing part of the first independent claim . The characteristic features of the method according to the invention are presented in the characteri zing part of the second independent claim .
In this document the metal-polymer j oining is based on j oining technique called a Through Slot Extrusion Joining with acronym TSEJ . This acronym TSEJ is used in this document for simplicity reasons and for improving clarity .
TSEJ is a method to produce continuous j oints between a metallic component and a polymeric-based component in an overlap- j oint configuration . The TSEJ method uses a rigid extrus ion die system which forms a continuous linear or non-linear slot through which the metallic component will be forced, or extruded, into the polymeric-based component . The continuous linear or non-linear slot is the aperture , or slit , formed by the inner edges of the rigid extrusion die system . The metallic component is forced by a rigid rotating tool , with a tool probe and a tool shoulder, into the polymeric-based component , through the continuous linear or non-linear slot of the rigid extrusion die system, when this rigid rotating tool is plunged in the metallic component and travels along the same path of the continuous linear or non-linear slot . The portion of the metallic component being mechanically processed by the rigid rotating tool softens as result of the heat energy release during the bulk plastic deformation . Thi s heated and softened portion of the metallic component is then forced through the continuous linear or non-linear slot of the rigid extrusion die system into the polymer-based component . During the processing phase of the TSEJ j oint, the tool shoulder keeps the top surface of the metallic component closed, and the tool probe produces the bulk plastic deformation of the metallic component . As the metallic component is forced into the polymeric-based component , the local interaction between these components results in that the constrained polymeric-based component , reacts by forcing its way into the metallic component , forming a geometrical complex shape in the forced, or extruded, portion of the metallic component resulting in the formation of a hook or crab claws shape . This hook or crab claws shape which is now filled with the polymeric-based component forms a strong mechanical interference , also known as clinching . The j oining mechanisms of TSEJ result from this strong mechanical interference , with the additional contribution of the physical and chemical adhesive and diffusion phenomena at the contacting interface between the metallic component and the polymeric-based component .
The idea of the proposed solution is to provide a structure wherein the mentioned continuous TSEJ j oint is implemented in a structure compri sing a T-j oint between the metallic component and the polymer-based component . An edge of the polymer-based component is in the T-j oint arranged perpendicularly against a planar surface of the metallic component . The TSEJ j oining technique forms hooks of the metallic component and the hooks are penetrated in the structure inside the polymer-bases component .
An advantage of the disclosed solution i s that the disclosed T-j oint has excellent mechanical strength properties and it can be implemented in a versatile manner in different structural pieces , elements , and components .
The structure comprises one or more metallic components , one or more polymer-based components , and at least one continuous j oint between them . The structure further comprises at least one T-j oint wherein the metallic component and the polymer-based component are orientated perpendicularly relative to each other . Further, cross-section of the continuous j oint is located at the T-j oint and comprises hook configuration made of the metallic component and extruded into the polymer-based component .
According to an embodiment , the metal lic component is of lightweight metallic material .
According to an embodiment , the metall ic component is of aluminium or aluminium alloy material . According to an embodiment , the metall ic component is of magnesium or magnesium alloy material .
According to an embodiment , the polymer-based material may be for example polyether ether ketone PEEK, carbon fiber reinforced polymer CFRP, glas s fiber reinforced polymer, or thermoplastic structural polymer .
According to an embodiment , at least one edge surface of the at least one polymer-based component is fastened by means of metallic hooks or claws to a planar surface of the at least one plate-like metallic component .
According to an embodiment , the structure has onesided configuration with one metal lic component and one or more transverse polymer-based components . Then there is one or more T-j oints only on one side of the structure .
According to an embodiment , the structure has two- sided configuration with two spaced metallic components and one or more transverse polymer-based components . Then there are one or more T-j oints on two oppos ite sides of the structure .
According to an embodiment , the continuous j oint at the T-j oint has a linear configuration .
According to an embodiment , the continuous j oint at the T-j oint has a non-linear configuration .
According to an embodiment , the polymer-based component comprises a waved contact surface facing towards a planar mating surface of the metallic component .
According to an embodiment , the structure comprises at least two T-j oints at a distance from each other .
According to an embodiment , the structure comprises at least two T-j oints on opposite sides of the polymer- based component .
According to an embodiment , the structure further comprises : two metallic components at a distance from each other and serving as flanges in the structure ; and at least one polymer-based component fastened by means of the T- j oints between the mentioned flanges and serving as a web in the structure .
