A composite material gasket and its manufacturing process

Abstract

This application discloses a composite material liner and its manufacturing process. The manufacturing process includes: subjecting a foam substrate to plasma surface activation treatment to obtain an activated foam substrate; placing the activated foam substrate and a polyester film in an ultraviolet irradiation device for modification and composite treatment to obtain a composite substrate; irradiating the composite substrate line by line along a preset grid pattern using a laser to form a grooved network structure on the surface of the composite substrate to obtain a grid substrate with grid marking lines; applying a nano-coating to the grid substrate to obtain a coated substrate; hot-pressing and shaping the coated substrate to obtain a liner semi-finished product; and laser-cutting the liner semi-finished product according to a preset size to obtain the composite material liner. This application, through integrated process design, significantly overcomes the technical bottleneck of insufficient surface structure processing precision in existing technologies, and significantly improves the applicability and reliability of the product in the electronic equipment, automotive interior, and packaging industries.

Description

Technical Field

[0001] This application relates to the field of composite material gasket technology, and more particularly to a composite material gasket and its manufacturing process. Background Technology

[0002] Composite material liners possess excellent cushioning, flexibility, and durability, and are widely used in the electronics, automotive interiors, and packaging industries. In the prior art, composite material liners are manufactured by combining a foam base with a functional film (such as a polyethylene film or a polypropylene film) to enhance the liner's mechanical properties or surface characteristics.

[0003] The main technical shortcomings of existing composite gasket manufacturing processes lie in the insufficient precision and consistency of surface structure processing. During manufacturing, to improve the gasket's flexibility, breathability, or integration with other components, specific patterns or grooves are often formed on the surface of the composite substrate. However, existing methods such as mechanical embossing or manual cutting easily lead to uneven surface patterns, rough edges, or damage to the internal structure of the material. This lack of processing precision directly affects the gasket's mechanical properties, such as fluctuations in tensile strength or fatigue resistance, especially under high loads or long-term use. Furthermore, the application of functional surface coatings is often separate from surface structuring, making it difficult for the coating to fully bond with irregular surfaces, resulting in insufficient adhesion or peeling during use. Insufficient surface structure processing precision has become a key technical bottleneck limiting the performance and application range of composite gaskets.

[0004] Therefore, there is an urgent need for a completely new production process that, through integrated process design, overcomes the limitations of existing technologies in terms of surface structure processing precision, and achieves composite material gaskets with consistent performance and precise structure. Summary of the Invention

[0005] The purpose of this application is to provide a composite material gasket and its manufacturing process, solving the technical problem of insufficient surface structure processing precision in existing composite material gaskets. To achieve this objective, this application adopts the following technical solution:

[0006] A manufacturing process for a composite material gasket includes:

[0007] The foam substrate is subjected to plasma surface activation treatment to obtain activated foam substrate;

[0008] The activated foam substrate and the polyester film were placed in an ultraviolet irradiation device for modification and composite treatment to obtain a composite substrate;

[0009] Based on the laser irradiating the composite substrate line by line along a preset grid pattern, a grooved network structure is formed on the surface of the composite substrate, resulting in a grid substrate with grid marking lines.

[0010] The mesh substrate is subjected to nano-coating spraying treatment to obtain a coated substrate;

[0011] The coated substrate is subjected to hot pressing and shaping treatment to obtain a gasket semi-finished product;

[0012] The semi-finished pad is laser-cut to a preset size to obtain a composite material pad.

[0013] Furthermore, the polyester film is one or more of PET film, PBT film and PEN film.

[0014] Further, the step of performing plasma surface activation treatment on the foam substrate to obtain an activated foam substrate includes:

[0015] A polyurethane foam substrate is placed in an ultrasonic cleaning device, and a mixed solution of deionized water and isopropanol is used as the cleaning medium to clean the polyurethane foam substrate, thereby obtaining a foam substrate.

[0016] The foam substrate is placed in a low-pressure plasma treatment chamber, and a mixture of argon and nitrogen is introduced. The volume ratio of argon to nitrogen is controlled at 3:1, and the power is set to 200W to obtain a primary activated substrate.

[0017] Exhaust the gas and introduce a mixture of oxygen and carbon tetrafluoride, controlling the volume ratio of oxygen to carbon tetrafluoride to be 4:1, and set the power to change periodically between 250W and 350W to obtain an activated foam substrate.

[0018] Further, the step of placing the activated foam substrate and the polyester film in an ultraviolet irradiation device for modification and composite treatment to obtain a composite substrate includes:

[0019] A propylene mixture of acrylate prepolymer containing a photoinitiator and nano zinc oxide particles is coated on the surface of the polyester film, and pre-curing treatment is carried out under inert gas protection to obtain the initial polyester film.

[0020] The initial polyester film was placed in an ultraviolet irradiation device for modification treatment. The device was set with an ultraviolet light source of wavelength 355~365nm and an irradiation intensity of 100~150mW / cm² to obtain a modified polyester film.

[0021] An environmentally friendly polyurethane hot melt adhesive is coated onto the surface of the activated foam substrate, and then flattened by a cooling roller to obtain an adhesive foam substrate.

[0022] The modified polyester film is hot-melt laminated with the adhesive foam substrate at a temperature of 120-140°C for 30-60 seconds to form a composite substrate.

