Tapered Protrusion Dry Adhesive for Strong Reversible Bonding

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Solution Overview

Problem

Existing dry adhesive systems are limited in their versatility and application range due to their composition and adhesion mechanisms, offering lower adhesion strength compared to liquid and pressure-sensitive adhesives and being restricted to specific environments.

Innovation Solution

The development of adhesive systems comprising flexible materials with arrays of tapered protrusions or grooves that provide a reversible adhesive interaction through substantial interleaving, offering a force per unit area of 1 N/cm² to 100 N/cm², and are designed to be reusable and resistant to contaminants.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If dry adhesive systems use typical compositions and adhesion mechanisms, then they offer reusable and contaminant resistant properties, but they exhibit lower adhesion strength and are limited to certain applications and environments

Engineering Contradiction:

Improveadhesion strengthVSAvoidapplication range

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The adhesive surface is segmented into arrays of tapered protrusions that can interleave with complementary structures. This segmentation allows the adhesive to function through multiple mechanisms (mechanical interlocking, van der Waals forces) rather than relying on a single composition-based mechanism, thereby increasing both strength and versatility across different environments and applications.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention changes the physical parameters of the adhesive system by using tapered protrusions with specific geometric parameters (taper angle, height, spacing) rather than relying on material composition parameters. This allows the same basic structure to adapt to different applications and environments by adjusting geometric parameters rather than requiring different material compositions.

Inventive Principle:

Principle #35Parameter changes

2Strength

If liquid or pressure-sensitive adhesives are used to achieve strong adhesion, then adhesion strength is improved, but the adhesive forms permanent or single-use bonds that lack reusability

Engineering Contradiction:

Improveadhesion strengthVSAvoidreusability

Core Design Contradiction:

StrengthVSDuration of action of moving object

Solution Approach 1:

The adhesive system transitions from a static, permanent bond (liquid adhesives) to a dynamic, reversible bond. The tapered protrusions can be engaged and disengaged mechanically, allowing the adhesive to be applied and removed multiple times while maintaining strong adhesion strength when engaged, thus achieving both strength and reusability.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The invention replaces the chemical bonding mechanism of liquid adhesives (which forms permanent bonds) with a mechanical interlocking system using tapered protrusions. This mechanical system allows for reversible engagement and disengagement while maintaining comparable adhesion strength, enabling reusability without sacrificing bonding strength.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If dry adhesives are designed for specific environments, then they maintain reliable performance in those environments, but they cannot be utilized in diverse environments and applications

Engineering Contradiction:

Improveperformance consistencyVSAvoidenvironmental range

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The tapered protrusion structure serves multiple functions across different environments: mechanical interlocking for strong bonding, geometric design for contaminant resistance, and reversible engagement for reusability. This multi-functional design allows a single adhesive system to reliably perform across diverse environments and applications rather than requiring environment-specific formulations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

These adhesive systems enable diverse applications across various environments with a strong, reversible adhesive interaction, maintaining effectiveness even with misalignments and in the presence of liquids, while being impermeable and resistant to contamination.

Implementation Method 1

PSAs (e.g., foam and rubber tapes), rely on a bond formed by van der Waals forces between two surfaces

Methodology Applied

Scientific Effectvan der Waals forces: Van der Waals Force

Data Source

PatentUS8635749B2Microadhesive systems and methods of making and using the same

Publication Date: 2014.01.28 FLEXCON CO INC

AI summary

Disclosed are adhesive systems and methods of making and using such systems. Exemplary adhesive systems include protrusions and/or grooves that can interleave to form a reversible adhesive interaction.