Layer Assembly Bonding Air Bubble Removal
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Solution Overview
Problem
The existing methods for bonding natural stone slabs to glass cover layers often result in air bubbles, which introduce mechanical weaknesses and aesthetic issues, particularly in high-quality interior decoration articles.
Innovation Solution
A method involving a substrate and cover layer assembly where the substrate and cover layer are initially positioned at an angle, forming a 'V' shape, allowing air bubbles in the adhesive to rise and escape, followed by pivoting to bring the edges together, ensuring a bubble-free bond and integration of functional elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional bonding methods are used to join natural stone slabs to glass cover layers, then the bonding process is simple and quick, but air bubbles are trapped in the adhesive layer causing mechanical weaknesses and aesthetic issues
Solution Approach 1:
The bonding process uses a dynamic pivoting movement where the substrate and cover layer are rotated from an initial parallel position through a 'V' shape configuration back to parallel alignment. This dynamic motion enables air bubbles to escape during the bonding process while maintaining structural integrity, resolving the contradiction between bond reliability and process complexity.
Solution Approach 2:
The method applies preliminary action by positioning the substrate and cover layer at an initial angle (parallel or 'V' shape) before bonding begins. This pre-positioning creates a configuration that facilitates air bubble escape during subsequent pivoting, improving bond reliability without requiring complex additional equipment.
2Ease of manufacture
If the substrate and cover layer are bonded in a parallel position, then the bonding process is straightforward, but air bubbles cannot escape and become trapped in the adhesive layer
Solution Approach 1:
The process transitions from static parallel positioning to dynamic pivoting motion. The substrate and cover layer are rotated through a 'V' shape configuration during bonding, enabling air bubbles to escape while maintaining ease of manufacture. After bonding, the assembly returns to parallel position for final alignment, achieving both manufacturing ease and precision.
Solution Approach 2:
The method changes the geometric parameter of the assembly configuration during bonding. By rotating the substrate and cover layer from parallel through 'V' shape back to parallel, the process enables air bubble escape while maintaining straightforward bonding procedures, resolving the contradiction between manufacturing ease and bond quality precision.
3Manufacturing precision
If a 'V' shape configuration is used during bonding, then air bubbles can escape effectively, but the process requires additional positioning steps
Solution Approach 1:
The 'V' shape configuration is implemented as a dynamic intermediate state during pivoting rather than a static positioning step. The substrate and cover layer rotate continuously through the 'V' shape configuration, enabling air bubble escape without requiring separate positioning operations. This dynamic approach achieves manufacturing precision while minimizing process complexity.
4Area of stationary object
If adhesive is applied generously to ensure complete coverage, then bonding coverage is sufficient, but more air bubbles are trapped in the adhesive layer
Solution Approach 1:
The dynamic pivoting process enables generous adhesive application without compromising bond reliability. As the substrate and cover layer rotate through the 'V' shape configuration, air bubbles rise and escape from the adhesive layer, allowing sufficient adhesive coverage while maintaining bond strength through effective bubble removal.
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 effectively reduces air bubbles in the adhesive layer, enhancing the mechanical strength and aesthetic appeal of the composite material, making it suitable for decorative and architectural applications.
Implementation Method 1
allowing air bubbles in the adhesive to rise and escape
Data Source
AI summary
A method for producing a layer assembly, wherein the layer assembly includes a substrate, an outer layer and an adhesive layer arranged between the substrate and the outer layer and the adhesive layer makes at least partial contact with the substrate and the outer layer, includes the step of: swiveling the substrate and the outer layer towards one another, such that the distance between the top substrate edge and the top outer layer edge decreases and the adhesive is moved in the direction of the top substrate edge and of the top outer layer edge; wherein this is carried out in such a manner that, during at least part of step B), the angle bisector of the angle α adopts an angle of ≥−45° to ≤45° with respect to the vertical.