Atmospheric Plasma Cleaning for Fastener Adhesive Bonding
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Solution Overview
Problem
Existing methods for preparing the surfaces of fasteners and nutplates for adhesive bonding are inefficient, time-consuming, and often result in weak joints due to improper surface preparation, and existing plasma devices are either too large or expensive for on-site use.
Innovation Solution
A compact, handheld atmospheric pressure plasma device that generates low-voltage, low-temperature plasma for precise surface treatment of fasteners and nutplates, using a showerhead or direct plasma generation configurations to clean and activate the surfaces for strong adhesive bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional surface preparation methods (mechanical abrading and wet chemical treatment) are used, then surface cleaning can be achieved, but the process becomes time-consuming and labor-intensive
Solution Approach 1:
The patent replaces mechanical abrading and wet chemical treatment with atmospheric pressure plasma treatment. The plasma process achieves surface cleaning and activation without mechanical contact or harsh chemicals, significantly reducing preparation time while maintaining or improving surface quality for adhesive bonding.
Solution Approach 2:
The invention changes the physical and chemical parameters of the surface through plasma treatment, including surface energy, wettability, and chemical composition. This transforms the surface properties to enhance adhesive bonding without requiring time-consuming mechanical or chemical preparation steps.
2Manufacturing precision
If conventional plasma devices are used for surface treatment, then effective plasma cleaning can be achieved, but the devices are too large or expensive for on-site use
Solution Approach 1:
The patent extracts the essential plasma generation functionality from complex vacuum plasma systems and implements it in a simplified atmospheric pressure configuration. This allows effective plasma treatment without requiring large vacuum chambers or expensive equipment, making the device suitable for on-site use.
Solution Approach 2:
The invention employs a cost-effective atmospheric pressure plasma generator that can be used portably for on-site surface preparation. The system avoids expensive vacuum systems and complex infrastructure, providing an economical solution for field applications.
3Manufacturing precision
If high voltage plasma is used for surface treatment, then effective cleaning is achieved, but the process becomes unsafe for manual operation
Solution Approach 1:
The patent changes the operating parameters from high voltage vacuum plasma to low voltage atmospheric pressure plasma. This transformation maintains effective surface cleaning capability while dramatically improving safety for manual operation, allowing operators to handle and operate the device without specialized protective equipment.
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 device effectively cleans and activates the surfaces of fasteners and nutplates, producing durable bonds with a low adhesive failure mode, suitable for various materials and environments, including aerospace manufacturing.
Implementation Method 1
An atmospheric pressure plasma is applied to the nutplates to provide surface cleaning and generate a high energy surface
Implementation Method 2
The reactive gasses generated by the plasma interacts with the surface to improve the material properties
Data Source
AI summary
Atmospheric pressure plasma devices and methods for preparing the surfaces of fasteners, e.g. nutplates, for adhesive bonding are disclosed. A device supports a fastener to dispose a contact surface of the fastener to receive an atmospheric pressure plasma flow, thereby activating the contact surface to be bonded. A spacer is used to properly support the fastener to receive the plasma treatment. A spacer can comprise a plurality of standoffs on a showerhead port comprising a ground electrode of the plasma generator where plasma is formed in a gas flow across the electrodes.