Joined Member Assembly Using Expandable Fabric Seam
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Solution Overview
Problem
The existing methods for joining components using adhesives or fastening members face challenges with shape tolerance, leading to gaps between mating surfaces, which can result in fracture or deformation under tensile load, and require labor-intensive machining to create a seam to fill these gaps.
Innovation Solution
A joined member assembly method employing a multilayer structure fabric that expands when heated, woven with reinforcing materials, is inserted into the gap, impregnated with resin, and cured to form a seam that provides the necessary strength and rigidity to prevent deformation and excessive load on fastening members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a fastening member is used to join components, then joining strength is improved, but gap between mating surfaces causes excessive tensile load on fastening member leading to fracture risk
Solution Approach 1:
The patent applies beforehand cushioning by inserting a filler material into the gap between mating surfaces before fastening. This filler material (such as adhesive, sealant, or deformable material) pre-cushions the gap to distribute and reduce the tensile load that would otherwise concentrate on the fastening member, preventing excessive stress and potential fracture during operation.
Solution Approach 2:
The patent uses an intermediary material (filler material) placed between the mating surfaces and the fastening member. This intermediary serves as a mediator that transfers and distributes the mechanical loads, reducing the direct tensile stress on the fastening member while maintaining the structural integrity of the joint.
2Manufacturing precision
If gap filling is performed by traditional machining methods, then gap filling precision is improved, but assembly time and labor cost increase significantly
Solution Approach 1:
The patent applies self-service by using a filler material that automatically adapts to the gap shape without requiring precise pre-machining. The deformable or flowable filler material self-adjusts to fill the gap conformally when inserted, eliminating the need for labor-intensive measurement and custom machining of seam components while maintaining accurate gap filling.
Solution Approach 2:
The patent changes the physical state or properties of the filler material (such as using adhesive that transitions from liquid to solid, or sealant that changes viscosity with temperature) to enable easy insertion into the gap followed by curing or setting. This parameter change allows the material to flow into the gap shape and then solidify, achieving precise gap filling without mechanical machining.
3Ease of manufacture
If adhesive alone is used for joining, then assembly simplicity is improved, but joining strength guarantee becomes difficult
Solution Approach 1:
The patent merges two joining methods by combining adhesive bonding with mechanical fastening. The adhesive is applied to the mating surfaces and the fastening member is inserted through the bonded surfaces, creating a hybrid joint that leverages both the simplicity and strength benefits of adhesive bonding and the reliable mechanical connection of fasteners.
Solution Approach 2:
The patent creates a composite joining system that combines different joining mechanisms (adhesive bonding and mechanical fastening) into a unified structure. This composite approach allows the adhesive to provide baseline bonding and seal the joint, while the fastening member provides additional mechanical strength and structural support.
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 increases assembly efficiency by omitting the need for machining a seam and provides improved strength and rigidity to the joined portions, preventing deformation and excessive load on fastening members.
Implementation Method 1
a base material which is constituted by a multilayer structure fabric that is expandable by heating
Implementation Method 2
filling the gap with a resin so as to cause the base material to be impregnated with the resin
Data Source
AI summary
A joined member assembly method includes: a step in which a substrate is inserted in a gap between a superposed first component and a second component, said substrate being configured from a multilayer fabric that is capable of expanding as a result of heating and that is flexible after expansion and a reinforcing material woven into the multilayer fabric; a step in which the substrate is heated and made to expand in the thickness direction; a step in which the gap is filled with a resin and the substrate is impregnated with the resin; and a step in which the resin is cured. A step in which a seam is created by machining in accordance with a measured gap shape is omitted.