Printable Structural Adhesive for Fast Large-Area Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing adhesive compositions for bonding metal parts in vehicles and fuel cell stacks require long cycle times for application and lack efficient sealing and bonding properties, especially in large and complex areas, and there is a need for fast and precise application methods.
Innovation Solution
A printable structural adhesive composition with a viscosity of less than 100 Pa·s at 65°C, comprising epoxy resin, epoxy curing agent, and toughening agent, allowing for application by printing methods such as jet, pad, or stencil printing, which provides strong bonding and sealing properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If structural adhesive is applied by robotic dispensing to large and complex bonding areas, then bonding coverage is improved, but cycle time increases significantly
Solution Approach 1:
The patent replaces the mechanical robotic dispensing system with a printing system that can apply adhesive more rapidly. The printing method allows for faster deposition of adhesive material across large and complex areas without the time penalties associated with robotic nozzle movement, thereby reducing cycle time while maintaining comprehensive bonding area coverage.
Solution Approach 2:
The patent modifies the viscosity parameter of the adhesive composition to enable printing application. By adjusting the rheological properties of the adhesive, it becomes suitable for printing methods while maintaining its structural bonding capabilities, thus allowing faster application compared to traditional dispensing methods.
2Ease of operation
If adhesive viscosity is reduced for easier application, then printability is improved, but bonding strength may be compromised
Solution Approach 1:
The patent carefully adjusts the viscosity parameter of the adhesive to an optimal range that enables printing application while preserving bonding strength. The modified viscosity allows the adhesive to flow properly during printing without compromising its ability to form strong bonds after curing.
Solution Approach 2:
The adhesive composition is formulated as a composite material containing epoxy resin, curing agent, and toughening agents in specific proportions. This composite formulation ensures that the adhesive maintains both printability and bonding strength by balancing flow characteristics with mechanical properties.
3Reliability
If multiple materials are used for bonding and sealing, then functional performance is improved, but process complexity increases
Solution Approach 1:
The patent develops a universal adhesive composition that performs both bonding and sealing functions simultaneously. This multi-functional adhesive eliminates the need for separate sealing materials and processes, thereby reducing process complexity while maintaining reliable bonding and sealing performance.
Solution Approach 2:
The patent merges the bonding and sealing functions into a single adhesive material and application process. By combining these previously separate functions into one unified system, the process complexity is reduced while the overall functional performance is maintained through the adhesive's dual capabilities.
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
Enables fast and precise application of adhesive compositions over large areas or complex patterns, achieving strong bonding and sealing with improved mechanical properties and resistance to fluids, suitable for automotive and fuel cell applications.
Implementation Method 1
a printable structural adhesive composition, comprising (a) at least one first epoxy resin; (b) at least one epoxy curing agent
Implementation Method 2
the printable structural adhesive composition exhibits a viscosity according to DIN 54458 at 65° C. of less than 100 Pa×s
Data Source
AI summary
The present disclosure provides a printable structural adhesive composition. The present disclosure further provides methods for applying a structural adhesive onto a substrate, the method comprising printing the structural adhesive onto the substrate. Printing may be carried out by jet printing, pad printing, screen printing and/or stencil printing.