Fastener Flange Bonding With UV Edge Cure and Anaerobic Set
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Solution Overview
Problem
Existing methods for joining fasteners to workpieces, particularly in the automotive industry, are cumbersome and time-consuming, especially when using composite materials that are difficult to weld or require multiple adhesive types, and are limited by heat-dependent curing processes.
Innovation Solution
A UV-curing adhesive method for fasteners, where the adhesive is applied and cured at the edge of the flange using UV radiation, followed by anaerobic curing underneath, allowing for quick assembly and broad material compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heat-dependent adhesive curing is used, then strong bonding is achieved, but the process time is extended and material compatibility is limited
Solution Approach 1:
The adhesive bonding process is segmented into two distinct curing mechanisms: UV-curing at the flange edges and anaerobic curing underneath the flange. This segmentation allows different curing methods to operate in different zones, enabling faster overall processing while maintaining strong bonding throughout the joint.
Solution Approach 2:
The invention changes the curing parameters by introducing UV-radiation as an additional curing mechanism alongside traditional heat-dependent anaerobic curing. This parameter change enables the adhesive to cure partially under UV light (faster) and complete curing anaerobically (strong bonding), thereby reducing total process time while maintaining bond strength.
2Adaptability or versatility
If multiple adhesive types are used for different materials, then material compatibility is improved, but device complexity increases
Solution Approach 1:
The adhesive composition is designed with multi-functionality to work with diverse materials including plastics, fibre composite components, and metal substrates. The universal adhesive formula contains reactive groups that can bond to various material types, eliminating the need for multiple specialized adhesives while maintaining broad material compatibility.
Solution Approach 2:
The adhesive itself is a composite composition containing multiple functional components: UV-reactive groups for rapid initial curing, anaerobic curing agents for complete bonding, and modifiers for adhesion to different substrates. This composite adhesive structure provides both versatility across materials and simplified application methodology.
3Loss of time
If UV-curing is applied to the entire flange, then processing time is reduced, but adhesive quality at edges deteriorates
Solution Approach 1:
The curing process applies different quality characteristics to different locations: UV-curing provides rapid initial set at the flange edges where visible bonding is critical, while anaerobic curing provides complete chemical bonding underneath the flange where structural strength is critical. This local quality differentiation ensures both speed and precision are achieved in their respective zones.
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
Enables fast and secure attachment of fasteners to a wide range of materials with reduced cycle time, providing immediate loadability and strong bonding without the need for heat-dependent processes.
Implementation Method 1
curing the adhesive at the outer edge of the flange by applying an UV radiation
Implementation Method 2
finishing the curing of the adhesive underneath the flange by anaerobical curing
Data Source
Figure 1~2
Figure 3A~3C
Figure 4
AI summary
Joining device, joining apparatus and method for joining a fastener to a workpiece comprising the steps of: - providing a workpiece (24); - providing a fastener (10) including an anchor section which extends between a first end section and a second end section along an anchor axis (X); a flange (18) formed on and extending radially to the first end section of the anchor section (12), the flange being radially delimited by an outer edge (20), and the flange at least partially forms an application section (22), the application section being at a non-zero distance from the outer edge, wherein the fastener (10) is a one-piece metal fastener (10); - applying an adhesive (28) on the application section, characterized in that the adhesive (28) is an UV-curing adhesive and the method further comprises the steps of - arranging the flange of the fastener (10) on the carrier surface of the workpiece (24) and pushing said flange (18) against the workpiece such that the adhesive is squeezed toward the outer edges until it reaches the outer edges of the flange (20); - curing the adhesive (28) at the outer edge (20) of the flange by applying an UV radiation, such that the fastener is pre-assembled to the workpiece; - finishing the curing of the adhesive (28) underneath the flange by anaerobical curing.