According to an embodiment , the structure comprises several polymer-based and spaced webs . The spaced webs may be parallel or non-parallel .
According to an embodiment , the structure comprises only one web and is a beam .
According to an embodiment , the structure has I - shaped cross-section, whereby the structure is an I -beam . In the I -beam structure width of the web may be greater than width of the flanges .
According to an embodiment , the structure has H- shaped cross-section, whereby the structure is a H-beam . In the H-beam structure width of the flanges may be greater than width of the web between the flanges .
According to an embodiment , the structure comprises two polymeric-based webs at a transverse distance from each other .
According to an embodiment , the structure comprises three , four, five , or more polymeric-based webs at a transverse distance from each other .
According to an embodiment , the structure has a boxlike configuration . The box may be closed or open .
According to an embodiment , the structure has a boxlike configuration with a closed shape and comprises a top panel , a bottom panel , and a side panel between the top panel and the bottom panel . The top panel and the bottom panel both comprise the metallic components . The side panel comprises at least one polymer-based component . Further, the top panel and the bottom panel are j oined to the side panel by means of the T-j oints .
According to an embodiment , the structure has a boxlike configuration with an open shape and comprises a top panel , a bottom panel , and a side panel between the top panel and the bottom panel . The top panel and the bottom panel both comprise the metallic components . The side panel comprises at least one polymer-based component and has at least one side opening. Further, the top panel and the bottom panel are joined to the side panel by means of the T- oints .
According to an embodiment, the structure has a boxlike configuration with an open shape and comprises one of the following panels formed of the metallic components: a top panel, a bottom panel. The panel formed of the metallic component is joined to a side panel formed of the polymer- based component by means of the T-joint.
According to an embodiment, the structure has a boxlike configuration with rectangular shape.
According to an embodiment, the structure has a boxlike configuration with circular, oval or curved shape. Then the side panel or web may have waved, tubular or rounded form.
According to an embodiment, providing the structure with at least one T-joint wherein the continuous joint has a closed joint geometry. The T-joint may surround a top panel or bottom panel of a box-like structure for example.
According to an embodiment, the continuous joint at the T-joint is a load bearing structural joint. An advantage is that the joint is capable of bearing mechanical stresses.
According to an embodiment, the closed joint geometry formed by the continuous joint is a fluid pressure tight joint. The closed joint may be gas and liquid tight. This feature is advantageous for example when forming boxlike structures or cover elements.
According to an embodiment, the structure comprises an extrusion die plate structure between the metallic component and the polymer-based component. Further, the extrusion die plate structure comprises a slot with a path corresponding to the path of the continuous joint.
According to an embodiment, the structure comprises an extrusion die plate structure or extrusion die system during the j oining process but is removed from the final structure after the j oint in finished .
According to an embodiment , the disclosed solution relates also to a method for j oining one or more metallic components and one or more polymer-based components together by means of one or more j oints . The method comprises : placing a metallic component and a polymeric-based component towards each other at a j oint area ; providing the j oint area with an extrusion die plate structure comprising a through opening; rotating and plunging a probe of a non-consumable tool across the thickness of the metallic component ; and extruding part of the metallic component through the opening of the extrusion die plate structure into the polymer-based component for forming hooks protruding into the polymeric- based component and forming a j oint between the metallic component and the polymer-based component . The method further comprises : placing the polymeric-based component transversally in relation to the metallic component and forming thereby a T-shaped configuration at the j oint area ; and implementing an extrusion die plate structure compris ing a slot and providing the j oint with a continuous j oint path along the j oint whereby the j oint area comprises at least one T-j oint for the T-shaped configuration of the metallic component and the polymer-based component .
According to an embodiment , the method further comprises : arranging at least one polymer-based component between two metallic components ; orientating the polymer- based component transversally in relation to planar surfaces of the two metallic components ; and j oining the two metal lic components to opposing edge surfaces of the polymer-based component by means of the T-j oints .
According to an embodiment , the metal lic component and the polymer-based component may be orientated perpendicular in relation to each other .
According to an alternative embodiment , the metallic component and the polymer-based component may be angled in relation to each other. The angle may be 20 - 160°, typically 30°, 45° or 60°, or 120°, 135° or 150°, for example .
