Surface geometry for adhesive bonding of polymer components

Patent metadata

Field	Value
Publication number	US-2018290423-A1
Application number	US-201715479401-A
Country	US
Kind code	A1
Filing date	Apr 5, 2017
Priority date	Apr 5, 2017
Publication date	Oct 11, 2018
Grant date	—

Abstract

A method of joining polymer components includes additively manufacturing first and second mating features on first and second polymer components such that a mechanical lock is created through undercut geometric features of an adhesive material when the polymer components are joined. Adhesive is added between the mating components to strengthen the joint.

First claim

1 . A method of bonding polymer components comprises:
additively manufacturing a first polymer component having a first mating feature; additively manufacturing a second polymer component having a second mating feature, the second mating feature designed to fit with the first mating feature; and joining the first and second polymer components with an adhesive to form a mechanical lock wherein the mechanical lock comprises the first mating feature, the second mating feature and the adhesive.

2 . The method of claim 1 , further comprising additively manufacturing an undercut wall structure on the first mating feature.

3 . The method of claim 1 , further comprising additively manufacturing an undercut wall structure on the second mating feature.

4 . The method of claim 1 , wherein additively manufacturing a first polymer component having a first mating feature comprises additively manufacturing a recess into the first polymer component.

5 . The method of claim 4 , wherein additively manufacturing a second polymer component having a second mating feature comprises additively manufacturing a protrusion onto the second polymer component, the protrusion configured to mate with the first mating feature.

6 . The method of claim 4 , wherein additively manufacturing a second polymer component having a second mating feature comprises additively manufacturing a recess into the second polymer component.

7 . The method of claim 1 , wherein additively manufacturing a first polymer component having a first mating feature comprises additively manufacturing a void space; and wherein additively manufacturing a second polymer component having a second mating feature comprises additively manufacturing a projection, the projection complementing the void space.

8 . The method of claim 1 , wherein additively manufacturing a first polymer component having a first mating feature comprises additively manufacturing a recessed blade; and wherein additively manufacturing a second polymer component having a second mating feature comprises additively manufacturing a raised blade, the raised blade fitted to the recessed blade.

9 . The method of claim 1 , wherein additively manufacturing a first polymer component having a first mating feature comprises additively manufacturing a recessed ring; and wherein additively manufacturing a second polymer component having a second mating feature comprises additively manufacturing a raised ring, the raised ring fitted to the recessed ring.

10 . A polymer article comprises:
a first polymer component having a first surface and an edge, the first polymer component comprising a first mating feature on the first surface; a second polymer component having a second surface and an edge, the second polymer component comprising a second mating feature on the second surface; and a mechanical lock comprising the first mating feature fitted to the second mating feature by an adhesive.

11 . The polymer article of claim 10 , further comprising an undercut wall structure configured to increase the surface area of the first mating feature.

12 . The polymer article of claim 10 , wherein the first mating feature comprises a recess.

13 . The polymer article of claim 12 , wherein the second mating feature comprises a protrusion configured to mate with the first mating feature.

14 . The polymer article of claim 12 , wherein the second mating feature comprises a recess.

15 . The polymer article of claim 10 , wherein the first mating feature comprises a void space and the second mating feature comprises a protrusion.

16 . The polymer article of claim 10 , wherein the first mating feature comprises a recessed blade and the second mating feature comprises a raised blade.

17 . The polymer article of claim 10 , wherein the first mating feature comprises a recessed ring and the second mating feature comprises a raised ring.

18 . The polymer article of claim 10 , further comprising a bumper connected to the edge of the first polymer component and connected to the edge of the second polymer component.

19 . The polymer article of claim 10 , wherein the edges of the first and second polymer components are tapered.

20 . The polymer article of claim 19 , further comprising a first buried taper adjacent to the edge of the first polymer component, and a second buried taper adjacent to the edge of the second polymer component.

Assignees

• United Technologies Corp

Inventors

• Twelves Jr Wendell V
• Butcher Evan

Classifications

• B29C66/322

  Providing cavities in the joined article to collect the burr · CPC title

• B29C65/56

  using mechanical means {or mechanical connections, e.g. form-fits} · CPC title

• B29C66/30325

  making use of cavities belonging to at least one of the parts to be joined · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title

• B29C65/606

  the rivets being integral with one of the parts to be joined, i.e. staking · CPC title