Segmented Industrial Frame Adhesive Bonding
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Solution Overview
Problem
Current input and output devices for industrial use face challenges in meeting mechanical robustness, resistance to external influences, and hygienic requirements due to high material losses and costs associated with manufacturing one-piece frames, which are not effectively addressed by existing methods such as machining, die-casting, or ultrasonic welding.
Innovation Solution
The frame parts are joined using an adhesive bond with a formed adhesive gap filled between abutting surfaces, creating a completely closed outer end face and peripheral surface, allowing for cost-effective production and meeting industrial requirements for stability and sealing, while also enabling easy control and reliability in the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If one-piece frames are manufactured using machining processes, then mechanical robustness and sealing are improved, but material waste and production cost increase significantly
Solution Approach 1:
The frame is divided into multiple individual frame parts that are connected to each other at the corners to form the complete frame. This segmentation allows each part to be manufactured separately with minimal material waste, while the adhesive bonding of multiple parts achieves the required mechanical robustness and sealing without requiring high material removal like traditional machining of one-piece frames.
2Productivity
If one-piece frames are manufactured using die-casting or injection molding, then production efficiency is improved, but tooling costs and initial investment increase due to high tooling costs
Solution Approach 1:
The frame is divided into multiple individual frame parts that can be manufactured using simple extrusion or cutting processes without requiring expensive die-casting or injection molding tools. These segmented parts are then joined using adhesive bonding, achieving production efficiency through standardized components while avoiding the high tooling costs associated with one-piece molding processes.
Solution Approach 2:
An adhesive bonding layer is introduced as an intermediary between the individual frame parts to join them together. This adhesive mediator enables the assembly of segmented frame parts into a complete, sealed frame structure, achieving the productivity benefits of modular assembly without requiring complex one-piece molding tooling.
3Strength
If frame parts are joined by ultrasonic welding, then joining strength is improved, but direct contact between components is required which complicates the sealing structure
Solution Approach 1:
An adhesive bonding layer is introduced as an intermediary substance between the frame parts to join them together. This adhesive mediator provides both the required joining strength and the sealing function simultaneously, eliminating the need for complex sealing structures that would be required if ultrasonic welding or other direct-contact joining methods were used.
4Ease of manufacture
If frame parts are assembled with gaps for adhesive bonding, then ease of assembly is improved, but potential leakage paths are created compromising sealing
Solution Approach 1:
The adhesive bonding layer serves as an intermediary that simultaneously provides both the ease of assembly (by filling the gap and bonding the parts) and the sealing function (by creating a leak-proof barrier). The adhesive is applied in the gap between frame parts and forms a bonding layer that is completely closed in the area of the outer end face and outer circumferential surface, thus maintaining both assembly ease and sealing reliability.
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 solution results in a cost-effective, stable, and sealed frame that meets industrial standards for mechanical robustness and hygiene, reducing material waste and production complexity, and ensuring the frame is impermeable to external influences like splash water.
Implementation Method 1
joining the frame parts at their abutting surfaces with an adhesive bond. This is achieved by filling an adhesive gap of 0.05 mm to 0.2 mm between two abutting frame parts with an adhesive, and by forming a bonding layer
Data Source
Figure 1~2
Figure 3~6
AI summary
The problem addressed by the invention is that of producing an input and output device (1) for industrial use as economically as possible, which input and output device (1) also meets the demanding requirements in the industrial sector. This problem is solve in that the frame (2) of the input and output device (1) is assembled from a plurality of individual frame parts (2a, 2b, 2c, 2d), which are connected to each other at the corners (14a, 14b, 14c, 14d) in order to form the frame (2a, 2b, 2c, 2d) and which are joined in a bonded manner at the abutting connecting surfaces (15) in order to form a completely closed outer end face (6) of the frame (2) and a completely closed peripheral surface (13) of the frame (2).