According to an embodiment, the disclosed solution:
- processes bulk materials into novel structures;
- does not coat a surface with processed powdered material ;
- does not rely on adaptor components and materials between the metallic component and polymer-based component to be joined, rather, it joins the components directly;
- utilizes no interfacial adhesives by necessity or intent ;
- uses no fasteners to create a joint;
- joins metal to polymer as a primary joint, with the polymer capable of constituting a structural member;
- the joints are created with a combination of mechanical interlocking, adhesive bonding, and diffusion mechanisms;
- is capable of long, continuous joints.
The above-presented embodiments and the features they contain may be combined to provide desired configurations .
Brief description of the figures
Some embodiments of the proposed solution are illustrated more specifically in the following figures, in which,
Figure 1 shows schematically steps of using through- slot extrusion joining TSEJ in manufacture of a multi-material structural system with T-joint design,
Figure 2 comprises subfigures 2a - 2e and shows schematically a structure with a T-joint design implementing single-side TSEJ joining process along a linear path, Figure 3 shows schematically some dif ferent crosssections of hook-type j oints formed by means of the TSEJ process for T-j oints ,
Figure 4 comprises subfigures 4a - 4c and shows schematically use of the TSEJ process for producing a T- j oint between a planar metallic component and a wavy polymer-based component ,
Figure 5 comprises subfigures 5a and 5b and shows schematically use of the TSEJ j oining technique for producing a beam-like single-web structure with a double sided T- j oint design,
Figure 6 comprises subfigures 6a - 6d and shows schematically a beam-like s ingle-web structure with a wavy polymer-based web fastened between two metallic flanges ,
Figure 7 comprises subfigures 7a - 7c and shows schematically a double-web structure with two polymeric- based webs fastened between two metallic flanges ,
Figure 8 comprises subfigures 8a - 8c and shows schematically a triple-web structure with three polymeric- based webs fastened between two metallic flanges ,
Figure 9 comprises subfigures 9a - 9c and shows schematically an open box-shaped structure in Figure 9b and its production in Figures 9a and 9c,
Figure 10 comprises subfigures 10 a - 10 c and shows schematically a closed box-shaped structure in different angles of view,
Figure 11 comprises subfigures I l a - 11 c and shows schematically an alternative open box-shaped structure ,
Figure 12 comprises subfigures 12 a - 12 c and shows in Figure 12a picture of a cross-section of a T-j oint and Figures lb and 12c are pictures showing top and bottom views of the same .
For clarity purposes , some embodiments of the proposed solutions are illustrated in a simplified form in the figures . The same reference numbers are used in the figures to denote the same elements and features . Detailed description of some embodiments
Figure 1 discloses a sequence via through-slot extrusion joining (TSEJ) of manufacturing of a multi-material structural system with T-joint design, in single-side, along a linear path: Step i) the exploded perspective of the components; Step ii) the tool (5) is positioned above a pre hole (8) and the multi-component extrusion die (3) is closed to form the extrusion slot (4) ; Step iii) the start position of the manufacturing system, with the components clamped and the tool (5) ready to travel with rotation implement the joining process on the T-joint design; Step iv) the perspective upon extraction of the tool (5) but before extraction of the multicomponent extrusion die; Step v) the perspective upon extraction of the multicomponent extrusion die (3) .
Figure 2 discloses a perspective on the T-joint design, in single-side, along a linear path, with an exemplary embodiment of a joint cross-sectional structure depicting in Detail a, the extruded metallic plate (1) into the shape of a hook or crab (6) acting as a joining mechanism for the T-joint design. At the top with the multicomponent extrusion die (3) and at the bottom, without the multicomponent extrusion die (3) .
Figure 3 discloses exemplary embodiments of structures formed with TSEJ. The crab claw-like structure can develop asymmetrically (A) ; with long and thin structures (B) ; short and thick (C) ; or short and symmetric rounded claws (D) . The tool geometry (5a, 5b) determines the form of these structures.
Figure 4 discloses implementation of the T-joint design, in single-side, along a non-linear waved joining path ( 7 ) .
Figure 5 discloses simultaneous implementation in double side, with one flange, of the T-joint design along a linear joining path (7) . This results in a I- or H- shape beam with the two flanges made of lightweight metallic material and the web made of polymer-based material.
Figure 6 discloses simultaneous implementation in double-side, with one flange, of the T-joint design along a non-linear joining path (7) . This results in a I- or H- shape beam with the two flanges made of lightweight metallic material and the web made of polymer-based material.
