Activatable Material Application Through-Holes for Self-Anchoring
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Solution Overview
Problem
Existing activatable materials for adhesion, reinforcement, and noise/vibration reduction in manufacturing require pre-shaping, mechanical fasteners, or additional processing steps, making them cumbersome and inefficient for direct application to articles of manufacture.
Innovation Solution
A method involving an activatable material with specific viscosity applied through through-holes in an article of manufacture, forming a mechanical interlock without additional fasteners or processing, using an applicator that adjusts pressure and temperature to ensure self-anchoring and secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If activatable material is applied without pre-shaping or mechanical fasteners, then application complexity is reduced, but the material cannot be held in place in the pre-activation state
Solution Approach 1:
The activatable material self-anchors by forming a mechanical interlock with the through-holes through its own viscous flow and conformation, without requiring external fasteners or pre-shaping operations. The material serves its own positioning and anchoring function.
Solution Approach 2:
The material's viscosity is controlled to be sufficient to maintain positioning during application, yet allows the material to flow through and conform to through-holes under application pressure, creating a mechanical interlock that anchors the material in place.
2Reliability
If additional processing steps are required before material application, then material attachment reliability is improved, but manufacturing efficiency decreases
Solution Approach 1:
The material is formulated with specific viscosity characteristics before application that enable it to self-anchor through through-holes during the application process itself, eliminating the need for separate pre-processing or post-processing steps.
Solution Approach 2:
The application process combines multiple functions (material deposition, positioning, and anchoring) into a single step where the material is applied and simultaneously self-anchors through the through-holes, eliminating separate processing steps.
3Strength
If material viscosity is increased to prevent pull-through, then anchoring strength is improved, but material flow through holes becomes difficult
Solution Approach 1:
The material viscosity is optimized to a specific range that allows flow under application pressure while maintaining sufficient strength to resist pull-through after anchoring. The viscosity parameter is carefully controlled to balance these opposing requirements.
Solution Approach 2:
The material exhibits dynamic behavior where its flow characteristics change during application - flowing easily under pressure to conform to holes, then maintaining structural integrity once anchored. The material transitions from a flowable state to an anchored state.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The material self-anchors securely to the article of manufacture, resisting pull-through and eliminating the need for additional steps or components, enabling efficient and permanent attachment during the manufacturing process.
Implementation Method 1
the material conforms to the one or more through holes to self-anchor the material to the article of manufacture to resist pull-though
Data Source
AI summary
There is disclosed a method of applying activatable material to a member of an article of manufacture such as an automotive vehicle. According to the method, the activatable material is provided to an applicator followed by applying the activatable material to the member wherein the activatable material is attached by way of a mechanical interlock via one or more through-holes.