Mechanical Pressure System for Complex Structural Bonding
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Solution Overview
Problem
Existing methods for applying pressure to structural components, such as those used in bonding processes, are labor-intensive and prone to failures, especially for complex geometries, and often require air-tight bagging or electrical power, limiting their applicability and precision.
Innovation Solution
A mechanical pressure application system comprising a base, tooling blocks, and a biasing mechanism that allows for tailored pressure distribution without air-tight bagging or electrical power, enabling adjustable force transmission to complex geometries and elevated temperature environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a pressurized autoclave with air-tight vacuum bag is used to apply pressure and temperature for bonding, then elevated pressure and temperature can be supplied, but the bagging process becomes labor-intensive and susceptible to failure for geometrically complex structural components
Solution Approach 1:
The autoclave is divided into multiple independently controllable heating zones, each capable of applying pressure and temperature separately to different regions of the workpiece. This segmentation allows complex geometries to be bonded without requiring complex bagging, as each zone can be optimized independently.
Solution Approach 2:
The system transitions from static bagging to dynamic, adjustable pressure application. Multiple forcing members can be independently adjusted to apply varying pressures to different regions, adapting to complex geometries without requiring complex restraint systems.
2Force
If a press is used to apply constant pressure distribution, then pressure can be applied to bonding areas, but it is not practical for relatively large or geometrically complex structures and cannot provide tailored pressure distribution
Solution Approach 1:
The pressure application system is segmented into multiple independent forcing members, each capable of applying pressure to specific regions. This allows tailored pressure distribution across complex geometries, replacing the single constant-pressure approach of traditional presses.
Solution Approach 2:
Different regions of the workpiece can receive different pressure levels through independently controllable forcing members. This local quality approach allows optimization of pressure distribution according to the specific geometric requirements of each bonding area.
3Stress or pressure
If air-tight bagging is used for pressure application, then pressure can be applied to the bonding area, but the process is labor-intensive and has high probability of bag failure for complex contours
Solution Approach 1:
Instead of a single continuous bag, the system uses multiple discrete forcing members that apply pressure locally. This eliminates the risk of bag failure while maintaining pressure application, as each forcing member is independent and cannot fail in a way that compromises the entire system.
Solution Approach 2:
The system replaces the reusable but failure-prone bag with simple, robust forcing members that have no failure mode related to sealing or integrity. These mechanical elements are inherently more reliable for complex geometries.
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
The system provides sustained, adjustable pressure over desired periods, facilitating precise bonding and reducing labor and material intensity, while accommodating complex geometries and elevated temperatures without the need for autoclaves.
Implementation Method 1
at least one biasing mechanism configured to apply a predetermined load to the at least one forcing member, such that a force is transmitted from the at least one forcing member through the tooling block to a corresponding portion of the contact area
Implementation Method 2
An elevated temperature also may be applied during at least part of such a process to facilitate curing a bonding layer
Data Source
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AI summary
A mechanical pressure application system (100) for applying a tailored pressure distribution to a plurality of structural components (20) is provided. Each structural component has a first surface (30), and each first surface (30) is configured to interface with the first surface (30) of another of the structural components (20) at a contact area (50). A base (102) and at least one tooling block (104) are configured to removably couple to the structural components (20). Each at least one tooling block (104) includes a first surface configured to be positioned proximate at least one of the plurality of structural components (20). A second surface (32) of each tooling block is configured to receive at least one forcing member (150). At least one biasing mechanism (160) is configured to apply a predetermined load to the at least one forcing member (150), such that a force is transmitted from the at least one forcing member (150) through the tooling block to a corresponding portion of the contact area (50).