Figure 7 discloses implementation in double-side, with two-spaced webs, of the T-joint design along a linear joining path (7) . This results in two flanges made of lightweight metallic material and a double-web made of polymer- based material.
Figure 8 discloses implementation in double-side, with three-spaced webs, of the T-joint design along a linear joining path (7) . This results in two flanges made of lightweight metallic material and a triple-web made of polymer- based material.
Figure 9 discloses implementation in an open boxshaped flange structural system, with the T-joint design applied in single-side along a square non-linear joining path (7) . This results in an open box-shape structural system with one end flanges made of lightweight metallic material and the box-shape web made of polymer-based material.
Figure 10 discloses implementation in a closed boxshaped flange structural system, with the T-joint design applied in double-side along a square non-linear joining path (7) . This results in a closed box-shape structural system with two end flanges made of lightweight metallic material and the box-shape web made of polymer-based material .
Figure 11 discloses implementation in an open boxshaped flanged structural system, with the T-joint design applied in double-side along a square non-linear joining path (7) . This results in an open box-shape structural sys- tem with two end flanges made of lightweight metallic material and the open box-shape web made of polymer-based material .
Figure 12 discloses a real-world T-joint design made between a metallic component (1) and a polymer based component (2) with a removable extrusion die system (3) . The top image is a cross-section with the extruded hook/crab joining mechanism (6) , and the lower images are the top and bottom side of the finished component.
TSEJ is a method to produce continuous joints between a metallic component (1) and a polymer-based component (2) in an overlap- j oint configuration. The TSEJ method uses a rigid extrusion die system (3) which forms a continuous slot (4) through which the metallic component (1) will be forced, or extruded, into the polymer-based component (2) . The continuous slot (4) is the aperture, or slit, formed by the inner edges of the rigid extrusion die system (3) . The metallic component (1) is forced by a rigid rotating tool (5) , with a tool probe (5a) and a tool shoulder (5b) , into the polymer-based component (2) , through the continuous slot (4) of the rigid extrusion die system (3) , when this rigid rotating tool (5) is plunged in the metallic component (1) and travels along the same path of the continuous slot (4) . The portion of the metallic component (1) being mechanically processed by the rigid rotating tool (5) softens as result of the heat energy release during the bulk plastic deformation. This heated and softened portion of the metallic component (1) is then forced through the continuous slot (4) of the rigid extrusion die system (3) into the polymer- based component (2) . During the processing phase of the TSEJ joint (7) , the tool shoulder (5b) keeps the top surface of the metallic component (1) closed, and the tool probe (5a) produces the bulk plastic deformation of the metallic component (1) . As the metallic component (1) is forced into the polymer-based component (2) , the local interaction between these components results in that the constrained polymer-based component (2) , reacts by forcing its way into the metallic component (1) , forming a geometrical complex shape in the forced, or extruded, portion of the metallic component (1) resulting in the formation of a hook or crab claws shape (6) . The process evolutes in a quasi-conserva- tion of volume, so no significant voids are formed in the joining zone. The hook or crab claws shape (6) which is filled with the polymer-based component (2) forms a strong mechanical interference, also known as clinching. The joining mechanisms of TSEJ result from this strong mechanical interference, with the additional contribution of the physical and chemical adhesive and diffusion phenomena at the contacting interface between the metallic component (1) and the polymer-based component (2) .
The TSEJ cycle develops along the following sequence :
-The metallic component (1) , the polymer-based component (2) with the rigid extrusion die system (3) in between, are brought together and clamped in overlap- j oint, or T-joint configuration;
-To prevent the formation of flash, during the initial plunge of the tool probe (5a) of the rigid rotating tool (5) , a pre-hole (8) may be opened in the metallic component (1) at the start position of the TSEJ joint (7) . This pre-hole (8) can be cylindrical or conical. This prehole (8) can be blind or through. This pre-hole (8) can be larger, smaller, or equal to the diameter of the tool probe (5a) ;
-The tool probe (5a) of the rigid rotating tool (5) , is plunged at the start position of the TSEJ joint (7) until the tool shoulder (5b) contacts the top surface of the metallic component (1) ; -Upon a given dwell time, that can be equal to zero seconds or more, the rigid rotating tool (5) travels along the path of the continuous slot (4) , with constant or variable travel speed;
-At the end position of the TSEJ joint (7) , the rigid rotating tool (5) is extracted from the metallic component ( 1 ) ;
-The consolidated TSEJ joint (7) and inherent structural system is extracted from the clamping.