[0023] Further, the step of irradiating the composite substrate line by line with a laser along a preset grid pattern to form a grooved network structure on the surface of the composite substrate, thereby obtaining a grid substrate with grid marking lines, includes:

[0024] The first surface morphology data of the composite substrate is collected by computer equipment, and a laser irradiation path is generated based on the first surface morphology data. The laser irradiation path includes intersecting lines in different directions and a region of varying depth.

[0025] The composite substrate is subjected to incident irradiation treatment at multiple angles according to the laser irradiation path to form a primary network substrate, wherein the intersection of the multiple angles forms a region of varying depth.

[0026] Collect the second surface morphology data of the primary network substrate, and optimize the curvature of the intersection point based on the second surface morphology data to form an optimized curvature parameter;

[0027] The primary network substrate is subjected to secondary laser irradiation according to the optimized curvature parameters to form an optimized network substrate.

[0028] The inner wall of the groove on the optimized network substrate is etched using a laser, and the edge of the inner wall of the groove is locally melted to obtain a mesh substrate with grid marking lines.

[0029] Further, the step of performing a secondary laser irradiation treatment on the primary network substrate according to the optimized curvature parameters to form an optimized network substrate includes:

[0030] The surface of the primary network substrate is divided into multiple energy zones based on the second surface morphology data and optimized curvature parameters of the primary network substrate.

[0031] Each energy zone is assigned a corresponding laser power, and the primary network substrate is irradiated according to the laser power to obtain the optimized network substrate.

[0032] Further, the step of performing a nano-coating spraying treatment on the mesh substrate to obtain a coated substrate includes:

[0033] A composite solution containing nano-titanium dioxide, silane coupling agent and polyurethane resin is sprayed onto the surface of the mesh substrate to form a preliminary coating mesh substrate. The composite solution contains 6-8% titanium dioxide, 2-3% silane coupling agent, and the remainder is polyurethane resin.

[0034] The pre-coated mesh substrate is placed in a reaction vessel and cured at a low temperature of 50~60℃ for 1.5~2 hours to obtain a cured mesh substrate.

[0035] A polishing slurry containing nano-alumina particles is coated onto the surface of the cured mesh substrate. The cured mesh substrate coated with the polishing slurry is then polished using a polishing device to obtain a coated substrate. The alumina particles have a size of 50~80nm, and the polishing pressure is 0.1~0.15MPa.

[0036] Further, the step of hot-pressing and shaping the coated substrate to obtain the gasket semi-finished product includes:

[0037] The coated substrate is placed in a reaction vessel and preheated and softened at a temperature of 120~130°C to obtain a preheated substrate.

[0038] A fluorinated non-stick coating is sprayed onto the surface of the pre-forming mold, and the preheated substrate is placed in the pre-forming mold and pre-shaped at 0.5~1MPa to obtain the pre-shaped substrate.

[0039] The pre-shaped substrate is transferred to a high-temperature and high-pressure hot press for high-temperature and high-pressure shaping to obtain a shaped substrate. The hot pressing temperature is set to 160~180℃ and the pressure is 2.5~3.5MPa.

[0040] The shaped substrate is subjected to gradient cooling treatment. In the first stage, the temperature is reduced from 180°C to 100°C at a rate of 5°C / min. In the second stage, the temperature is reduced from 100°C to 50°C at a rate of 35°C / min, resulting in a semi-finished gasket.

[0041] Further, the step of laser-cutting the semi-finished pad according to a preset size to obtain a composite material pad includes:

[0042] The semi-finished pad is laser-cut according to a preset contour using a multi-wavelength laser to obtain a cut substrate, wherein the short-wavelength laser corresponds to the polyester film layer and the long-wavelength laser corresponds to the foam substrate.

[0043] The integrity of the marking lines on the surface of the cutting substrate is obtained based on optical inspection equipment to determine whether the cutting substrate meets the preset size requirements;

[0044] If it does not meet the requirements, the cut substrate is modified until the preset size requirements are met to obtain a composite material liner.

[0045] This application also discloses a composite material gasket, which is manufactured using a composite material gasket manufacturing process as described in any of the preceding claims.

[0046] Compared with the prior art, this application has the following beneficial effects:

[0047] This application discloses a manufacturing process for a composite material gasket. Through plasma surface activation treatment and ultraviolet irradiation modification composite treatment, a high-strength molecular-level bond is achieved between the foam substrate and the polyester film, improving the mechanical properties of the composite substrate, such as tensile strength and fatigue resistance. Based on the groove network structure formed by laser irradiation along a preset grid pattern, it has extremely high processing precision and consistency. The grid marking lines have smooth edges and regular patterns, solving the problems of surface unevenness and material damage caused by mechanical embossing or manual cutting. It significantly enhances the flexibility of the gasket and its ability to fit with other components. The synergistic design of nano-coating spraying treatment and groove network structure allows the coating to adhere evenly to complex surfaces, significantly improving the coating's adhesion and durability, and effectively preventing peeling.

[0048] In summary, the manufacturing process of this invention, through the organic integration of each step, achieves composite material gaskets with consistent performance, precise structure, and durability, significantly improving the applicability and reliability of the product in the electronics, automotive interiors, and packaging industries. Attached Figure Description

[0049] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0050] The structures, proportions, sizes, etc., shown in the accompanying drawings are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed in the specification, and are not intended to limit the implementation conditions of this application. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in the proportions, or adjustments to the size should still fall within the scope of the technical content disclosed in this application, provided that they do not affect the effects and purposes that this application can produce.

