Rotor Blade Vortex Generator Adhesive Injection Bonding
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Solution Overview
Problem
Existing methods for attaching add-on parts to rotor blades, such as vortex generators, often result in temporary adhesive connections that require long fixation times and are prone to air inclusions and bubbles, leading to incomplete bonding.
Innovation Solution
A method involving an adhesive surface on the rotor blade and the add-on part, where a gap is formed between the surfaces, and liquid adhesive is injected through openings to fill the gap completely, sealed by double-sided adhesive tape, ensuring a strong and permanent bond without the need for prolonged fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is applied to bonding surfaces and components are held in place until curing, then adhesive bond strength is achieved, but attachment time and productivity are reduced
Solution Approach 1:
The adhesive surface is prepared in advance on the rotor blade, and the component is pre-equipped with adhesive-conducting openings during manufacturing. This preliminary preparation eliminates the need for time-consuming on-site adhesive application and positioning, allowing rapid assembly while ensuring strong bonding through the injection process
2Strength
If adhesive is applied to bonding surfaces, then bond strength is achieved, but air inclusions and bubbles are trapped leading to bonding defects
Solution Approach 1:
Liquid adhesive is injected through openings in the component base plate using pressure injection (hydraulic principle), forcing the adhesive to completely fill the gap between bonding surfaces. This injection method eliminates air inclusions and bubbles by displacing air through the adhesive flow, ensuring homogeneous and defect-free bonding
Solution Approach 2:
The component base plate is designed with adhesive-conducting openings (porous structure) that allow liquid adhesive to pass through and fill the bonding gap. These openings enable complete adhesive penetration and eliminate air pockets, ensuring uniform bonding without defects
3Reliability
If long setting and curing times are used to extend service life, then bond permanence is improved, but attachment time and productivity are reduced
Solution Approach 1:
The adhesive surface and component openings are prepared in advance during manufacturing, allowing rapid assembly. The component is pre-equipped with adhesive-conducting openings and positioning features, enabling quick installation without prolonged fixation time while ensuring permanent bonding through complete adhesive filling
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
This method enables a quick, reliable, and permanent adhesive connection between the add-on part and the rotor blade, preventing air bubbles and ensuring a strong bond, thus improving the durability and efficiency of the attachment process.
Implementation Method 1
The invention relates to a method for attaching a component to an adhesive surface of a rotor blade... both bonding surfaces of the attachment and the rotor blade are first coated with adhesive... The attachment is pressed with its adhesive surface against the corresponding adhesive surface... Simultaneously, adhesive is injected into the gap
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
The invention relates to a method for attaching an attachment (3, 33) to a component, in particular a rotor blade (1), in that the component is provided with an adhesive surface (36), the attachment (3, 33) is provided with a corresponding adhesive surface (9), the attachment (3, 33) is provided with an adhesive-conducting connection to the corresponding adhesive surface (9), the adhesive surface (36) is placed against the corresponding adhesive surface (9), a gap (53) is formed between the adhesive surface (36) and the corresponding adhesive surface (9), the attachment (3, 33) is pressed against the corresponding adhesive surface (9) and simultaneously the adhesive (80) is injected into the gap (53) through the adhesive-conducting connection.