Elastic Blank Adhesive for Antiparallel Surface Connection
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Solution Overview
Problem
Existing methods fail to achieve a uniform and air-inclusion-free connection between two joining partners with antiparallel contact surfaces, particularly when one partner is a rigid electronic pixel matrix display, due to non-planar surfaces and varying cavity distances.
Innovation Solution
A method involving a blank of elastic material with an adhesive layer is arranged between the joining partners, heated using microwave or infrared radiation to adapt shape and enhance adhesion, and then cured using UV light to form a durable, inclusion-free connection, maintaining the elastic properties of the blank.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional gluing methods are used on antiparallel contact surfaces, then the adhesive can be applied, but air inclusions and non-uniform wetting occur making full-surface connection impossible
Solution Approach 1:
The patent changes the physical state and properties of the adhesive by heating it to elevated temperatures (e.g., 50-150°C or higher), which reduces its viscosity and increases its fluidity. This parameter change enables the adhesive to flow into the cavity formed by antiparallel surfaces and displace air, achieving uniform wetting and eliminating air inclusions that prevent full-surface connection.
Solution Approach 2:
The patent employs a multi-stage heating process with different temperature levels and durations. Initially, heating is applied to activate the adhesive and improve flow; then, controlled cooling or maintenance heating ensures complete filling and proper bonding. This periodic thermal action allows the adhesive to progressively wet the surfaces and eliminate trapped air, achieving uniform distribution without defects.
2Ease of operation
If the contact surfaces are non-planar with varying cavity distances, then the joining partners can be connected, but the adhesive cannot spread uniformly across the full surface
Solution Approach 1:
The patent applies thermal energy to change the adhesive's physical parameters, specifically reducing viscosity through heating. This enables the adhesive to flow and self-level across non-planar surfaces with varying cavity distances, achieving uniform distribution without requiring complex application mechanisms or precise surface preparation.
Solution Approach 2:
The patent replaces mechanical methods of adhesive application (such as spreading tools or pressure systems) with thermal activation. By heating the adhesive, its rheological properties change, allowing it to flow and distribute uniformly across the cavity automatically, eliminating the need for complex mechanical spreading equipment and simplifying the overall connection process.
3Stability of the object's composition
If one joining partner is rigid and thick (like an electronic pixel matrix display), then structural stability is achieved, but bending to create contact is impossible
Solution Approach 1:
The patent introduces a cavity-filling adhesive as an intermediary medium between the rigid joining partner and the other component. This adhesive fills the gap created by the non-planar surfaces and varying distances, enabling thermal contact and heat transfer without requiring the rigid component to bend or deform, thus maintaining structural stability while achieving thermal connection.
Solution Approach 2:
The patent replaces mechanical contact methods (which would require bending or deforming the rigid component) with thermal activation of the adhesive. By heating the adhesive to reduce its viscosity and improve flow, it can automatically fill the cavity and establish thermal contact, eliminating the need for mechanical deformation of the rigid joining partner.
4Quantity of substance
If the cavity distance varies along the contact surface, then the joining partners can be positioned, but complete filling without air inclusions cannot be achieved
Solution Approach 1:
The patent changes the adhesive's physical parameters through heating, reducing its viscosity and increasing its flow capability. This enables the adhesive to penetrate into regions with larger cavity distances and displace air effectively, ensuring complete filling of the entire cavity volume regardless of distance variations, and eliminating air inclusions that would compromise reliability.
Solution Approach 2:
The patent employs a controlled heating process that progresses through different stages: initial heating to activate flow, sustained heating to ensure complete filling and air displacement, and final cooling to set the bonded structure. This periodic thermal action ensures that the adhesive has sufficient time and energy to fill the entire cavity uniformly without trapping air, achieving both complete filling and absence of inclusions.
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 ensures a complete, inclusion-free filling of the cavity without material flow-out, achieving a durable and uniform connection between the joining partners, even with non-planar surfaces and varying distances, suitable for rigid and transparent materials like PMMA and glass.
Implementation Method 1
heating the blank including the adhesive layer by means of irradiation with microwave radiation
Implementation Method 2
heating the blank including the adhesive layer by means of irradiation with microwave radiation and/or infrared radiation
Implementation Method 3
curing and/or cross-linking the adhesive layer of the blank takes place in a subsequent step
Data Source
AI summary
The present disclosure relates to a method for the full-surface connection of contact surfaces, which form a cavity between them and extend in an antiparallel manner, of a first, transparent joining partner and a second joining partner, comprising the steps of: providing and arranging the first joining partner, the second joining partner and a blank made of an elastic material, such that the blank is disposed in the cavity formed between the contact surfaces extending in an antiparallel manner, and wherein the blank has an outer adhesive layer; heating the blank by irradiation with microwave radiation and/or infrared radiation (IR); curing or cross-linking the adhesive layer of the blank in order to form a layer structure of the first joining partner, the blank and the second joining partner.