[0051] Figure 1 This is a schematic diagram of the overall steps in the production process of a composite material gasket. Detailed Implementation

[0052] To make the inventive objectives, features, and advantages of this application more apparent and understandable, the technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the embodiments described below are only some embodiments of this application, and not all embodiments. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0053] In the description of this application, it should be understood that the terms "upper," "lower," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application. It should be noted that when a component is considered to be "connected" to another component, it can be directly connected to the other component or there may be a component centrally located at the same time.

[0054] The technical solution of this application will be further described below with reference to the accompanying drawings and specific embodiments.

[0055] refer to Figure 1 This application provides a manufacturing process for a composite material gasket, comprising:

[0056] S1: The foam substrate is subjected to plasma surface activation treatment to obtain activated foam substrate;

[0057] In step S1, a foam substrate material is selected, and polyurethane foam with a thickness of 2-5 mm can be used as the initial material. This thickness range can balance the lightweight of the lining and the structural strength. Plasma surface activation treatment introduces active groups and optimizes the surface microstructure by bombarding with high-energy plasma, thereby improving surface energy and hydrophilicity. In actual operation, plasma surface activation treatment is carried out in a low-pressure plasma device. The polyurethane foam is placed in the plasma treatment chamber, and a mixed atmosphere of argon and oxygen is used as the working gas. The pressure is controlled within the range of 50-100 Pa to ensure the stability and uniformity of the plasma. Argon mainly plays a physical bombardment role in the plasma, which can slightly etch the foam surface and increase the surface roughness. After 10 minutes, oxygen promotes the breaking of surface chemical bonds and the generation of active groups through chemical action. During the treatment, the equipment power is set to 100-200 W, and the treatment time is controlled within 3-5 minutes to avoid surface damage caused by overtreatment. High-energy electrons, ions, and free radicals in plasma interact with molecules on the foam surface, breaking carbon-hydrogen bonds and introducing oxygen-containing functional groups such as hydroxyl (-OH) and carboxyl (-COOH). These active groups significantly increase the surface polarity and chemical activity, raising the surface energy from the initial 30 mN / m to over 50 mN / m, while simultaneously reducing the surface contact angle, indicating a significant enhancement in hydrophilicity. Furthermore, plasma treatment effectively removes oil and impurities from the foam surface, further cleaning the surface and increasing its micro-roughness. This increased roughness further strengthens the bond with the polyester film through mechanical interlocking. It is important to note that the plasma treatment parameters need to be optimized based on the specific characteristics of the foam substrate and subsequent process requirements. For example, for 2 mm thick polyurethane foam, a lower power (approximately 100 W) and a shorter treatment time (3 minutes) can be used to balance the activation effect and material integrity.

[0058] S2: The activated foam substrate and the polyester film are placed in an ultraviolet irradiation device for modification and composite treatment to obtain a composite substrate;

[0059] In step S2, a polyester film material is selected, preferably polyethylene terephthalate (PET) film, due to its good mechanical strength, chemical stability, and transparency, making it suitable as a reinforcing layer for composite material pads. The thickness of the PET film is controlled between 0.1-0.2 mm. The PET film undergoes surface modification, followed by hot-pressing lamination of the modified PET film with an activated foam substrate. During the surface modification stage, an acrylate prepolymer containing a photoinitiator is selected as the modified coating material. This prepolymer can rapidly polymerize under ultraviolet light to form a cross-linked network, thereby improving the surface properties of the PET film. During operation, the acrylate prepolymer is uniformly coated onto the surface of the PET film, with the coating thickness controlled at 5-10 micrometers to ensure effective modification while avoiding excessive coating thickness that could affect flexibility. Subsequently, the PET film coated with the prepolymer was placed in an ultraviolet irradiation device using a 365 nm ultraviolet light source. This wavelength effectively excites the photoinitiator, triggering the free radical polymerization reaction of the prepolymer. The irradiation time was controlled at 2-3 minutes to ensure complete cross-linking of the prepolymer and the formation of a stable network structure. Through this process, a cross-linked coating with high elasticity and adhesive activity was formed on the surface of the PET film, significantly increasing surface energy and reducing the contact angle from the initial 80° to approximately 50°, indicating a significant improvement in hydrophilicity and adhesion. After the ultraviolet modification of the PET film, the hot-pressing lamination stage began. The modified PET film was laminated with the activated foam substrate obtained in step S1 using a hot melt adhesive coating machine. An environmentally friendly polyurethane hot melt adhesive was selected as the adhesive, as it possesses excellent bonding strength and environmental friendliness. The coating thickness was controlled at 20-30 micrometers to balance bonding effect and material cost. The lamination process is carried out in a hot melt adhesive coating machine, with the equipment temperature set at 120~140℃, pressure controlled at 0.5~1 MPa, and lamination time at 10~20 seconds to achieve optimal adhesion. In step S1, the activated foam substrate surface has been treated with plasma to introduce active groups such as hydroxyl and carboxyl groups, resulting in a surface energy of over 50 mN / m. These groups form chemical bonds and physical intercalation with the crosslinked coating on the modified PET film surface, significantly improving interfacial adhesion. Tests show that the peel strength of the composite substrate can reach over 10 N / cm, far exceeding that of the unmodified composite material, exhibiting excellent interfacial stability.

