Coupling element, coupling assembly with such a coupling element and method of coupling a first substrate to such a coupling element
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Solution Overview
Problem
Existing coupling technologies rely on solvent-based adhesives, which pose environmental and health hazards, and require high energy for thermal joining methods that can damage substrate materials.
Innovation Solution
A coupling element with a transition polymer bonding material and a printed heater that heats to the melting temperature of the polymer, allowing for adhesive bonding without substrate melting, using lower energy and eliminating solvent-based adhesives, and optionally incorporating foaming agents for gap closure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solvent-based adhesives are used for connecting pipes, then bonding strength is achieved, but environmental and health hazards increase due to evaporating chemical substances
Solution Approach 1:
The invention changes the chemical composition parameters of the bonding material by using a transition polymer instead of solvent-based adhesives. This parameter change eliminates harmful volatile organic compounds while maintaining bonding effectiveness through controlled thermal activation.
Solution Approach 2:
The invention utilizes phase transition of the transition polymer material, which transitions from solid to molten state during bonding and then solidifies to form the adhesive joint. This phase transition mechanism replaces chemical solvent evaporation with physical melting and solidification, eliminating harmful emissions.
2Strength
If high energy thermal joining methods are used to melt substrate materials, then bonding strength is improved, but substrate material damage occurs
Solution Approach 1:
The invention introduces a transition polymer as an intermediary bonding material between the heating element and the substrate. This intermediary layer absorbs the thermal energy and controls the melting process, preventing direct high-temperature contact with the substrate and thus avoiding substrate damage while still achieving strong bonding.
Solution Approach 2:
The invention changes the thermal parameters by using a transition polymer with a lower melting point than the substrate material. This parameter change allows bonding at lower temperatures that do not damage the substrate, while the transition polymer provides sufficient bonding strength through its controlled melting and solidification process.
3Strength
If transition polymer bonding material is heated to melting temperature, then adhesive bonding is achieved without substrate melting, but energy consumption increases
Solution Approach 1:
The transition polymer material provides self-service by undergoing automatic phase transition from solid to molten state when heated to its melting temperature, and then self-solidifying upon cooling. This self-service mechanism eliminates the need for additional bonding agents or complex processing steps, achieving adhesive bonding with controlled energy input only for the phase transition.
4Reliability
If foaming agents are incorporated to compensate for diameter tolerances, then gap closure and watertightness are improved, but device complexity increases
Solution Approach 1:
The foaming agent utilizes phase transition from solid/liquid to gas state when heated, expanding to fill gaps and compensate for diameter tolerances. This phase transition mechanism provides automatic gap closure and watertight sealing without requiring complex adjustment mechanisms or additional components.
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 solution provides a solvent-free, energy-efficient bonding method that maintains structural integrity and ensures watertightness by only melting the bonding material, reducing environmental impact and substrate damage, while allowing for continuous monitoring and feedback through integrated sensors.
Implementation Method 1
The heating element will receive the energy (electrical, magnetic field, exotermic reaction initiation...) and heat (by joule effect, exotermic reaction...)
Implementation Method 2
The bonded transition polymer provides for the adhesion between the coupling element and a substrate of another element, by melting and sticking to the substrate
Implementation Method 3
Another foaming agent is used in KR 20130004866 in which a foam sheet is foamed while expanding in volume. The water tightness is ensured by pressure generated by the expanded foam sheet
Data Source
Figure 1A~2
Figure 3~4
Figure 4B~5
AI summary
The present invention proposes a coupling element comprising a coupling body (12) having a first joining surface (13), said coupling body (12) comprising a bonding material being weldable at a melting temperature. At least one heating element (50) is provided to heat the bonding material at a temperature equal to or greater than the melting temperature, the at least one heating element being encapsulated with the bonding material or provided at the first joining surface. The bonding material being a transition polymer.The at least one heating element comprises a resistance heatable by Joule effect or induction. The present invention also proposes a coupling assembly comprising such a coupling element and a first substrate assembled on the first joining surface, and a method of obtaining a such a coupling assembly comprising the steps of adjoining the first substrate on the coupling element and providing energy to the at least one heating element to cause the heating of the bonding material up to the melting temperature.