Mini-Core Surface Bonding With Fixed-Paste Protrusion Transfer
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Solution Overview
Problem
Current methods for bonding mini-cores to turbine vane cores are inefficient due to difficulties in metering paste, leading to poor joint interfaces and requiring skilled technicians for manual cleaning, which is labor-intensive and prone to variability.
Innovation Solution
A method involving mini-cores with attachment devices such as protrusions, posts, or bumpers that are dipped into a paste to transfer a fixed amount, allowing for easy affixing to the core surface, forming a fillet and eliminating the need for precise paste dispensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If paste is metered into the hole using conventional methods, then the bonding process can be performed, but it is difficult to meter the correct amount of paste due to the viscous nature of the paste, leading to too much or not enough paste in the joint
Solution Approach 1:
The system allows the paste to be applied automatically through the viscous flow mechanism itself. The paste's natural viscosity causes it to flow into the hole and form a fillet without requiring precise metering or manual control, making the paste application process self-regulating and eliminating the need for complex metering equipment.
Solution Approach 2:
The invention changes the approach from controlling paste quantity through metering to controlling paste behavior through viscosity management. By accepting the viscous nature of the paste and designing the application process around its flow characteristics rather than trying to overcome them, the system achieves reliable paste placement without complex metering mechanisms.
2Reliability
If manual cleaning of the bond area is performed, then the bond area can be prepared, but the process is difficult, labor intensive and variable due to the area being small and inaccessible
Solution Approach 1:
The system performs preliminary cleaning actions automatically before bonding. The robotic system includes cleaning mechanisms that automatically prepare the bond area prior to paste application, eliminating the need for manual cleaning and ensuring consistent preparation quality without adding time to the process.
Solution Approach 2:
The invention replaces manual mechanical cleaning with an automated robotic system. The robotic arm with integrated cleaning tools can access small, difficult-to-reach areas and perform cleaning operations consistently, replacing the variable and labor-intensive manual process with a repeatable automated sequence.
3Stability of the object's composition
If paste is thickened with filler to prevent shrink, then shrink in the eventual arrangement is prevented, but the thickened paste is hard to work with and does not flow well
Solution Approach 1:
The invention changes the paste formulation parameters to achieve the right balance between shrink resistance and flowability. By optimizing the paste composition and viscosity characteristics, the system obtains a paste that maintains its structural integrity without excessive shrinkage while remaining sufficiently fluid for automatic application and fillet formation.
Solution Approach 2:
The paste is formulated to be self-regulating in its application behavior. The optimized viscosity and flow characteristics allow the paste to automatically fill the joint space and form appropriate fillets during the dipping process without requiring thickening agents that would compromise workability. The paste's natural properties enable both shrink prevention and ease of application.
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 simplifies the bonding process, reduces manual labor, and produces a high-quality bond with improved joint detail, enabling a skilled technician to complete bonding in minutes rather than hours, while accommodating slight core variances.
Implementation Method 1
dipping the protrusion into a supply of paste to transfer a fixed quantity of paste to the protrusion
Implementation Method 2
dipping the protrusion into a supply of paste to transfer a fixed quantity of paste to the protrusion
Implementation Method 3
pressing the protrusion onto the surface to drive the paste toward forming a fillet at a base of the protrusion
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A method of bonding a mini-core (410) to a surface (402) of a core (401) is provided. The method includes providing the mini-core (410) with an attachment device that includes a protrusion of a surface of the mini-core (410), dipping the protrusion into a supply of paste (420) to transfer a fixed quantity of paste (420) to the protrusion and affixing the protrusion to the surface (402) of the core (401) with the fixed amount of paste (420) interposed between the surface (402) and the protrusion.