The hook or crab claws shape (6) formed by the metallic component (1) in interaction with the polymer-based component (2) can have the following configurations:
-Configuration of a hook, where only one of the sides of the extruded portion of the metallic component (1) extends into the polymer-based component (2) ;
-Configuration of a symmetrical crab claw, where both sides of the extruded portion of the metallic component (1) extends equally into the polymer-based component (2) ;
-Configuration of an asymmetrical crab claw, where both sides of the extruded portion of the metallic component
(1) extends differently into the polymer-based component
(2) .
The width of the continuous slot (4) is greater than zero, and it can be constant or variable. The continuous slot (4) can follow a one-dimensional, two-dimensional, or three-dimensional path.
The rigid extrusion die system (3) can be made of one (e.g., monolithic die (3a) ) , or more components (e.g. strips (3b) ) , which define an inner continuous slot (4) . After the TSEJ cycle is completed, if the rigid extrusion die system (3) if made of multiple components, it may be kept, within the joint, or it may be extracted.
The rigid extrusion die system (3) can be fully, or partially, embedded in the metallic component (1) , or in the polymer-based component (2) , or partially embedded in both the metallic component (1) and the polymer-based component (2 ) .
The surface of the polymer-based component (2) , facing the joining domain, can be flat, or have one or more shallow grooves, to mate with the fully, or partially embedded rigid extrusion die system (3) .
The surface of the metallic component (1) , facing the joining domain, can be flat, or have one or more shallow grooves, to mate with the fully, or partially embedded rigid extrusion die system (3) .
The rigid extrusion die system (3) is made of high- strength material compared with the strength of the metallic component (1) and the polymer-based component (2) . The rigid extrusion die system (3) is made with minimum thickness, as long as it provides rigidity effect to act as rigid, i.e. non-def ormable, extrusion die.
The joint configuration between the overlapping metallic component (1) and the polymer-based component (2) forms a T-joint design. The rigid extrusion die system (3) is positioned parallel, under and in contact with the metallic component (1) , while the polymer-based component (2) is positioned perpendicular to the metallic component (1) .
In TSEJ, the TSEJ joint (7) length is longer than zero, with no maximum length. A TSEJ joint (7) can include zones of overlap and/or intersection with previous TSEJ joint (7) processed zones.
The rigid rotating tool (5) can be made in one single component or made of multicomponent assembled together, namely a tool probe (5a) and a tool shoulder (5b) .
T-joint design with a linear joint enables to get a T-shape structural beam, i.e., a load-bearing system, with the one flange made of lightweight metallic material and the one web made of polymer-based material.
The web can be planar, joining the multilateral components with a linear T-joint design. The web can be non-planar (e.g., waved) joining the multilateral components with a non-linear T-joint design.
T-joint design enables to get a I- or H-shape structural beam, i.e., a load-bearing system, with two flanges made of lightweight metallic material and one web made of polymer-based material with a shape that can be planar or non-planar, e.g., a waved shape.
T-joint design enables to get a multi-web-shape structural beams, i.e., a load-bearing system, with the two flanges made of lightweight metallic material and two, or more, webs made of polymer-based material, with a shape that can be planar or non-planar, e.g., a waved shape.
The TSEJ manufacturing of the T-joint design in I- shape, H-shape, and multi-web-shape structural beams can be made in sequence or simultaneously.
The TSEJ manufacturing of the T-joint design enables other complex-shape structural beams such as closed and open box-shaped flanged structural system, with the T-joint design applied in single or double-side along non-linear joining path (7) . In these structures, the end flange (s) are made of lightweight metallic material and the open or closed box-shape web made of polymer-based material.
The length of the tool probe (5a) and the plunged position of the rigid rotating tool (5) during the manufacturing of the TSEJ joint (7) , is such that the tip of the tool probe (5a) can be positioned above, below, or at the level of the rigid extrusion die system (3) .
