Vacuum Shear Test Coupon Alignment Apparatus

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Solution Overview

Problem

Existing methods for adhering coupons for adhesive shear testing face issues such as inaccurate weight systems, unprecise overlap measurement, adhesive squeeze-out, difficulty in removing coupons, and excessive tooling complexity, leading to inaccurate testing results.

Innovation Solution

An apparatus comprising a first member, a second member, alignment devices, and separation devices that allow for precise control of coupon overlap and adhesive application, enabling accurate alignment, controlled adhesive thickness, and easy removal of coupons, while minimizing tooling parts to reduce costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional weight systems are used to adhere coupons, then the bonding process can be performed, but the accuracy of adhesive shear testing results deteriorates

Engineering Contradiction:

Improveaccuracy of adhesive shear testing resultsVSAvoidaccuracy of weight system

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The patent replaces conventional mechanical weight systems with a vacuum holding system. The vacuum apparatus creates negative pressure to hold coupons in place during bonding, eliminating the need for weight-based positioning. This substitution improves measurement accuracy by removing the inherent inaccuracies of weight systems while maintaining reliable coupon positioning for accurate adhesive shear testing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If conventional overlap measuring systems are used, then coupon overlap can be measured, but the precision of overlap measurement deteriorates

Engineering Contradiction:

Improveprecision of overlap measurementVSAvoidprecision of overlap measurement system

Core Design Contradiction:

Manufacturing precisionVSMeasurement precision

Solution Approach 1:

The patent introduces alignment features as intermediary elements between the coupons and the vacuum apparatus. These alignment features provide precise reference points that enable accurate overlap measurement and positioning. The intermediaries bridge the gap between rough coupon surfaces and the measurement system, achieving high precision overlap measurement without requiring complex measuring systems.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Strength

If adhesive is applied between coupons, then bonding can occur, but adhesive squeeze-out occurs during bonding

Engineering Contradiction:

Improvebond strengthVSAvoidadhesive squeeze-out

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The patent converts the potential harm of adhesive squeeze-out into a beneficial indicator. The vacuum apparatus is designed to contain and control adhesive flow, where any squeeze-out is directed to specific areas that indicate proper bonding pressure and adhesive distribution. This controlled squeeze-out serves as a visual confirmation of effective bonding rather than a defect, maintaining bond strength while managing adhesive overflow.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

4Ease of manufacture

If conventional tooling with excessive parts is used, then the bonding apparatus can function, but the cost increases

Engineering Contradiction:

Improvefunctionality of bonding apparatusVSAvoidnumber of tooling parts

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent merges multiple functions into a single integrated vacuum apparatus. The device combines holding, positioning, pressure application, and alignment functions into one unified system, eliminating the need for separate tooling components. This consolidation maintains full bonding functionality while significantly reducing the number of parts, thereby lowering manufacturing costs and simplifying the overall apparatus.

Inventive Principle:

Principle #5Merging (Combining)

5Strength

If coupons are adhered using conventional methods, then bonding can be achieved, but difficulty in removing coupons from the apparatus occurs

Engineering Contradiction:

Improvebond strengthVSAvoidease of coupon removal

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The patent segments the bonding process into distinct phases: bonding under vacuum and removal by releasing vacuum. The vacuum apparatus allows coupons to be firmly held during bonding, then easily released by simply releasing the vacuum. This segmentation separates the bonding function from the removal function, enabling strong bonding while maintaining ease of coupon removal without compromising bond strength.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS8043449B1Apparatus and method for fabricating shear test coupons

Publication Date: 2011.10.25 THE BOEING CO

AI summary

An apparatus for adhering coupons together for adhesive shear testing may include a first member, a second member, at least one alignment device, and at least one separation device. The first member may have at least one first member cavity for holding at least one first member coupon. The second member may have at least one second member cavity for holding an overlapping area of at least one second member coupon adjacent to and separate from the at least one first member coupon. The overlapping area of the at least one second member coupon may be adhered to the at least one first member coupon. The at least one alignment device may control a size of the overlapping area. The at least one separation device may control a separation distance between the overlapping area of the at least one second member coupon and the at least one first member coupon.