Epoxy Resin Bonding Open Cavity Manufacturing
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Solution Overview
Problem
Existing methods for bonding shaped bodies, such as in motor vehicle construction, require sealed fluid-tight cavities for adhesives, leading to complex and costly manufacturing processes.
Innovation Solution
A method using a one-component thermosetting epoxy resin composition that allows bonding without sealed fluid-tight spaces, utilizing an open system with a cavity between shaped bodies, where the epoxy resin composition includes an epoxy resin with multiple epoxy groups, a curing agent activated by elevated temperature, and a polyester polyol, enabling self-sealing and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If sealed fluid-tight cavities are used for adhesive injection, then bonding strength is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The invention extracts the sealing function from the cavity system by allowing the adhesive to bond shaped bodies directly in an open system. The adhesive composition itself provides the bonding function without requiring the cavity to be sealed, thereby removing the complex sealing components while maintaining bonding strength.
Solution Approach 2:
The adhesive composition acts as an intermediary that enables bonding without requiring a sealed cavity environment. The specific chemical composition and properties of the adhesive allow it to function effectively in an open system, mediating the bond between shaped bodies without the need for fluid-tight containment.
2Strength
If sealed fluid-tight cavities are used for adhesive injection, then bonding strength is improved, but manufacturing cost increases
Solution Approach 1:
The invention removes the requirement for expensive sealed cavity systems by extracting the sealing function and replacing it with an open system approach. This eliminates the need for precision seals and tight tolerances, significantly reducing manufacturing costs while maintaining bonding strength through the optimized adhesive composition.
Solution Approach 2:
The invention employs a disposable-like approach where the adhesive composition is applied directly without requiring reusable sealed cavity infrastructure. This eliminates the need for expensive, precision-manufactured sealed systems and allows for simpler, more cost-effective manufacturing processes.
3Reliability
If sealed fluid-tight cavities are used for adhesive injection, then adhesive containment is improved, but manufacturing tolerances must be reduced
Solution Approach 1:
Instead of containing the adhesive within sealed cavities with tight tolerances, the invention inverts the approach by allowing the adhesive to be applied in an open system where the shaped bodies themselves define the bonding interface. This eliminates the need for precision sealed cavities and associated tight manufacturing tolerances.
Solution Approach 2:
The shaped bodies themselves serve the function of defining the bonding space, eliminating the need for separately manufactured sealed cavities. The adhesive is applied directly to the shaped bodies, which self-define the bonding interface, thereby removing the requirement for precision sealed structures and tight manufacturing tolerances.
4Ease of manufacture
If open systems are used for adhesive bonding, then manufacturing cost and complexity are reduced, but adhesive containment becomes difficult
Solution Approach 1:
The invention changes the parameters of the adhesive composition itself to enable effective bonding in an open system. By optimizing the viscosity, curing characteristics, and chemical composition of the adhesive, it can be contained and controlled during application in an open system without requiring sealed cavities, thereby achieving both cost reduction and reliable adhesive containment.
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 approach simplifies the bonding process, reduces manufacturing costs, and allows for greater manufacturing tolerances, as it eliminates the need for sealed spaces and the challenges of air displacement in closed cavities, while providing strong structural bonds.
Implementation Method 1
The polyester polyol PP serves as a nucleating agent for the epoxy resin composition on cooling
Implementation Method 2
it has been found that epoxy resin compositions of this kind show a very sharp increase in viscosity on cooling
Data Source
AI summary
A method of bonding two shaped bodies S1 and S2 including the steps of: a) providing shaped body S1; b) arranging shaped body S2 wherein shaped body S1, forming cavity between two shaped bodies, c) introducing one-component thermosetting epoxy resin compositions into cavity, wherein one-component thermosetting epoxy resin composition is one-component thermosetting epoxy resin composition including: at least one epoxy resin A having average of more than one epoxy group per molecule; at least one curing agent B for epoxy resins activated by elevated temperature; at least one polyester polyol PP obtainable by reaction of at least one diol having structure HO—(CH2)x′—OH the value of x′=2-10, and —at least one dicarboxylic acid having structure HOOC—(CH2)y′—COOH and derivatives of dicarboxylic acid, value of y′=8-18, and wherein proportion of polyester polyol PP is 1.5% to 20% by weight, based on total weight of one-component thermosetting epoxy resin composition.