Fiber Composite Fastening Using Vibration-Activated Resin Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for fastening objects, particularly in industries using lightweight materials like fiber composites, face challenges such as limited mechanical strength, precision issues in positioning, and prolonged curing times due to the small ductility of these materials and the need for pre-drilling or specific adhesive curing conditions.
Innovation Solution
A method involving the use of mechanical vibration to activate a flowable resin between two objects, allowing it to cross-link and create a strong adhesive bond without weakening the materials, which can penetrate structures for a positive-fit connection, thus overcoming the limitations of traditional fastening techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional riveting techniques are used to fasten objects to fiber composite materials, then mechanical fastening is achieved, but the small ductility of fiber composite materials limits the effectiveness and requires pre-drilling which creates positioning precision issues
Solution Approach 1:
The patent replaces the mechanical riveting system with a chemical adhesive bonding system. Instead of using rivets that require pre-drilled holes and mechanical deformation, the invention uses adhesives that can bond directly to the fiber composite surfaces without compromising the material structure or requiring precise hole positioning.
Solution Approach 2:
The patent changes the bonding mechanism from mechanical (riveting) to chemical (adhesive bonding). This parameter change allows the bonding process to accommodate the low ductility of fiber composites by eliminating the need for mechanical deformation and pre-drilling, thereby improving positioning precision while maintaining bond strength.
2Strength
If adhesive connections are used to fasten objects, then strong bonding is achieved, but curable adhesives require considerable curing time which increases production time
Solution Approach 1:
The patent utilizes the phase transition of the adhesive from liquid (flowable state) to solid (cross-linked state) to achieve bonding. By controlling this phase transition through UV irradiation or heat, the curing time is significantly reduced compared to conventional thermal curing adhesives, thereby increasing production speed while maintaining bond strength.
Solution Approach 2:
The patent employs periodic action through UV irradiation or controlled heating to accelerate the curing process. Instead of relying on slow ambient thermal curing, the adhesive is exposed to periodic energy input that triggers and accelerates the cross-linking reaction, reducing curing time from minutes/hours to seconds/minutes while achieving full bond strength.
3Productivity
If UV curable adhesives are used to reduce curing time, then faster curing is achieved, but at least partially transparent connectors are required to allow curing radiation to reach the adhesive
Solution Approach 1:
The patent introduces an intermediary element (transparent connector or window) that allows UV radiation to pass through and reach the adhesive layer. This intermediary enables the use of UV curable adhesives with non-transparent connectors by transmitting the curing radiation through the transparent portion to the adhesive, thus maintaining both fast curing speed and material versatility.
4Ease of manufacture
If pre-drilling is performed to attach connectors to fiber composite parts, then mechanical fastening positions are created, but positioning precision issues arise especially when several parts are to be attached
Solution Approach 1:
The patent replaces the mechanical pre-drilling system with an adhesive bonding system that does not require pre-defined holes. The adhesive can be applied to the surface and will flow to fill gaps and create bonds without requiring precise hole positioning, thereby eliminating positioning precision issues while maintaining ease of manufacture.
5Weight of moving object
If lightweight materials with reduced mechanical strength are used, then weight is reduced, but fastenings that require material weakening such as bores are more and more to be avoided
Solution Approach 1:
The patent replaces mechanical fastening systems (rivets, bolts requiring holes) with adhesive bonding systems. This substitution eliminates the need to create holes or weaken the lightweight materials, preserving their structural integrity while maintaining ease of manufacture. The adhesive bonds to the surface without requiring material removal or weakening.
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 provides a rapid, reliable, and strong mechanical bond that does not require pre-defined structures or precise positioning, accelerating the curing process by an order of magnitude and allowing for tolerance adjustments, while avoiding the need for material weakening or specific positioning precision.
Implementation Method 1
causing mechanical vibration to act on the second object or the first object or both, thereby activating the resin to cross-link
Data Source
AI summary
A method of fastening a second object to a fiber composite part including a structure of fibers embedded in a matrix material includes: providing the fiber composite part including an attachment surface, with a portion of the structure of fibers being exposed at the attachment surface; providing the second object; placing the second object relative to the fiber composite part, with a resin in a flowable state between the attachment surface and the connector; pressing the second object and the fiber composite part against each other and causing mechanical vibration to act on the second object or the fiber composite part or both, thereby causing the resin to infiltrate the exposed structure of fibers and activating the resin to cross-link; whereby the resin, after cross-linking, secures the second object to the fiber composite part.