Composite Structural Joint with Flexible Adhesive Layer
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Solution Overview
Problem
Conventional structural joints, such as those using mechanical fasteners and adhesive bonding, face challenges like labor-intensive installation, stress concentrations, corrosion, difficulty in adhesive preparation, and limited tolerance accommodation, which increase weight and complexity.
Innovation Solution
A composite structural joint system featuring 'T' or 'L' shaped members with overlapping base portions and adhesive layers, allowing for flexible alignment and pressure application during curing, enabling efficient bonding and tolerance accommodation without the need for extensive surface preparation or mechanical fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical fasteners are used to join structural members, then the joint strength and reliability are improved, but the installation complexity and labor intensity increase due to drilling and deburring operations
Solution Approach 1:
The patent removes the fastener holes and mechanical fastening elements from the structural members, extracting the problematic drilling and deburring operations entirely. The members are designed with overlapping base portions that directly bond through adhesive application, eliminating the need for hole preparation and fastener installation while maintaining joint reliability.
Solution Approach 2:
The patent replaces the mechanical fastening system with an adhesive bonding system. Instead of using mechanical fasteners that require drilled holes, the invention uses adhesive layers applied between overlapping base portions to create the structural joint, thereby eliminating drilling and deburring operations.
2Strength
If mechanical fasteners are used to join structural members, then the joint strength is improved, but the weight and size of the members increase due to stress concentrations
Solution Approach 1:
The patent removes the fastener holes and associated stress concentration zones from the structural members. By eliminating the need for holes and mechanical fasteners, the members can be designed with optimized, continuous geometries that reduce weight while maintaining joint strength through adhesive bonding of overlapping base portions.
3Stability of the object's composition
If adhesive bonding is used with a rigid adapter and slot geometry, then the joint stability is improved, but the manufacturing complexity increases due to difficult surface preparation
Solution Approach 1:
The patent introduces flexibility into the adhesive bonding system by using a flexible adhesive layer between the overlapping base portions. This flexible bond line can accommodate surface imperfections and variations in the bonding surfaces, eliminating the need for extensive sanding and cleaning operations while maintaining joint stability.
4Reliability
If a rigid adapter with fixed slot geometry is used, then the joint reliability is improved, but the adaptability decreases due to limited tolerance accommodation
Solution Approach 1:
The patent uses a flexible adhesive layer that can dynamically accommodate variations in part dimensions and alignment. The flexible bond line adapts to tolerance variations in the overlapping base portions, allowing the joint to maintain reliability across a range of dimensional variations without requiring precise, fixed geometry.
Solution Approach 2:
The patent changes the physical state and properties of the bonding interface by using a flexible adhesive layer with specific viscoelastic properties. This allows the bond line to deform and accommodate tolerance variations in the parts being joined, providing adaptability while maintaining joint reliability under various loading conditions.
5Adaptability or versatility
If a large slot is used in the adapter to accommodate tolerance variations, then the adaptability is improved, but the weight and expense increase due to increased adhesive requirements
Solution Approach 1:
The patent uses a flexible adhesive layer that can accommodate tolerance variations without requiring a large slot or increased adhesive volume. The flexible bond line dynamically adjusts to dimensional variations within the overlapping base portions, maintaining adaptability while minimizing adhesive requirements and associated weight.
6Manufacturing precision
If fixed geometry slots are used in adapters, then the manufacturing precision is improved, but the ease of operation decreases due to inability to apply positive bonding pressure
Solution Approach 1:
The patent uses a flexible adhesive layer that allows for the application of positive bonding pressure during curing. The flexible bond line can be compressed between the overlapping base portions, enabling easy application of bonding pressure without requiring complex slot geometries or adjustment mechanisms, thereby improving ease of operation while maintaining manufacturing precision.
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 system simplifies the installation process, reduces stress concentrations, allows for various adhesive types and customizable bond line thickness, and accommodates part tolerances, resulting in improved bond quality and reduced installation complexity.
Implementation Method 1
a first member (305) and a second member (307) configured for attaching a panel (309) to a skin (303)... with an adhesive layer (317b) between the inner base portions (305a, 307a) of the first and second members (305, 307)
Data Source
AI summary
A structural joint includes a first member having a first base portion and a first leg portion. The structural joint further includes a second member having a second base portion and a second base portion. The first base portion and the second base portion are coupled together at an overlapping portion. The first leg portion and the second leg portion form a cavity for structurally coupling to a structural member.