Convex Adhesive Sheet Structure for Narrow-Space Insertion
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Solution Overview
Problem
Existing adhesive sheets used in narrow spaces, such as those for EV motors, face challenges in achieving high adhesion while ensuring ease of insertion and maintaining various characteristics during and after heating, particularly when using thermosetting adhesives with softening points above 50°C.
Innovation Solution
An adhesive sheet comprising a first adhesive layer with a softening point of 50°C or higher and a second adhesive layer that is tacky and foamed by heat, featuring convex structures on its surface, allowing for easy insertion and enhanced adhesion properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a thermosetting adhesive with softening point of 50°C or higher is used to ensure favorable ease of insertion, then the ease of insertion is improved, but the selection of components is restricted and reactivity, foamability, and adhesivity are limited
Solution Approach 1:
The adhesive sheet is divided into two distinct adhesive layers: a first adhesive layer containing thermosetting adhesive with softening point ≥50°C for ease of insertion, and a second adhesive layer with different properties for enhanced adhesion and foamability. This segmentation allows each layer to be optimized independently, resolving the contradiction between ease of insertion and component versatility.
Solution Approach 2:
Different regions of the adhesive sheet (first and second adhesive layers) are given different material properties and functions. The first layer provides low-friction insertion properties, while the second layer provides high adhesion and foamability. This local differentiation allows the overall system to achieve both ease of insertion and component versatility.
2Ease of operation
If a thermosetting adhesive with softening point of 50°C or higher is used, then ease of insertion is improved, but reactivity, foamability, and adhesivity during or after heating are restricted
Solution Approach 1:
The adhesive functionality is segmented across two layers: the first layer handles insertion with its non-tacky, high-softening-point thermosetting adhesive, while the second layer handles post-heating adhesion with adhesive composition optimized for reactivity and foamability. This resolves the contradiction between ease of insertion and adhesivity after heating.
Solution Approach 2:
The first adhesive layer performs the preliminary action of facilitating easy insertion before heating. The second adhesive layer then performs the subsequent action of providing strong adhesion and foam expansion after heating. This sequential action pattern resolves the contradiction between insertion ease and post-heating reliability.
3Volume of moving object
If an adhesive sheet is inserted into a narrow space, then the application requirement is met, but adhesive performance needs to be sufficiently high after adhesion
Solution Approach 1:
The adhesive sheet uses local quality differentiation where the first adhesive layer provides thin-profile insertion capability for narrow spaces, while the second adhesive layer provides localized high-strength adhesion and foam expansion at the bonding interface. This resolves the contradiction between narrow space insertion and adhesion strength.
Solution Approach 2:
The adhesive sheet is a composite structure combining two different adhesive materials with complementary properties. The first layer enables narrow space insertion, while the second layer provides high adhesion strength through its specific composition and foam expansion characteristics. This composite approach resolves the contradiction between insertion feasibility and adhesion performance.
4Strength
If the adhesive sheet has convex structures on the surface, then adhesion and shear strength are improved, but the surface complexity increases
Solution Approach 1:
The adhesive sheet incorporates convex structures (curved surface features) on the first adhesive layer that increase surface area and mechanical interlocking capability. These curved features improve adhesion and shear strength while adding minimal structural complexity compared to flat surfaces. This resolves the contradiction between shear strength and surface 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
The adhesive sheet ensures favorable ease of insertion into narrow spaces and exhibits improved adhesion and shear strength after heating, overcoming limitations of traditional adhesive sheets.
Implementation Method 1
an adhesive composition containing an epoxy resin having a softening point of 50° C. or higher and a thermal curing agent
Implementation Method 2
a second adhesive layer that has tackiness and is foamed and cured by heat
Data Source
AI summary
An adhesive sheet can ensure favorable ease of insertion even when inserted and used into a narrow space, and can also favorably exhibit various characteristics during or after heating. An adhesive sheet includes a first adhesive layer formed of an adhesive composition containing an epoxy resin having a softening point of 50° C. or higher and a thermal curing agent; and a second adhesive layer that has tackiness and is foamed and cured by heat. An outermost layer of the adhesive sheet is formed of the first adhesive layer, and the adhesive sheet has a plurality of convex structures on a surface on a side of the outermost layer.