The parameters controlling the process TSEJ are the following :
1. Geometry of the tool probe (5a) ;
2. Geometry of the tool shoulder (5b) ;
3. Rotation speed of the tool (5) , or of the probe (5a) , if the shoulder (5b) is static;
4. Plunging speed or plunging force of the tool (5) ;
5. Plunging depth of the tool (5) ; 6. Dwell time at the maximum plunge depth, in plunging force or vertical position control;
7. Extraction speed of the tool (5) ;
8. Travel speed of the tool (5) , if the probe (5a) is continuous plunged in the metal component (1) , traversing along the path of the slot (4) in the extrusion die system (3) ;
9. Offset distance between the central axis of the tool (5) and the center of the slot (4) ;
10. Material and thickness of the extrusion die system (3) ;
11. Dimensions (including thickness) and form of the extrusion die system (3) ;
12. Width of slot (4) of the extrusion die system (3) ;
13. Path and orientation of the slot (4) of the extrusion die (3) ;
14. Material and thickness of the metal component (1) ;
15. Material and thickness of the polymer-based component (2 ) .
List of reference numerals:
1. Metallic component
2. Polymer-based component
2a. Shallow groove (optional) in polymer component (2) , to mate with the extrusion die system (3)
3. Rigid extrusion die system (thin and rigid plate compared with the metal (1) and the polymer (2) , at processing thermomechanical conditions)
3a. Monolithic, or single component extrusion die system (3) 3b. Multi-body extrusion die system (3) consisting of multiple components to constitute the system
4. Slot, or aperture, formed by the extrusion die system (3)
5. Non-consumable and rigid joining tool
5a. Probe of the non-consumable and rigid welding tool (5)
5b. Shoulder of the non-consumable and rigid welding tool (5)
6. Hook or crab claw shape formed by the extruded portion of the metallic component into the polymer-based component when viewed on a cross section parallel to the processing path
7. TSE J j oint
8. Blind- or through-hole style pre-hole used at (or in the vicinity of) the plunge location
9. Metal-polymer-metal stack with doubleside TSEJ joint
10. Exit hole, where the tool exits
11. Joint start
12. Joint end
13. T-joint
14. Flange, formed of metallic component
15. Web, formed of polymer-based component
16. Edge side of polymer-based component
17. Planar surface of metallic component
18. One-sided structure
19. Double-sided structure
20. Box-like structure, closed
21. Box-like structure, open
22. Panel
23. Side panel
24. Top panel 25 . Bottom panel
26 . Opening, top or bottom panel missing, or side opening The figures and their description are only intended to illustrate the inventive idea . However, the scope of protection of the invention is defined in the claims of the application .

Claims

Claims
1. A structure comprising: at least one metallic component; at least one polymer-based component; and a continuous joint between the metallic component and the polymer-based component; cha ra ct e r i z ed in that, the structure comprises at least one T-joint wherein the metallic component and the polymer-based component are orientated transversally relative to each other; and wherein cross-section of the continuous joint at the T-joint comprises hook configuration made of the metallic component and extruded into the polymer-based component .
2. The structure according to claim 1, c h a r a c t e r i z e d in that, the continuous joint at the T-joint has linear configuration .
3. The structure according to claim 1, c h a r a c t e r i z e d in that, the continuous joint at the T-joint has non-linear configuration.
4. The structure according to claim 3, c h a r a c t e r i z e d in that the polymer-based component comprises a waved contact surface facing towards a planar mating surface of the metallic component.
5. The structure according to any one of the previous claims 1 - 4, c h a r a c t e r i z e d in that, the structure comprises at least two T-joints at a distance from each other.
6. The structure according to any one of the previous claims 1 - 5, c h a r a c t e r i z e d in that, the structure comprises at least two T-joints on opposite sides of the polymer-based component.
7. The structure according to any one of the previous claims 1 - 6, c h a r a c t e r i z e d in that, the structure further comprises: two metallic components at a distance from each other and serving as flanges in the structure; and at least one polymer-based component joined by means of the T-joints between the mentioned flanges and serving as a web in the structure.
8. The structure according to claim 6 or 7, c h a r a c t e r i z e d in that, the structure comprises one web and is a beam.
9. The structure according to claim 8, c h a r a c t e r i z e d in that, the structure has T-shaped cross-section, whereby the structure is an I-beam.
10. The structure according to claim 8, c h a r a c t e r i z e d in that, the structure has H-shaped cross-section, whereby the structure is a H-beam.
11. The structure according to claim 6, c h a r a c t e r i z e d in that, the structure comprises two polymeric-based webs at a transverse distance from each other.
12. The structure according to claim 6, c h a r a c t e r i z e d in that, the structure comprises at least three polymeric- based webs at a transverse distance from each other.