[0060] S3: Based on the laser irradiating the composite substrate line by line along the preset grid pattern, a grooved network structure is formed on the surface of the composite substrate to obtain a grid substrate with grid marking lines;

[0061] In step S3, the composite substrate is placed in a laser engraving machine using a nanosecond pulsed laser with a wavelength of 1064 nanometers. This type of laser, due to its short pulse width and high peak power, is suitable for micron-level precision ablation processing on polymer materials such as PET films, thereby inducing photothermal or photochemical reactions on the material surface to form the desired groove structure. The laser power range is 20-30 watts, and the engraving speed is 500-1000 mm / s. These parameters need to be fine-tuned according to the thickness and material properties of the composite substrate during actual operation. The preset grid pattern consists of 1 mm × 1 mm grid units, with a line width controlled at 50-100 micrometers and a groove depth of 10-20 micrometers, ensuring that the grid marking lines have sufficient visual recognition without compromising the overall structural integrity of the composite substrate. The process can be implemented using computer-aided design (CAD) software. The operator inputs the preset grid pattern into the system, and the laser beam scans line by line according to the program instructions, ablating point by point on the PET film surface to form a continuous network of grooves. During laser engraving, the high-temperature ablation of the PET film surface can trigger an oxidation reaction, leading to discoloration or the formation of unwanted byproducts, affecting the clarity and aesthetics of the grid marking lines. Introducing nitrogen into the processing area effectively isolates oxygen, preventing oxidation. Nitrogen also acts as a coolant, reducing the heat-affected zone and improving the precision and smoothness of the groove edges. For example, in actual production, the nitrogen flow rate is typically controlled at 5-10 liters per minute to balance protection and cost. In operation, the composite substrate is fixed on the laser engraving machine's worktable, ensuring a smooth and wrinkle-free surface to prevent laser focus deviation. The laser beam is rapidly deflected by a galvanometer system, scanning line by line across the PET film surface along a preset path. Each grid line is formed by the superposition of laser pulses. After processing, the grid substrate undergoes a quality inspection to confirm that the grid unit dimensions, line width, and groove depth meet design requirements. For example, an optical microscope can be used to measure whether the line width is within the range of 50-100 micrometers, or a surface profilometer can be used to check whether the groove depth reaches 10-20 micrometers. If a deviation is found, it may be necessary to adjust the laser power or engraving speed and then reprocess.

[0062] S4: Perform nano-coating spraying on the mesh substrate to obtain a coated substrate;

[0063] In step S4, the mesh substrate is placed in a spraying device, and a composite solution containing nano-titanium dioxide and a silane coupling agent is applied through a nozzle. The nano-titanium dioxide content in the composite solution is 5-10%, a proportion designed to balance the functionality and cost of the coating. Due to its photocatalytic properties, nano-titanium dioxide can decompose organic pollutants under light, thus giving the coating self-cleaning properties. Its high chemical stability also helps improve antibacterial effects. The silane coupling agent acts as a bridging agent, enhancing the adhesion between the nano-titanium dioxide particles and the PET film surface, improving the coating's adhesion and durability. The solution viscosity is controlled between 50 and 100 centipoise. This range ensures that the solution can evenly cover the substrate surface during spraying without causing uneven coating thickness or dripping due to excessive fluidity. The spraying device (KY) employs a high-pressure spraying system equipped with precision nozzles to achieve uniform application of micron-level coatings. The nozzle pressure is 0.2-0.3 MPa, a pressure range that forms a fine atomized spray on the substrate surface, controlling the coating thickness to 5-10 micrometers. In practice, the grid substrate is fixed on the worktable of the spraying equipment. The nozzle moves back and forth along the substrate surface at a constant speed. The composite solution is sprayed from the nozzle through compressed air or a pumping system, and uniformly deposited on the PET film surface and the grooved network structure. To avoid the coating clogging the grid marking lines, the spraying angle and distance need to be precisely adjusted. Typically, the distance between the nozzle and the substrate surface is maintained at 15-20 cm, and the spraying angle is close to perpendicular to ensure uniform solution coverage without excessive accumulation. Finally, the coating is cured at room temperature for 2 hours. During the curing process, the solvent in the solution gradually evaporates, and the coating gradually hardens, forming a protective layer with a hardness of 4H.

[0064] S5: The coated substrate is subjected to hot pressing and shaping treatment to obtain a gasket semi-finished product;

[0065] In step S5, high temperature and pressure are applied using a thermoforming machine to soften the foam substrate, further fusing it with the PET film and simultaneously promoting secondary curing of the nano-coating, thereby forming a high-density and high-strength liner semi-finished product. The mold surface of the thermoforming machine is coated with a non-stick coating, such as polytetrafluoroethylene (PTFE), to prevent the substrate from adhering to the mold under high temperature and pressure, ensuring a smooth and defect-free surface after demolding. This design is crucial for maintaining the clarity of the grid marking lines and the integrity of the coating. In practice, the coated substrate is placed in the working chamber of the thermoforming machine, with upper and lower molds corresponding to the upper and lower surfaces of the substrate, respectively. The shape and size of the molds are pre-customized according to the design requirements of the liner semi-finished product. The temperature of the thermoforming machine is set between 150 and 170 degrees Celsius. This temperature range softens the foam substrate (polyurethane or polyethylene foam) while activating molecular movement on the PET film surface, promoting interfacial bonding without causing overheating degradation or damage to the nano-coating. The pressure is controlled at 2-3 MPa to uniformly compress the substrate in the mold, eliminating internal pores and improving material density. The holding time is 5-8 minutes, allowing the foam substrate and PET film to fully fuse. Simultaneously, components such as the silane coupling agent in the nano-coating undergo further cross-linking at high temperatures, forming a more robust protective layer. During hot pressing, the porous structure of the foam substrate is compressed, and the thickness is precisely controlled. Reference information mentions a thickness deviation controlled within ±0.05 mm, indicating that the hot press is equipped with a high-precision pressure and displacement control system capable of real-time monitoring of the substrate's compression degree. After hot pressing, the substrate is cooled to near room temperature within the mold to fix its shape, preventing springback or warping, transforming the coated substrate into a structurally stable gasket semi-finished product.

