Structural assemblies using integrally molded, and welded mechanically locking z-pins
First Claim
1. A structure comprising:
- a. a first layer;
b. a second layer adjacent to the first layer; and
c. at least one z-pin embedded within the first and second layers to attach the first and second layers, the z-pin embedded therein defines a pull out force with respect to the first layer less than a pull out force with respect to the second layer, each z-pin having at least two radially extending flanges with at least one flange embedded within the first layer to greater depth compared to a depth to which the flange section is embedded within the second layer to compensate for the lower pull out force of the z-pin from the first layer compared to the pull out force of the z-pin from the second layer.
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Accused Products
Abstract
A structure is provided which includes first and second layers. The first and second layers are attached to each other by embedding or otherwise attaching at least one mechanically locking z pin to the first layer and then subsequently joining the protruding portion of the z pin to the second layer prior to the second layer being processed to a fully cured state. Alternatively, the z pin material is injected into a cavity formed in the first and second layer and then brought to a fully cured state. The z pin may have physical characteristics such as orientation, melting point and hardness as a function of the physical characteristics of the first and second layer and the forces subjected upon the first and second layers. For example, the z pin may define a longitudinal axis and be embedded within the first and second layers in alignment with an applied force subjected on the first and second layers. This ensures that the z-pin is subjected primarily to tensile forces which allows designs to better control the failure mode of the attached first and second layers.
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Citations
24 Claims
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1. A structure comprising:
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a. a first layer;
b. a second layer adjacent to the first layer; and
c. at least one z-pin embedded within the first and second layers to attach the first and second layers, the z-pin embedded therein defines a pull out force with respect to the first layer less than a pull out force with respect to the second layer, each z-pin having at least two radially extending flanges with at least one flange embedded within the first layer to greater depth compared to a depth to which the flange section is embedded within the second layer to compensate for the lower pull out force of the z-pin from the first layer compared to the pull out force of the z-pin from the second layer. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. A structure comprising:
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a. a first layer defining an interface surface and having at least one depression, each depression configured as a female mating flange of a z-pin;
b. a second layer defining an interface surface with at least one nub being unitary with the second layer, each nub configured as at least one flange of the z-pin. - View Dependent Claims (14, 15, 16, 17, 18, 19)
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- 20. A method for limiting delamination between attached first and second layers, the method comprising step a) of embedding a plurality of z-pins into an interface surface of the first layer, and embedding a plurality of z-pins into an interface surface of the second layer, each z-pin having at least two radially extending flanges, at least one flange section being embedded into respective first and second layers, and at least one flange sections protruding externally from the interface surfaces of respective first and second layers.
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24. A method of embedding z-pins within first and second layers, the method comprising:
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a. forming female flange sections within the first and second layers with a channel connected to each of the female flange sections;
b. aligning the female flange sections of the first and second layers to each other;
c. filling liquid z-pin material into the aligned female flange sections of the first and second layers through the channel; and
d. solidifying the liquid z-pin material.
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Specification