Composite Joint Bonding with Segmented Pressure for Undercut Shapes
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Solution Overview
Problem
Existing methods for producing composite material joint bodies with hollow portions, such as those with undercut shapes, face challenges in using bladder bags due to insertion difficulties, leading to inadequate adhesive forces.
Innovation Solution
A method involving the formation of a hollow body with cells of varying pressures, where the first cell is pressurized more than the second cell, using an expansion member for the first cell and gas for the second, with overlapping composite material portions bonded by an adhesive.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bladder bag is used to pressurize all cells in the internal pressure forming method, then uniform adhesive force can be achieved, but the method becomes inapplicable when cells have undercut shapes that prevent bladder bag insertion
Solution Approach 1:
The hollow body is divided into multiple cells (first cell, second cell, third cell) with different pressurization methods. The first cell uses an expansion member for high pressure, while the second and third cells use gas for lower pressure, allowing adaptation to different cell geometries including undercut shapes
Solution Approach 2:
Different pressurization strategies are applied to different cells based on their specific geometric characteristics. Cells with undercut shapes that cannot accommodate expansion members use gas pressurization, while cells suitable for expansion members receive higher pressure for better adhesive bonding
2Adaptability or versatility
If gas is used to pressurize all cells, then the method can be applied to cells with undercut shapes, but the adhesive force becomes insufficient compared to expansion member pressurization
Solution Approach 1:
The pressurization system is segmented into high-pressure zones (first cell with expansion member) and low-pressure zones (second and third cells with gas), allowing each zone to be optimized for its specific requirements
Solution Approach 2:
The pressure parameter is varied across different cells, with the first cell receiving higher pressure from the expansion member and the second and third cells receiving lower pressure from gas, optimizing both adhesive force and geometric adaptability
3Reliability
If an expansion member is inserted into all cells, then high adhesive force can be achieved, but the device complexity increases and cells with undercut shapes cannot be processed
Solution Approach 1:
The expansion member insertion process is segmented and selective rather than universal. Expansion members are inserted only into cells where geometric conditions permit, simplifying the overall process while maintaining high adhesive force where needed
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 maintains adhesive force and facilitates production of composite material joint bodies with hollow portions, even in cases where bladder bags cannot be used, enhancing manufacturing efficiency and adhesive strength.
Implementation Method 1
the first cell includes an expansion member that pressurizes a first inner surface in contact with the first inner surface facing the first cell of a first cell member that surrounds the first cell
Implementation Method 2
the second cell includes gas that pressurizes a second inner surface in contact with the second inner surface facing the second cell of a second cell member that surrounds the second cell
Implementation Method 3
a portion of the first cell member includes an overlapping portion in which the composite materials overlap each other in a thickness direction of the first cell member with an adhesive interposed between the composite materials
Data Source
AI summary
A method for producing a composite material joint body includes steps of: bonding a plurality of composite materials, forming a hollow body including at least a first cell and a second cell adjacent to the first cell, and adjusting a pressure so that a first pressure in the first cell is greater than a second pressure in the second cell. In the step of forming the hollow body, the first cell includes an expansion member pressurizing a first inner surface facing the first cell of a first cell member, and the second cell includes a gas pressurizing a second inner surface facing the second cell of a second cell member, and in the step of adjusting the pressure, the first pressure generated by the expansion member pressurizing the first inner surface is increased as compared with the second pressure generated by the gas pressurizing the second inner surface.