[0066] S6: The semi-finished pad is laser-cut according to a preset size to obtain a composite material pad.

[0067] In step S6, before laser cutting, specific requirements for preset dimensions need to be set. These dimensions can be determined by product design drawings or customer requirements. For example, assuming the pad is used as an internal cushioning component in electronic devices, it needs to be cut into rectangular sheets with dimensions of 100 mm × 50 mm and a thickness of 2 mm, with tolerances controlled within ±0.1 mm. The laser cutting equipment can be a high-precision CNC laser cutting machine equipped with a high-power laser (such as a CO2 laser or fiber laser), capable of achieving micron-level cutting precision. In specific operation, the semi-finished pad is fixed on the worktable of the laser cutting machine using vacuum adsorption or clamps to prevent material displacement during cutting. After fixing, the preset cutting paths are input through the CNC system. These paths are generated based on the product design drawings and imported into the equipment in vector file format (such as DXF or G-code). The cutting paths include not only the outer contour of the pad but also some internal functional openings or marking lines. For example, if the pad needs to have holes pre-drilled at specific locations for installation, the laser cutting machine can complete the cutting of the outer contour and inner holes in one processing cycle, improving production efficiency. The laser power and cutting speed need to be optimized based on the material characteristics of the semi-finished pad. For example, composite pads may contain a foam base, polyester film, and nano-coating. These materials have different heat sensitivities, so the laser power (within the range of 50~200W) and cutting speed (10~100 mm / s) need to be controlled to avoid overheating that could cause material scorching or coating peeling. Assuming the foam base of the pad is sensitive to high temperatures, a lower power and a faster cutting speed can be selected to reduce the heat-affected zone. After laser cutting, the resulting composite pad needs to undergo subsequent inspection to ensure product quality meets requirements. The optical inspection system includes a high-resolution CCD camera and image processing software to check the integrity of the grid marking lines, coating uniformity, and the presence of surface defects. The grid marking lines are a network of grooves formed by laser irradiation in step S3, and their integrity directly affects the pad's functionality (such as flow guidance or positioning). During inspection, the camera scans the pad surface, and the software analyzes the continuity and depth of the grid lines. If broken lines or insufficient depth are found, the pad is deemed defective. In addition, coating uniformity testing determines whether the nano-coating is evenly applied by analyzing the intensity distribution of reflected light on the surface; any areas of missing or accumulated coating are marked as defects. Surface defect detection focuses on minor imperfections such as scratches, bubbles, or foreign matter, which may affect the mechanical properties or appearance quality of the gasket. Through optical inspection, the product pass rate can reach 99.5%, and defective products will be rejected or reworked. Gaskets that pass inspection are vacuum-packed with anti-static PE film to prevent moisture or electrostatic damage during transportation, thus forming composite material gaskets.

[0068] In one embodiment, the polyester film is one or more of PET film, PBT film and PEN film.

[0069] In this embodiment, PET film, PBT film, and PEN film all possess high mechanical strength and chemical stability. PET film (polyethylene terephthalate film) is the preferred material due to its good transparency and wide applicability. Depending on the specific application requirements, PBT film (polybutylene terephthalate film) and PEN film (polyethylene naphthalate film) can be used as alternatives or supplementary choices. PBT film has high heat resistance and dimensional stability, making it suitable for composite gaskets used in high-temperature environments; PEN film has excellent weather resistance and barrier properties, making it suitable for applications requiring long-term outdoor exposure or special gas barrier requirements.

[0070] In one embodiment, the step of performing plasma surface activation treatment on the foam substrate to obtain an activated foam substrate includes:

[0071] A polyurethane foam substrate is placed in an ultrasonic cleaning device, and a mixed solution of deionized water and isopropanol is used as the cleaning medium to clean the polyurethane foam substrate, thereby obtaining a foam substrate.

[0072] The foam substrate is placed in a low-pressure plasma treatment chamber, and a mixture of argon and nitrogen is introduced. The volume ratio of argon to nitrogen is controlled at 3:1, and the power is set to 200W to obtain a primary activated substrate.

[0073] Exhaust the gas and introduce a mixture of oxygen and carbon tetrafluoride, controlling the volume ratio of oxygen to carbon tetrafluoride to be 4:1, and set the power to change periodically between 250W and 350W to obtain an activated foam substrate.

