Adhesive layers are commonly used in devices to connect one component to another component at a joint. For example, adhesive joints may be used to attach cosmetic and functional components of a device.
Examples are disclosed that relate to heat-based cutting of an adhesive joint of a device. One disclosed example provides a device comprising an adhesive joint connecting a first component and a second component via an adhesive layer, and a cutting affordance incorporated within the device and positioned within the adhesive joint or adjacent the adhesive joint.
This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Furthermore, the claimed subject matter is not limited to implementations that solve any or all disadvantages noted in any part of this disclosure.
The repair an electronic device may involve the separation of adhesive joints within the device, for example, to access interior structures of a device or to remove a part for replacement. Some approaches for disassembling an adhesive joint include use of a solvent to dissolve the adhesive, applying heat to soften the adhesive, and mechanically cutting the adhesive. However, each of these approaches risk damaging components of the device. For example, if applied inaccurately, a solvent can dissolve or otherwise degrade components positioned near the adhesive joint. Exposure to heat (e.g., from a heat gun) can damage components positioned near the adhesive joint. Further, an adhesive joint may be difficult to access with a mechanical cutting tool, and such cutting tools can damage other components.
Accordingly, examples are disclosed that relate to affordances incorporated into devices for the heat-based cutting of adhesive joints of the devices. A cutting affordance may take the form of a structure to receive insertion of a heat-based cutting tool, and/or may take the form of a heat-based cutting tool incorporated into the device during manufacturing to facilitate later cutting, as examples. A heat-based cutting tool further may include structures for coupling to a heat source operable to heat the heat-based cutting tool. The heat source may provide energy to heat the heat-based cutting tool to a temperature above a glass transition temperature of an adhesive employed in the adhesive joint, thereby allowing the heat-based cutting tool to soften the adhesive. The heat source and heat-based cutting tool also may include mechanical features to facilitate the application of a pulling force on the heat-based cutting tool. In this manner, localized heating may be applied by the heat-based cutting tool to the adhesive layer of the adhesive joint with little thermal effect on other surrounding components of the device. Moreover, because the adhesive layer is softened by the localized heating, the heat-based cutting tool may be pulled through the adhesive joint with little or no net force being applied to the other surrounding components. These and other examples are described in more detail below.
In the depicted example, the cutting affordance 110 includes a heat-based cutting tool 112 positioned within a space 111 between the first component 104 and the second component 106 of sufficient clearance to allow the heat-based cutting tool 112 to move within the space 111. In other implementations, a cutting affordance may include a heat-based cutting tool positioned within the adhesive joint 102, such that the heat-based cutting tool is held in place by the adhesive. In either case, the heat-based cutting tool 112 may be incorporated into the device 100 at the time of manufacture to provide for convenient access for any repair processes.
The heat-based cutting tool 112 may have a shape and placement configured to allow the heat-based cutting tool to be drawn through the adhesive joint (when heated) without impediment from other parts. The heat-based cutting tool 112 may be configured to connect to a heat source (examples of which are shown in
The depicted heat-based cutting tool 112 includes a first end 114 and a second end 116. The first end 114 and the second end 116 may be positioned within the device 100 for convenient access during a repair process. For example, as shown in
When it is desired to cut the adhesive joint 102, the heat-based cutting tool 112 may be connected to the heat source to heat the heat-based cutting tool 112 to a temperature at or above the glass transition temperature (Tg) of the adhesive. At such temperatures, the heat-based cutting tool 112 may be pulled through the adhesive layer 108 (from left to right in the illustrated example) to soften and cut the adhesive, and thereby separate the first component 104 from the second component 106.
Once the first component 104 is separated from the second component 106, one or both of the first and second components 104, 106 may be repaired or replaced as desired. Further, after repair, the heat-based cutting tool 112 may be re-positioned in device 100, and the adhesive joint 102 may be reformed by re-applying the adhesive layer 108 between the first component 104 and the second component 106, thereby reforming the cutting affordance 110 for possible future use.
In one specific, non-limiting implementation, a nichrome wire may be used in conjunction with an adhesive joint 102 having a width of 16 mm, a length of 10 mm, and a layer of an adhesive having a thickness of 0.2 mm and a Tg of 80° C. In such an example, the adhesive joint 102 may be cut by pulling the heat-based cutting tool 112 with a force of ˜6-8 N when the heat-based cutting tool 112 is heated to or above the Tg. It will be understood that numerous other configurations are possible.
