Adhesive Bond Pressurization Using Load Feedback to Prevent Gaps
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Solution Overview
Problem
Existing methods for bonding components using adhesives struggle to ensure consistent connection of adhesives during the pressurization process, leading to reduced adhesive strength due to potential gaps between adhesive locations.
Innovation Solution
A manufacturing method involving an adhesive application process, component placement, and pressurization process, where the load or compression speed is monitored using sensors to detect specific increase or decrease periods, allowing for precise control of pressurization to ensure adhesive connection, with the pressurization stopped during rapid increase or decrease periods to guarantee adhesive connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If adhesive is applied to multiple locations and pressurization is performed to expand and connect adhesives, then adhesive can be applied to wide area using relatively low load, but it is difficult to grasp the expanded area of adhesive and adhesives may not be connected reliably
Solution Approach 1:
The patent applies feedback control by monitoring the load applied to the pressurizer during the pressurization process. When the load reaches a predetermined threshold value, the pressurization is automatically stopped. This feedback mechanism ensures that adhesives are reliably connected without requiring complex sensing of adhesive expansion, thus resolving the contradiction between wide area coverage and connection reliability.
2Reliability
If high load is applied to pressurize components to ensure adhesive connection, then adhesive connection is reliable, but high load may damage the components
Solution Approach 1:
The patent uses feedback control to monitor the load during pressurization and automatically stops when a predetermined threshold is reached. This prevents excessive load application while ensuring sufficient pressure for reliable adhesive connection, thus resolving the contradiction between connection reliability and force magnitude.
3Manufacturing precision
If pressurization is performed without precise control, then process is simple, but adhesive expansion and connection cannot be precisely controlled
Solution Approach 1:
The patent implements feedback control by monitoring load and automatically stopping pressurization when a predetermined value is reached. This provides precise control over adhesive expansion and connection without requiring complex control systems, sensors, or visual inspection mechanisms, thus resolving the contradiction between manufacturing precision and device complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method ensures reliable connection of adhesives during the bonding process, preventing gaps and enhancing adhesive strength, while also allowing for accurate control of adhesive distribution and properties like thixotropy and thermal conductivity.
Implementation Method 1
In the pressurization process, a pressurizer pressurizes the second component toward the first component, to compress the adhesive
Implementation Method 2
When the pressurization process is performed, the adhesive is compressed and expanded in the lateral direction
Implementation Method 3
a load applied to the pressurizer changes such that the load goes through a curvilinear increase period in which the load increases in a curved line as an amount of compression of the adhesive increases, and a rapid increase period in which the load increases in a polygonal line
Data Source
Figure 1~2
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Figure 5~6
AI summary
A method of manufacturing adhered components includes a process of applying adhesive (20, 20a, 20b) to application areas (21a, 21b) on a surface of a first component (12), a process of placing a second component (16) above the first component (12), and a process of pressurizing the second component (16) toward the first component (12). In the pressurization process, the load applied to a pressurizer (30) changes while sequentially undergoing a curvilinear increase period in which the load increases in a curved line as the compression amount of the adhesive (20, 20a, 20b) increases, and a rapid increase period in which the load increases in a polygonal line with respect to the trajectory of the load in the curvilinear increase period as the compression amount increases. During pressurization by the pressurizer (30), the load is detected by a load sensor (40), the rapid increase period is detected based on the detection value of the load sensor (40), and the pressurization is stopped during the rapid increase period.