[0074] In the above embodiments, the polyurethane foam substrate is placed in an ultrasonic cleaning device, using a mixed solution of deionized water and isopropanol as the cleaning medium. Deionized water effectively removes water-soluble impurities, while isopropanol helps dissolve organic contaminants such as grease or processing residues. Assuming a deionized water to isopropanol volume ratio of 2:1, the ultrasonic device frequency is set to 40kHz, the power to 300W, and the cleaning time is controlled at 5-10 minutes. During the cleaning process, the cavitation effect induced by ultrasound causes the tiny bubbles in the solution to expand and burst rapidly, generating localized high pressure and microjets, thereby thoroughly removing particles and dirt from the foam surface. After cleaning, the foam substrate needs to be dried with nitrogen in a clean environment to prevent secondary contamination and then placed in a drying oven at 50°C for 30 minutes to remove any residual moisture. After cleaning and drying, the foam substrate undergoes plasma surface activation treatment. The foam substrate is placed in a low-pressure plasma treatment chamber, which is a vacuum environment with a pressure controlled at 0.1-1 Pa, to ensure efficient ionization of gas molecules and stable plasma generation. A mixture of argon and nitrogen gas (3:1 volume ratio) is introduced into the cavity. Argon, as an inert gas, generates stable plasma, while nitrogen helps introduce nitrogen-containing functional groups (such as amino groups) onto the foam surface, thereby improving surface hydrophilicity and chemical activity. The plasma treatment power is set to 200W, and the treatment time is 3-5 minutes. During this process, high-energy particles in the plasma bombard the foam surface, breaking surface molecular bonds, forming free radicals and active sites, and simultaneously removing residual organic contaminants, resulting in a primary activated substrate. Next, the gas in the cavity is vented, and a mixture of oxygen and carbon tetrafluoride gas (4:1 volume ratio) is introduced, with the power periodically varying between 250W and 350W. The purpose of this stage is to introduce oxygen-containing functional groups (such as hydroxyl and carboxyl groups) through oxygen plasma, further improving surface polarity and adhesion, while simultaneously using carbon tetrafluoride plasma to deposit a thin fluorinated layer on the surface, enhancing chemical corrosion resistance and hydrophobicity. Periodic power variation means that the power switches between 250W (low power stage, focusing on functional group introduction) and 350W (high power stage, focusing on fluorination layer deposition) every 30 seconds. The total processing time is 5 to 7 minutes. Dynamic power adjustment can balance the effects of surface activation and fluorination modification, and avoid problems such as over-etching or uneven coating that may occur under a single power.

[0075] In one embodiment, the step of placing the activated foam substrate and the polyester film in an ultraviolet irradiation device for modification and composite treatment to obtain a composite substrate includes:

[0076] A propylene mixture of acrylate prepolymer containing a photoinitiator and nano zinc oxide particles is coated on the surface of the polyester film, and pre-curing treatment is carried out under inert gas protection to obtain the initial polyester film.

[0077] The initial polyester film was placed in an ultraviolet irradiation device for modification treatment. The device was set with an ultraviolet light source of wavelength 355~365nm and an irradiation intensity of 100~150mW / cm² to obtain a modified polyester film.

[0078] An environmentally friendly polyurethane hot melt adhesive is coated onto the surface of the activated foam substrate, and then flattened by a cooling roller to obtain an adhesive foam substrate.

[0079] The modified polyester film is hot-melt laminated with the adhesive foam substrate at a temperature of 120-140°C for 30-60 seconds to form a composite substrate.

[0080] In the above embodiments, a propylene mixture of acrylate prepolymer containing a photoinitiator and nano-zinc oxide particles is coated onto the surface of a polyester film. The acrylate prepolymer can rapidly crosslink and cure under UV light initiation to form a high-toughness coating, while the nano-zinc oxide particles enhance the mechanical strength of the coating and impart antibacterial and UV-shielding functions. The formulation of the propylene mixture can be: 60 wt% acrylate prepolymer, 2 wt% photoinitiator (such as benzophenone), 5 wt% nano-zinc oxide (particle size 20-50 nm), and the remainder being solvent (such as ethyl acetate). Coating is performed using a precision blade coating device, with the coating thickness controlled at 10-15 μm, followed by pre-curing under an inert atmosphere protected by nitrogen. Pre-curing involves irradiation with low-intensity UV light (wavelength 365 nm, intensity 50 mW / cm²) for 30 seconds to partially crosslink the coating surface, forming an initial polyester film and preventing coating flow or adhesion during subsequent processing. Nitrogen protection prevents oxygen from inhibiting free radical polymerization, thereby improving pre-curing efficiency. The initial polyester film is modified by placing it in an ultraviolet irradiation device. The device uses an ultraviolet light source with a wavelength of 355-365nm, an irradiation intensity of 100-150mW / cm², and a treatment time of 60-90 seconds. High-intensity ultraviolet light induces deep cross-linking of the acrylate coating. Simultaneously, the nano-zinc oxide particles generate a photocatalytic effect under ultraviolet light excitation, producing active oxygen substances, further modifying the polyester film surface and enhancing its surface polarity and adhesion to the adhesive layer. In another embodiment, helium gas and a small amount of vinyltrimethoxysilane (volume ratio 10:1) can be introduced, with the pressure controlled at 0.5Pa, the power at 50W, and the treatment time at 2 minutes. The vinyltrimethoxysilane decomposes under plasma and deposits on the film surface, forming a nano-coating containing siloxane and vinyl groups, improving surface activity, providing additional chemical bonding sites for subsequent hot-melt lamination, and significantly enhancing the interlayer bonding strength of the composite substrate. Environmentally friendly polyurethane hot melt adhesive is uniformly coated onto the surface of an activated foam substrate, with a coating thickness controlled at 20-30 μm. A hot melt adhesive spraying device is used to ensure a uniform, bubble-free adhesive layer. After coating, the foam substrate is flattened using a cooling roller (temperature 15-20℃) for approximately 10 seconds to stabilize the adhesive layer morphology and prevent adhesive penetration into the foam pores, resulting in an adhesive foam substrate. Before applying the hot melt adhesive, the activated foam substrate is placed in a microwave treatment device with a microwave frequency of 2.45 GHz, a power of 100 W, and a treatment time of 20 seconds, under a low-pressure helium atmosphere (0.2 Pa). Microwave treatment selectively heats the activated functional groups (such as hydroxyl and amino groups) on the foam surface, enhancing its chemical activity, while slightly altering the surface microstructure, increasing porosity and roughness, thereby enhancing the penetration and adhesion of the hot melt adhesive. Subsequently, the modified polyester film and the adhesive foam substrate enter the hot melt lamination stage. The lamination temperature is controlled at 120-140℃, the lamination time is 30-60 seconds, and a hot press lamination machine is used to make the pressure uniform (about 0.5MPa).During this process, the polyurethane hot melt adhesive softens at high temperature and penetrates into the surface coating of the modified polyester film, forming chemical bonds and physical intercalation with the siloxane and vinyl coatings, ultimately forming a high-strength composite substrate.