The cutting affordance 110 may be configured to allow the heat-based cutting tool 112 to be pulled through the adhesive joint 102 in any suitable direction. The pulling direction 118 may be based on a layout of the adhesive joint 102, a shape/dimensions of the first component 104 and the second component 106, as well as the configuration other components in the device 100 and the device 100 as a whole.
Next referring to
In some implementations, a device may include physical features other than a ramp configured to guide the heat-based cutting tool during disassembly via the heat-based cutting tool, and/or to ensure that other components are not damaged during cutting. Examples include, but are not limited to, thermal insulators, mechanical stops, and cutting tool guides.
First,
Next,
A heat-based cutting tool for cutting an adhesive joint may have any suitable configuration.
In some implementations, the cutting segment 801 may be configured to heat substantially uniformly along its length. In other configurations, the cutting segment 801 may include a plurality of portions (e.g., 804A, 804B, 804C) that heat at different rates. For example, a first portion 804A and a third portion 804B may be configured to heat at a slower rate than a second portion 804B. The cutting segment 801 may include any suitable number of such portions, and the portions may utilize any suitable properties, such as different electrical resistances, to heat at different rates. As one example, the first and third portions 804A, 804C may be formed from steel and the second portion 804B may be formed from a nichrome alloy.
The plurality of connectors 802 may be configured to mechanically connect to a pulling tool operable to pull the cutting segment 801 through an adhesive joint of a device. The plurality of connectors 802 may take any suitable form. For example,
In some implementations, the cutting segment of a heat-based cutting tool may include a plurality of different internal structures that each serve a particular purpose with regard to cutting an adhesive joint.
The load carrier element 1101 may help strengthen the heat-based cutting tool 1100 to prevent the heat-based cutting tool 1100 from breaking during pulling. For example, the load carrier element 1101 may include Kevlar or another high-strength material. The thermal element 1102 may have thermal properties that allow the thermal element 1102 to quickly increase in temperature. For example, the thermal element 1102 may include a conductive material, such as a nichrome alloy or another resistive heating material.
The temperature sensor 1104 may be configured to measure a temperature of the cutting segment 801 and provide the measured temperature to a heat source (e.g., an electrical current source), such that the heat source may adjust heating of the cutting segment 801 based on the temperature measured by the temperature sensor 1104. The temperature sensor 1104 may include one or more thermocouples, and/or any other suitable temperature sensors. The heat-based cutting tool 1100 may include any number and/or type of core elements, including but not limited to those listed above. The core elements may be wound, braided, or otherwise coupled together in any suitable manner. Further, in some examples, the cutting segment 801 may be formed from a single material, e.g. an electrically resistive wire.
The electrical insulation coating 1106 may prevent different portions of the cutting segment 801 from electrically contacting each other. For example, in some implementations, the heat-based cutting tool 1100 may be heated by passing an electrical current through the cutting segment 801. As such, the electrical insulation coating may prevent the heat-based cutting tool 1100 from electrically shorting when different portions of the heat-based cutting tool 1100 come in contact with each other (e.g., such as during pulling in the layout 700 shown in
In some implementations, a single coating may provide both non-stick and electrically insulating properties. It will be understood that the heat-based cutting tool 112 may include any suitable number and/or type of coating elements, including but not limited to those above. Further, in some examples, coatings may be omitted.
In some implementations, the cutting tool 1100 may be configured to administer solvent to a local area of a joint to be cut. The localized application of solvent via the cutting tool 1100 may allow for easy cutting and disassembly of the joint. For example, the cutting tool 1100 may include a hollow tube including one or more nozzles or holes through which solvent may be delivered to the adhesive of the joint. Solvent may be delivered to the joint via the cutting tool 1100 in any suitable manner
In the example of
A heat-based cutting tool may be configured to connect with any suitable heat source and/or pulling tool to be pulled through an adhesive joint. In some implementations, the heat source and the pulling tool may be separate devices. In other implementations, the heat source and the pulling tool may be a single device.
In some implementations, the pulling tool 1400 may include mechanical connectors other than hooks 1406, such as clamps or slots. In some examples, pulling tool 1400 may include separate electrical and pulling force connectors. Additionally, in some examples, the handle 1402 may be partitioned into two parts to allow different pull directions for different layouts of heat-based cutting tools.
In the illustrated example, a single connector 1510 extends from the inductive receiver coil 1506 to pull the heat-based cutting tool 1502 through an adhesive joint 1512 of the device 1508. In other implementations, a plurality of connectors may be connected to the inductive receiver coil 1506 or another portion of the heat-based cutting tool 1502.