13. The structure according to any one of the previous claims 1 - 6, c h a r a c t e r i z e d in that, the structure has a box-like configuration with a closed shape and comprises a top panel, a bottom panel, and a side panel between the top panel and the bottom panel; the top panel and the bottom panel both comprise the metallic components; the side panel comprises at least one polymer-based component; and the top panel and the bottom panel are joined to the side panel by means of the T-joints.
14. The structure according to any one of the previous claims 1 - 6, c h a r a c t e r i z e d in that, the structure has a box-like configuration with an open shape and comprises a top panel, a bottom panel, and a side panel between the top panel and the bottom panel; the top panel and the bottom panel both comprise the metallic components; the side panel comprises at least one polymer-based component and has at least one side opening; and the top panel and the bottom panel are joined to the side panel by means of the T-joints.
15. The structure according to any one of the previous claims 1 - 6, c h a r a c t e r i z e d in that, the structure has a box-like configuration with an open shape and comprises one of the following panels formed of the metallic components: a top panel, a bottom panel; the panel formed of the metallic component is joined to a side panel formed of the polymer-based component by means of the T-joint.
16. The structure according to any one of the previous claims 1 - 15, c h a r a c t e r i z e d in that, the structure comprises an extrusion die plate structure between the metallic component and the polymer- based component; and the extrusion die plate structure comprises a slot with a path corresponding to the path of the continuous j oint .
17. A method for joining a metallic component and a polymer-based component together by means of a joint, the method comprises: placing a metallic component and a polymeric-based component towards each other at a joint area; providing the joint area with an extrusion die plate structure comprising a through opening; rotating and plunging a probe of a non-consumable tool across the thickness of the metallic component; extruding part of the metallic component through the opening of the extrusion die plate structure into the polymer-based component for forming hooks protruding into the polymeric-based component and forming a joint between the metallic component and the polymer-based component; cha ra ct e r i z ed by placing the polymeric-based component transversally in relation to the metallic component and forming thereby a T-shaped configuration at the joint area; and implementing an extrusion die plate structure comprising a slot and providing the joint with a continuous joint path along the joint whereby the joint area comprises at least one T-joint for the T-shaped configuration of the metallic component and the polymer-based component.
18. The method according to claim 17, c h a r a c t e r i z e d by implementing double-sided joining comprising : arranging at least one polymer-based component between two metallic components; orientating the polymer-based component transversally in relation to planar surfaces of the two metallic components; and joining the two metallic components to opposing edge surfaces of the polymer-based component by means of the T- j oints .
PCT/FI2023/050149 2022-03-15 2023-03-15 Method for joining a metal component and a polymer component and a structure comprising said components WO2023175242A1 (en)

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Citations (7)

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Publication number Priority date Publication date Assignee Title
JP2010158885A (en) * 2008-12-09 2010-07-22 Nippon Light Metal Co Ltd Method of joining resin member to metal member, and method of manufacturing liquid-cooled jacket
JP2017104885A (en) * 2015-12-10 2017-06-15 太平洋工業株式会社 Bonding method and conjugate
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EP3645251A1 (en) * 2017-06-28 2020-05-06 Aalto University Foundation SR Method for joining a metal component and a polymer component, and structure comprising said components
EP3865283A1 (en) * 2018-10-12 2021-08-18 DIC Corporation Metal-resin composite and method for producing same
WO2022030015A1 (en) * 2020-08-07 2022-02-10 睦月電機株式会社 Metal resin joined body and method for manufacturing metal resin joined body

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2010158885A (en) * 2008-12-09 2010-07-22 Nippon Light Metal Co Ltd Method of joining resin member to metal member, and method of manufacturing liquid-cooled jacket
JP2017104885A (en) * 2015-12-10 2017-06-15 太平洋工業株式会社 Bonding method and conjugate
DE102016211708A1 (en) * 2016-06-29 2018-01-04 Sgl Carbon Se New material composite
EP3498416A2 (en) * 2016-09-30 2019-06-19 LG Chem, Ltd. Bonded structure of heterogeneous materials and method for manufacturing same
EP3645251A1 (en) * 2017-06-28 2020-05-06 Aalto University Foundation SR Method for joining a metal component and a polymer component, and structure comprising said components
EP3865283A1 (en) * 2018-10-12 2021-08-18 DIC Corporation Metal-resin composite and method for producing same
WO2022030015A1 (en) * 2020-08-07 2022-02-10 睦月電機株式会社 Metal resin joined body and method for manufacturing metal resin joined body

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