[0081] In one embodiment, the step of using a laser to irradiate the composite substrate row by row along a preset grid pattern to form a grooved network structure on the surface of the composite substrate, thereby obtaining a grid substrate with grid marking lines, includes:

[0082] The first surface morphology data of the composite substrate is collected by computer equipment, and a laser irradiation path is generated based on the first surface morphology data. The laser irradiation path includes intersecting lines in different directions and a region of varying depth.

[0083] The composite substrate is subjected to incident irradiation treatment at multiple angles according to the laser irradiation path to form a primary network substrate, wherein the intersection of the multiple angles forms a region of varying depth.

[0084] Collect the second surface morphology data of the primary network substrate, and optimize the curvature of the intersection point based on the second surface morphology data to form an optimized curvature parameter;

[0085] The primary network substrate is subjected to secondary laser irradiation according to the optimized curvature parameters to form an optimized network substrate.

[0086] The inner wall of the groove on the optimized network substrate is etched using a laser, and the edge of the inner wall of the groove is locally melted to obtain a mesh substrate with grid marking lines.

[0087] In this embodiment, the first surface morphology data of the composite substrate is acquired using computer equipment. Specifically, a high-resolution 3D laser scanner (resolution up to 0.1 μm) is used to perform a panoramic scan of the composite substrate surface to obtain 3D morphology data including information on surface roughness, microscopic defects, and material distribution unevenness. Based on this data, the computer generates a laser irradiation path using a dedicated algorithm (such as a Delaunay triangulation-based path optimization algorithm). The path design includes intersecting lines along the X and Y axes, with depth variation regions (e.g., depth gradually changing from 50 μm to 100 μm) set at the intersection points to form a functionally graded mesh structure. Following the generated laser irradiation path, a femtosecond laser (wavelength 1030 nm, pulse width 500 fs, repetition frequency 100 kHz) is used to irradiate the composite substrate row by row at multiple incident angles (e.g., 0°, 45°, and 90°) to form a primary network substrate. The ultrashort pulse characteristics of the femtosecond laser enable non-thermal processing, reducing damage to the composite substrate from the heat-affected zone. During irradiation, the laser power is controlled between 0.5-1W, and the scanning speed is 500mm / s. At the intersection points, a region of varying depth is formed by dynamically modulating the laser pulse energy (e.g., increasing the energy by 20%), with the depth error controlled within ±5μm. Following the initial irradiation, a micro / nanostructure induction step based on an adaptive light field is performed. Specifically, the composite substrate is placed in a light field system controlled by a spatial light modulator (SLM). A customized Bessel beam is generated using the SLM and focused on the intersection region, inducing the formation of periodic nanoscale stripes (period approximately 200nm). These nanostripes are embedded into the groove surface through photo-plasma, enhancing the surface functionality of the mesh structure (such as hydrophobicity or optical scattering). Secondary surface morphology data of the primary network substrate is collected, and a 3D laser scanner is used to analyze the curvature distribution at the intersection points and the morphological deviations at the groove edges. Based on this data, finite element simulation and curvature optimization algorithms (such as a curvature smoothing algorithm based on B-spline curves) are used to calculate and optimize the curvature parameters, ensuring a smooth geometric transition at the intersection points, with the curvature radius error controlled within ±2μm. The optimized curvature parameters were used to guide the secondary laser irradiation. A laser (wavelength 532nm, pulse width 10ps, power 0.3W) was used to refine the primary network substrate, with the scanning speed reduced to 200mm / s to improve accuracy. The secondary irradiation not only repaired minor defects in the primary processing (such as edge burrs) but also further optimized the geometric consistency of the grooves by precisely controlling the laser spot trajectory, forming an optimized network substrate. Finally, the inner walls of the grooves in the optimized network substrate were etched using a laser. An excimer laser (wavelength 248nm, pulse width 20ns, power 0.2W) was used to remove minor residues from the inner walls of the grooves with high precision. Simultaneously, the groove edges were locally melted by adjusting the laser pulse frequency (50Hz) to form a smooth edge transition, with the edge roughness Ra controlled below 0.5μm.Following etching, microstructure enhancement based on laser multiphoton polymerization is performed. Specifically, the optimized network substrate is placed in a liquid precursor containing photosensitive monomers (such as acrylate monomers) and a photoinitiator. A laser (wavelength 780 nm, pulse width 100 fs, power 10 mW) is used to scan along the inner wall of the grooves, inducing the photosensitive monomers to locally polymerize into a three-dimensional microporous structure (pore size approximately 1 μm) on the inner wall of the grooves. These microporous structures not only increase the surface area of ​​the grooves and enhance the adhesion of subsequent coatings or fillers, but also serve as microfluidic channels or catalyst carriers, improving the functional versatility of the mesh substrate. Notably, the marking lines are the linear portions of the grooved network structure formed by laser processing on the surface of the composite substrate. These lines constitute the mesh pattern on the mesh substrate. The mesh marking lines are the concrete manifestation of the grooved network structure, appearing as linear grooves with a certain width and depth extending along the X and Y axes (or other preset directions). These lines are formed according to a computer-generated laser irradiation path, which includes intersecting lines in different directions (e.g., horizontal and vertical lines intersecting to form a grid). The intersections also have preset depth variations (e.g., depth gradually changing from 50μm to 100μm). This depth variation at the intersections prevents stress concentration at any single point, instead distributing it evenly, thereby improving the compressive strength, toughness, and overall mechanical stability of the composite substrate. In printed pad applications, the grid pattern provides a specific patterned surface. The grooves formed by these lines and the varying intersection areas enhance adhesion and printing accuracy during the printing process. Due to the special design of the grid pattern, the printed coating can be evenly distributed on the pad surface, while simultaneously strengthening the adhesion between the coating and the pad substrate, improving the quality and stability of the final printed product.

