Saturated Bonding Mass for Shear-Resistant Composite Assembly
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Solution Overview
Problem
Current methods for combining rigid, planar materials using adhesives face challenges in achieving strong and consistent bonds due to surface refinement requirements, which increase time and costs, and often result in shear failure along the adhesive plane, particularly when using fiber-reinforced thermoset plastics.
Innovation Solution
A method involving a saturated bonding mass (SBM) of reinforcing fibers encased in a curing liquid resin, which forms a continuous matrix upon curing, effectively bonding and reinforcing materials by physically anchoring them within a shared resin matrix, eliminating the need for traditional adhesive coatings and enhancing bond strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional adhesive coatings are used to bond rigid planar materials, then bonding is achieved, but surface refinement requirements increase time and costs, and shear failure occurs along the adhesive plane
Solution Approach 1:
The invention changes the physical state and distribution parameters of the bonding material from a thin adhesive coating to a saturated bonding mass with high fiber concentration. The SBM transforms from a liquid/resin-based adhesive to a fiber-reinforced saturated mass that cures into a strong structural bond, eliminating the need for surface refinement while preventing shear failure through distributed fiber reinforcement throughout the bonding interface
Solution Approach 2:
The invention uses a composite saturated bonding mass comprising reinforcing fibers (glass, carbon, or organic) embedded in a resin matrix. This composite material provides both bonding functionality and structural reinforcement, replacing traditional adhesive coatings with a fiber-reinforced composite that resists shear failure and eliminates surface preparation requirements
2Strength
If fiber-reinforced thermoset plastics are used for high performance applications, then structural capabilities are improved, but they lack the aesthetic qualities and workability of traditional construction materials
Solution Approach 1:
The invention segments the fiber reinforcement into discrete layers within the bonding interface rather than creating a fully cured FRP composite. The saturated bonding mass with reinforcing fibers is applied in layers between substrates, allowing field installation and adjustment while maintaining structural benefits, then cured in place to create a bond that combines FRP strength with construction material workability
3Reliability
If fiber-reinforced thermoset plastics are used, then tensile properties and thermal characteristics are improved, but they are difficult to shape, modify or work with in the field after curing
Solution Approach 1:
The invention applies the saturated bonding mass with reinforcing fibers in a preliminary uncured state, allowing for field installation, positioning, and adjustment before curing. The SBM is applied to surfaces, fibers are embedded, and then the assembly is cured in place. This preliminary application in a workable state enables field manufacturing and modification while the cured product provides enhanced tensile and thermal properties
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 approach allows for the creation of composite assemblies with improved structural properties and workability, mimicking the aesthetic qualities of wood while using non-wood based substrates, by forming a single, permanent material with enhanced bond strength and reduced material costs.
Implementation Method 1
a fabric or other arrangement of reinforcing fiber, saturated with a curing liquid resin
Implementation Method 2
permanently attaches two or more elements, such as a wood-based material and a cellular polyvinylchloride material, to form a composite building material
Implementation Method 3
Thermoset plastics are permanent or permanently set when cured. These plastics begin as low viscosity resins that, when mixed with a cross-linking curing agent or other means, become permanently solid
Data Source
AI summary
A method of both permanently reinforcing and bonding, by means of a physical connection including a fabric or other arrangement of reinforcing fiber, saturated with a curing liquid resin, and building materials to create a composite assembly is disclosed. Once cured, the previously liquid resin, having surrounded the fiber and features of the surfaces of the elements being joined, combines them within a single, shared resin matrix. The resulting composite assembly incorporates a new method of providing reinforcement from within, and can be formed into any of various products or components in the light construction industry, such as window sashes, millwork, and the like.