Composite Vane Pocket Bonding with Reverse Adhesive Flow
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Solution Overview
Problem
Existing methods for joining vanes to supports, such as adhesive application and conventional injection molding, result in voids and uneven adhesive distribution, leading to reduced structural integrity and stress distribution issues.
Innovation Solution
A method involving reversing the flow of adhesive from an outlet towards an inlet, combined with pressure differentials and temperature control, to ensure complete filling of the vane-support interface and eliminate voids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional injection molding techniques are used, then the bonding process can be automated, but voids and air pockets form in the adhesive flow front reducing structural integrity
Solution Approach 1:
The patent applies reverse flow injection molding where the adhesive is injected from the outlet side rather than the conventional inlet side. This inversion of the injection direction allows the adhesive to push air bubbles ahead of it toward the inlet, preventing entrapment of air pockets in the bond line and eliminating voids that would compromise structural integrity.
2Ease of manufacture
If adhesive is injected through the cavity, then the bonding process is simplified, but adhesive is unevenly distributed on each side of the vane causing uneven stress distribution
Solution Approach 1:
By reversing the injection direction and injecting adhesive from the outlet side, the adhesive flows through the cavity in the opposite direction. This ensures more uniform distribution of adhesive on both sides of the vane, as the adhesive is pushed from the far end rather than the near end, preventing the concentration of adhesive only on one side and achieving balanced stress distribution.
3Adaptability or versatility
If complex geometries are used in the joint, then the design flexibility is improved, but air pockets form in the adhesive flow front due to difficult filling areas
Solution Approach 1:
The reverse flow injection technique allows adhesive to be pushed from the outlet side through complex geometries, ensuring that air bubbles are continuously pushed ahead toward the inlet rather than becoming trapped in difficult-to-fill areas. This maintains the ability to use complex geometries for design flexibility while eliminating void formation in challenging regions.
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
Achieves an air-tight seal and uniform adhesive distribution, enhancing structural integrity and stress distribution in the joint.
Implementation Method 1
causing an adhesive to flow between the vane and the support from an inlet to an outlet
Implementation Method 2
reversing the flow of adhesive from the outlet towards the inlet
Implementation Method 3
The temperature of the space may be increased before injecting the adhesive. This reduces the viscosity of the adhesive thus improving the flow of the adhesive through the space.
Data Source
AI summary
A method of bonding a composite vane to at least one support. The method includes positioning an end of a vane within a support, causing an adhesive to flow between the vane and the support from an inlet to an outlet, and reversing the flow of adhesive from the outlet towards the inlet.