Timed Bladder Bonding Assembly for Adhesive Overflow Control
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Solution Overview
Problem
Existing bonding technologies face challenges in efficiently managing excess adhesive flow, as it often results in unconstrained overflow onto undesirable areas, requiring time-consuming and ergonomically risky removal processes, and existing solutions like elevated temperature curing or masking methods either damage components or increase fabrication costs.
Innovation Solution
A bonding assembly system featuring a bladder system with a hollowed frame and inflatable bladder that restricts and guides excess adhesive flow, using inflation to apply uniform pressure and form a design feature element, such as a bead fillet, by controlling the inflation timing and pressure to take advantage of the adhesive's viscosity before curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If excess adhesive is allowed to flow unconstrained during bonding, then the bonding process is simpler and faster, but adhesive overflows onto undesirable areas requiring time-consuming and risky removal operations
Solution Approach 1:
The patent introduces a bladder system as an intermediary element between the adhesive application area and the surrounding components. The bladder is positioned to receive excess adhesive flow and redirect it to desired areas, preventing unwanted overflow while maintaining continuous bonding operation without interruption for cleanup
Solution Approach 2:
The patent converts the harmful effect of excess adhesive overflow into a beneficial feature by guiding the excess adhesive to form desired bead fillets or design features. The bladder system captures what would otherwise be waste material and transforms it into structurally compliant features that enhance the bonded joint
2Object-affected harmful factors
If removal operations are performed to clean excess adhesive, then adhesive overflow is eliminated, but the process becomes time-consuming and ergonomically risky
Solution Approach 1:
The bladder system performs preliminary anti-action by preventing adhesive from reaching undesirable areas in the first place. The bladder is positioned and configured to intercept excess adhesive flow before it can overflow onto components that would require cleanup, eliminating the need for subsequent removal operations
Solution Approach 2:
The bladder acts as a mediator that redirects adhesive flow away from areas requiring cleanup. By introducing this intermediate element, the system eliminates the harmful overflow before it occurs, rather than requiring post-bonding removal operations
3Object-affected harmful factors
If masking methods are used to prevent adhesive overflow, then adhesive containment is improved, but fabrication costs increase
Solution Approach 1:
The patent employs a pneumatic bladder system that uses inflated air pressure to contain and redirect adhesive flow. This replaces traditional masking materials with a reusable, adjustable pneumatic device that can be inflated to various pressures and deflated for removal, reducing material costs and setup time compared to masking methods
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 efficient formation of a structurally compliant bead fillet with improved uniform dimensions, reducing the need for additional operations and minimizing damage to components, while enabling easy removal of excess adhesive, thus enhancing the bonding process.
Implementation Method 1
In response to inflating the bladder, the outer portion of the bladder extends through the opening and applies a force against the at least one component so as to form a design feature element from the malleable material
Data Source
AI summary
An assembly system includes a fixture configured to support a structure including at least one component to receive a malleable material, and a bladder system coupled to the fixture. The bladder system includes a hollowed frame having sidewalls that support a bladder disposed therein. The hollowed frame has an opening that exposes an outer portion of the bladder and is configured to guide the exposed outer portion externally from the hollowed frame toward a targeted area of the structure. In response to inflating the bladder, the outer portion of the bladder extends through the opening and applies a force against the at least one component so as to form a design feature element from the malleable material.