Reformable Epoxy Adhesive Bracket Attachment

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Solution Overview

Problem

Existing adhesive and mounting systems for attaching brackets to panel structures in construction and transportation industries face issues such as long curing times, space requirements, high manufacturing costs, and damage to panels when brackets are removed, due to the use of thermoset adhesives which are not reversible and require accurate mixing.

Innovation Solution

A reformable epoxy resin adhesive that hardens quickly upon cooling, allowing for rapid attachment and debonding by reheating above its glass transition or melting temperature, eliminating the need for clamps and reducing waste, with the option of using a hot melt adhesive applied via a gun or as a film.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If thermoset adhesives are used to attach brackets to panels, then strong bonding is achieved, but long curing times and space requirements occur

Engineering Contradiction:

Improvebonding strengthVSAvoidcuring time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The patent changes the physical state parameters of the adhesive by using thermoplastic materials that transition between solid and molten states through temperature control, replacing traditional chemical curing processes with physical phase changes to achieve rapid bonding without long curing times

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent utilizes phase transitions of thermoplastic adhesive materials, heating them to molten state for application and cooling to solidify for bonding, enabling rapid attachment and detachment cycles without prolonged curing periods required by thermoset adhesives

Inventive Principle:

Principle #36Phase transitions

2Strength

If thermoset adhesives are used to attach brackets to panels, then strong bonding is achieved, but panels are damaged when brackets are removed

Engineering Contradiction:

Improvebonding strengthVSAvoidbracket removal

Core Design Contradiction:

StrengthVSEase of repair

Solution Approach 1:

The patent introduces dynamic reversibility to the bonding system by using thermoplastic adhesives that can be repeatedly softened and hardened through temperature cycling, allowing brackets to be removed and reattached multiple times without damaging the panel, unlike irreversible thermoset adhesives

Inventive Principle:

Principle #15Dynamics

3Strength

If thermoset adhesives are used to attach brackets to panels, then bonding is achieved, but accurate mixing is required which is time consuming

Engineering Contradiction:

Improvebonding strengthVSAvoidadhesive application

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent extracts the mixing step from the adhesive application process by using pre-manufactured thermoplastic adhesive materials that come in ready-to-use forms such as rods, films, or pre-mixed compounds, eliminating the time-consuming and error-prone mixing operation required for two-component thermoset adhesives

Inventive Principle:

Principle #2Taking out (Extraction)

4Strength

If thermoset adhesives are used to attach brackets to panels, then bonding is achieved, but added manufacturing cost occurs

Engineering Contradiction:

Improvebonding strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent replaces the complex chemical systems of thermoset adhesives with simpler thermoplastic materials that rely on physical phase changes rather than chemical reactions, eliminating the need for mixing equipment, climate control during curing, and clamp removal operations, thereby reducing manufacturing costs

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 reformable epoxy adhesive enables fast and efficient attachment with minimal waste, reduces storage needs, and allows for easy debonding, thereby lowering manufacturing costs and minimizing panel damage, while providing strong bonding and quick cleanup.

Implementation Method 1

heating the adhesive, and hardening the adhesive so the bracket is adhered to the panel structure. The hardening step may be accomplished by cooling the adhesive.

Methodology Applied

Scientific EffectPhase change (cooling hardening): Phase Change

Implementation Method 2

The heating step may be performed by induction heating with metal wires on the bracket. The heating step may be performed by heating metal within the adhesive or by heating metallic fillers located within the adhesive.

Methodology Applied

Scientific EffectInduction heating: Induction Heating

Implementation Method 3

The adhesive can be heated again above its glass transition temperature, its melting temperature, or both so the bracket and the panel structure are debonded.

Methodology Applied

Scientific EffectGlass transition:

Data Source

PatentUS10486406B2Method and apparatus for forming and adhering panel and bracket structures

Publication Date: 2019.11.26 ZEPHYROS INC

AI summary

The present invention includes a method for the attachment of a bracket to a panel structure comprising providing an adhesive for attaching the bracket to the panel structure; placing the bracket in a desired location on the panel structure; heating the adhesive; and hardening the adhesive so the bracket is adhered to the panel structure.