Partially Polymerized Connection Part for Complex Composite Assembly
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Solution Overview
Problem
Existing connection parts made of composite material for assembling complex-shaped mechanical parts, such as satellite antenna reflectors, require numerous components and time-consuming assembly processes at ambient temperature, leading to potential deformation and increased costs.
Innovation Solution
A thermohardenable connection part that is partially polymerized to be rigid at ambient temperature, allowing manipulation and subsequent adaptation to the mechanical part's shape during final polymerization, using methods like compression moulding and final polymerization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If connection parts are adapted at ambient temperature to fit complex shapes, then assembly precision is improved, but assembly time increases and stress is induced on the shell
Solution Approach 1:
The patent changes the temperature parameter from ambient to elevated temperature during assembly. The connection part is heated to a temperature where the thermohardenable material becomes more compliant, allowing it to adapt to complex shapes without inducing stress. After cooling and final hardening, the part maintains precise fit while reducing assembly time and eliminating the need for multiple adaptation steps.
Solution Approach 2:
The connection part is pre-formed with standard geometries before assembly. The thermohardenable material allows the part to be manufactured in advance with precise dimensions, then heated during assembly to facilitate adaptation to the specific complex shape without requiring time-consuming on-site fabrication or multiple trial adjustments.
2Adaptability or versatility
If multiple connection parts are used to adapt to variable shapes, then adaptability is improved, but device complexity increases
Solution Approach 1:
The patent creates a universal connection part design with standard geometries and interfaces that can be used across multiple assembly locations. The thermohardenable material enables a single standardized part type to adapt to various complex shapes through thermal processing, eliminating the need for multiple specialized part variants and reducing overall device complexity.
Solution Approach 2:
The connection part transitions from a rigid state during manufacturing to a compliant state during assembly when heated. This dynamic property allows the same part to maintain structural integrity during storage and transport, then become adaptable when heated for assembly, and finally return to a rigid state after cooling and hardening, providing versatility without requiring multiple static part designs.
3Object-affected harmful factors
If cold gluing is used to minimize stress, then shell deformation is reduced, but assembly time increases
Solution Approach 1:
The patent replaces the mechanical cold gluing process with a thermal processing approach. Instead of using adhesives that require extended curing time at ambient temperature, the connection part's thermohardenable material is heated to accelerate the hardening process. This substitution reduces assembly time while the controlled thermal process actually reduces stress and deformation compared to cold gluing, as the material becomes more compliant during heating and adapts smoothly to the shell shape.
Solution Approach 2:
The patent changes the temperature parameter from ambient to elevated temperature during the assembly process. This parameter change transforms the material properties of the thermohardenable connection part, making it more compliant during heating for stress-free adaptation, then accelerating the hardening process to reduce assembly time. The elevated temperature simultaneously achieves both reduced deformation and reduced assembly time.
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
Facilitates standardized, cost-effective assembly with improved mechanical strength and reliability by enabling the connection part to adapt to variable shapes during final polymerization, reducing the number of components and assembly time.
Implementation Method 1
it is partially polymerised in such a way as to be rigid at ambient temperature and capable of being subjected to a final later polymerisation
Implementation Method 2
In the presence of reactants and catalysts, and under the action of heat and pressure, macromolecular chains are formed consisting of identical or different repeating units
Implementation Method 3
The production method is a compression moulding method
Data Source
AI summary
A partially polymerised thermohardenable connection part and to methods for producing and assembling such a connection part are described herein. The connection part for connecting two mechanical parts is thermohardenable and is partially polymerised in such a way as to be rigid at room temperature and able to be subjected to a subsequent polymerisation, the connection part being thus both sufficiently rigid to be able to be manipulated and brought into contact with at least one of the two mechanical parts which it is to interconnect and able to be subjected to a subsequent additional polymerisation in order to achieve its final polymerised state, the material of the connection part being rendered sufficiently soft during the additional polymerisation that it can adapt to the form of at least one of the mechanical parts to which the connection part must be connected.