In another example, heat may be supplied directly to a heat-based cutting tool. In such implementations, the heat-based cutting tool may include a material with high thermally conductive material to quickly distribute the heat.
In another example implementation, a device, comprises an adhesive joint connecting a first component and a second component via an adhesive layer, and a cutting affordance incorporated within the device and positioned within the adhesive joint or adjacent the adhesive joint. In one example implementation that optionally may be combined with any of the features described herein, the cutting affordance comprise one or more mechanical guides configured to direct the heat-based cutting tool from the cutting affordance through the adhesive joint. In one example implementation that optionally may be combined with any of the features described herein, the cutting affordance comprises a heat-based cutting tool configured to connect to a heat source operable to heat the heat-based cutting tool, and to connect to a pulling tool operable to pull the heat-based cutting tool through the adhesive joint. In one example implementation that optionally may be combined with any of the features described herein, the heat-based cutting tool is configured to apply a net-zero shear force to the device. In one example implementation that optionally may be combined with any of the features described herein, the heat-based cutting tool is configured to apply a directional shear force to the device. In one example implementation that optionally may be combined with any of the features described herein, the heat source comprises an electrical current source. In one example implementation that optionally may be combined with any of the features described herein, the heat source includes an inductive transmitter coil, wherein the heat-based cutting tool includes an inductive receiver coil, and wherein the heat source is operable to inductively transfer electrical current from the inductive transmitter coil to the inductive receiver coil. In one example implementation that optionally may be combined with any of the features described herein, the heat-based cutting tool is configured to be connected to an ultrasonic source. In one example implementation that optionally may be combined with any of the features described herein, the heat-based cutting tool includes a load carrier element and a thermal element. In one example implementation that optionally may be combined with any of the features described herein, the heat-based cutting tool has a cross-section including a cutting edge and one or more separation features extending from the cutting edge.
In another example implementation, a heat-based cutting tool may be configured to separate an adhesive joint of a device. The heat-based cutting tool comprises a cutting segment configured to electrically connect to an electrical current source operable to heat the cutting segment and one or more connectors extending from the cutting segment. The one or more connectors may be configured to mechanically connect to a pulling tool operable to pull the cutting segment through the adhesive joint. In one example implementation that optionally may be combined with any of the features described herein, the cutting segment includes a load carrier element and a thermal element. In one example implementation that optionally may be combined with any of the features described herein, the cutting segment includes a temperature sensor configured to measure a temperature of the cutting segment and provide the temperature to the electrical current source. The electrical current source is configured to adjust heating of the cutting segment based on the temperature measured by the temperature sensor. In one example implementation that optionally may be combined with any of the features described herein, the cutting segment includes a coating. In one example implementation that optionally may be combined with any of the features described herein, the heat-based cutting tool is incorporated in an electronic device. In one example implementation that optionally may be combined with any of the features described herein, the cutting segment has a cross-section including a cutting edge and one or more separation features extending from the cutting edge.
In another example implementation, a device, comprises an adhesive joint connecting a first component and a second component via an adhesive layer, and a heat-based cutting tool incorporated within the device adjacent to or within the adhesive layer. The heat-based cutting tool may be configured to connect to a heat source operable to heat the heat-based cutting tool, and configured to mechanically connect to a pulling tool operable to pull the heat-based cutting tool through the adhesive joint. In one example implementation that optionally may be combined with any of the features described herein, the device includes a guide configured to direct the heat-based cutting tool through the adhesive joint. In one example implementation that optionally may be combined with any of the features described herein, the heat source includes one or more of an electrical current source, an inductive current source, and an ultrasonic source. In one example implementation that optionally may be combined with any of the features described herein, the cutting segment has a cross-section section including a cutting edge and one or more separation features extending from the cutting edge.
It will be understood that the configurations and/or approaches described herein are exemplary in nature, and that these specific embodiments or examples are not to be considered in a limiting sense, because numerous variations are possible. The specific routines or methods described herein may represent one or more of any number of processing strategies. As such, various acts illustrated and/or described may be performed in the sequence illustrated and/or described, in other sequences, in parallel, or omitted. Likewise, the order of the above-described processes may be changed.
The subject matter of the present disclosure includes all novel and nonobvious combinations and subcombinations of the various processes, systems and configurations, and other features, functions, acts, and/or properties disclosed herein, as well as any and all equivalents thereof.