Composite Material Bonding With Retractable Sheet Heating for Shorter Cycles
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Solution Overview
Problem
Existing composite material bonding methods require a step of conveying composite members to a pressurization-bonding forming device after melting, leading to increased cycle time and limited temperature rising rate, which hinders further cycle time reduction.
Innovation Solution
A composite material bonding apparatus and method utilizing a sheet heater that heats bonding surfaces in parallel and then retracts to allow immediate bonding, combined with a control unit to manage the heating and pressurization process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional infrared heater is used to heat bonding surfaces, then the heating process can be performed, but the temperature rising rate is limited and cycle time cannot be sufficiently shortened
Solution Approach 1:
The patent replaces the conventional infrared heater with a sheet heater that directly contacts or closely approaches the bonding surfaces. This substitution of the heating mechanism enables significantly faster temperature rise by eliminating the limitations of infrared radiation heating, thereby reducing cycle time while achieving rapid temperature increase.
Solution Approach 2:
The patent introduces a movable sheet heater that can dynamically adjust its position between an insertion position (for heating) and a retract position (for bonding). This dynamic positioning allows the heating process to be rapidly followed by immediate bonding operations, optimizing the cycle time by eliminating unnecessary conveyance steps.
2Ease of manufacture
If composite members are conveyed to a pressurization-bonding forming device after melting, then bonding can be performed, but cycle time increases
Solution Approach 1:
The patent merges the heating function and bonding function into a single integrated process. The sheet heater is positioned at an insertion position that allows simultaneous heating and subsequent bonding without requiring separate conveyance to a pressurization-bonding forming device. This consolidation eliminates the conveyance step and significantly reduces cycle time.
Solution Approach 2:
The sheet heater performs preliminary heating of the bonding surfaces to the required temperature, and then the bonding process can be immediately executed without waiting for or requiring separate conveyance to a pressurization device. This preliminary heating action integrated with the bonding process eliminates the conveyance step and reduces overall cycle time.
3Temperature
If the sheet heater remains at the insertion position during bonding, then heating can be maintained, but the bonding surfaces cannot be properly pressed together
Solution Approach 1:
The patent employs a movable sheet heater that dynamically transitions between an insertion position (for heating) and a retract position (for bonding). During the bonding phase, the sheet heater retracts from the insertion position, allowing the bonding surfaces to be properly pressed together without obstruction. This dynamic positioning ensures both effective heating when needed and proper bonding when required.
Solution Approach 2:
The sheet heater is extracted (retracted) from the insertion position during the bonding phase to remove any obstruction between the bonding surfaces. This extraction allows the bonding surfaces to be directly pressed together, ensuring proper bonding strength while the heater remains available for subsequent heating operations.
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 approach significantly shortens the cycle time by enabling simultaneous and uniform heating of bonding surfaces, followed by immediate bonding and pressurization, thereby optimizing the bonding process.
Implementation Method 1
a sheet heater (3) having a planar shape; a sheet heater moving device that locates the sheet heater at an insertion position between a first bonding surface (W1c) of a first composite member (W1) and a second bonding surface (W2c) of a second composite member (W2) facing the first bonding surface
Data Source
AI summary
Provided is a composite material bonding apparatus that can reduce a cycle time when composite material members are bonded to each other. The composite material bonding apparatus includes a sheet-heater moving device that places a graphite heater at an insertion position between a first bonded surface of a first composite material member and a second bonded surface of a second composite material member such that the graphite heater is parallel to the first bonded surface and the second bonded surface facing the first bonded surface, and retracts the graphite heater to a retraction position from the insertion position. The first bonded surface and the second bonded surface are heated at the insertion position by the graphite heater, and then the graphite heater is moved to the retraction position by the sheet-heater moving device.