Micro-encapsulated Adhesive Placement Vehicle for Automated Insert Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for installing inserts in structures, such as aerospace panels, face challenges with high mass, complex manual handling of two-component adhesives, and limited automation due to viscosity and air bubble issues, leading to inefficient and costly production processes.
Innovation Solution
A method and device utilizing a placement vehicle with micro-encapsulated two-component adhesive, where polymerization is initiated within the vehicle by temperature or electromagnetic radiation, allowing for controlled application and polymerization of the adhesive, facilitating automated installation of inserts with reduced viscosity and bubble formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adhesive application is used, then mixing homogeneity and air bubble control are improved, but production rate and automation are worsened
Solution Approach 1:
The patent introduces a robotic system with automated mixing and application mechanisms as an intermediary between the adhesive components and the final application. The robot equipped with specialized end effectors performs precise mixing and deposition, bridging the gap between manual precision and automated speed requirements.
Solution Approach 2:
The patent replaces manual mechanical mixing and application with automated robotic systems that use controlled mechanical movements, automated dispensing mechanisms, and computer-vision-guided positioning to achieve both precision and high-speed production.
2Strength
If two-component adhesive is used, then bonding strength is improved, but handling complexity and mixing difficulty are worsened
Solution Approach 1:
The patent merges the mixing and application operations into a single integrated robotic process. The robotic system combines both adhesive components in the correct proportions, mixes them thoroughly, and applies them in one continuous automated operation, reducing handling complexity while maintaining bonding strength.
Solution Approach 2:
The patent controls critical parameters such as mixing ratio, mixing time, temperature, and application speed through automated systems. By precisely controlling these parameters, the system achieves optimal bonding strength while simplifying the overall handling process through automation.
3Loss of time
If adhesive pot-life is extended, then application time is improved, but polymerization control and quality consistency are worsened
Solution Approach 1:
The patent implements feedback control systems that monitor adhesive temperature, mixing progress, and application timing in real-time. This feedback mechanism allows the system to adjust parameters dynamically, extending effective application time while maintaining consistent polymerization control and quality across all bonds.
4Productivity
If automated adhesive application is implemented, then production rate is improved, but air bubble formation and mixture quality control are worsened
Solution Approach 1:
The patent employs mechanical vibration or ultrasonic agitation during the mixing and application process to prevent air bubble formation. The vibrational energy helps eliminate trapped air while maintaining homogeneous mixing, enabling high-speed automated application without compromising mixture quality.
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 enables efficient, automated, and controlled installation of inserts with improved mechanical strength and reduced production costs by ensuring proper adhesive mixing and application, overcoming the limitations of traditional methods.
Implementation Method 1
a polymerizable adhesive, in which the polymerization is initiated or accelerated in the laying vehicle, before placing the insert in the structure
Implementation Method 2
initiating the polymerization of the adhesive in the laying vehicle
Data Source
Figure 1a~1b
Figure 2~3
Figure 4
AI summary
The invention relates to a device and a method for placing an insert (10) into an opening (24) in a structure (20). The device is a placement vehicle (40) comprising the insert (10) to be placed, a polymerizable adhesive (30), and an applicator (41); the applicator comprising: - an open chamber (50) in which the insert (10) and the adhesive (30) can be held; - deployment means adapted to push the insert (10) and the adhesive (30) out of the open chamber (50) to allow the placement of the insert (10) in the opening (24) of the structure. The placement vehicle (40) is configured to initiate the polymerization of the adhesive (30) held in the open chamber (50) of the applicator (41). Advantageously, the adhesive is micro-encapsulated in the form of microcapsules of resin and hardener; the polymerization step of the adhesive is initiated by the rupture of the microcapsules.