[0088] In another embodiment, the computer device calculates the optimized curvature using the following expression: ;in, The optimized curvature parameter represents the target curvature value at the intersection (unit: 1 / μm); κ(s) is the local curvature at a point ss along the path ΓΓ, reflecting the curvature distribution at the intersection of the primary network substrate, and is calculated from the second surface morphology data; The reference curvature value serves as the target benchmark for curvature optimization, measuring the deviation between the actual curvature and the ideal curvature. It is a second-order Laplace operator for the local curvature κ(s), which characterizes the spatial rate of change of curvature and is used to smooth the curvature distribution and reduce local abrupt changes (such as edge spikes). This is the stress distribution at a point s along the path Γ calculated by finite element method, reflecting the mechanical stress concentration at the intersection. , , Γ represents the weighting coefficients, corresponding to the contributions of the curvature smoothing term, curvature deviation term, and stress optimization term, respectively, balancing the influence of these three terms in the formula; Γ is the curvature optimization path in the intersection region, typically a closed curve along the edge of the groove; s is the arc length parameter on the path Γ, characterizing the position along the path and used to parameterize curvature and stress distribution; T(s) is the tangent vector at a point s on the path Γ, describing the geometric direction of the path, used to regularize the denominator and enhance the stability of curvature optimization; λ is the regularization coefficient (unit: none), controlling the influence of the tangent vector term to prevent the denominator from being too small or the calculation from being unstable; For the line integral along path Γ, based on arc length s, the curvature, stress, and tangent vector information are integrated into a global optimization result; The curvature deviation is quantified by the square of the deviation between the actual curvature and the reference curvature. The optimization objective is to make the actual curvature closer to the reference curvature. The square of the tangent vector modulus is used to enhance the geometric stability of the denominator and avoid numerical errors caused by abrupt changes in path direction.

[0089] In one embodiment, the step of performing a secondary laser irradiation treatment on the primary network substrate according to the optimized curvature parameters to form an optimized network substrate includes:

[0090] The surface of the primary network substrate is divided into multiple energy zones based on the second surface morphology data and optimized curvature parameters of the primary network substrate.

[0091] Each energy zone is assigned a corresponding laser power, and the primary network substrate is irradiated according to the laser power to obtain the optimized network substrate.

[0092] In this embodiment, the second surface morphology data of the primary network substrate is acquired. Morphology data obtained through microscopy or laser confocal scanning technology can characterize the microscopic features of the substrate surface in detail, including surface roughness, curvature variations, and structural discontinuities. A partitioning strategy is used to identify the unique energy input required for different regions of the substrate surface. Curvature parameters are integrated with the morphology data to generate a three-dimensional energy partitioning map. This partitioning map divides the substrate surface into multiple discrete regions, each with a unique curvature profile and material properties, such as local density or thermal conductivity, or directly using groove depth and width as the partitioning criteria. Different laser power settings are used for different energy partitions to ensure that each region receives laser energy most suitable for its surface characteristics. Specifically, for regions with large curvature or high surface roughness, the laser power is appropriately reduced to minimize the heat-affected zone and surface damage, maintaining the integrity and functionality of the material. Conversely, for regions with small curvature or smoother surfaces, the laser power can be appropriately increased to provide sufficient energy input for precise structural modification. By precisely controlling the laser power of each energy zone, not only is the geometry and curvature of the intersection points optimized, but material loss due to over-processing is also reduced, improving processing efficiency and the overall performance of the composite substrate. After secondary laser irradiation treatment, the resulting optimized network substrate has a more uniform and finer mesh structure, with smooth inner walls of the grooves and natural edge transitions, exhibiting excellent surface quality and mechanical strength, and enhancing the compressive strength and toughness of the mesh substrate.

[0093] In one embodiment, the step of performing a nano-coating spraying treatment on the mesh substrate to obtain a coated substrate includes:

[0094] A composite solution containing nano-titanium dioxide, silane coupling agent and polyurethane resin is sprayed onto the surface of the mesh substrate to form a preliminary coating mesh substrate. The composite solution contains 6-8% titanium dioxide, 2-3% silane coupling agent, and the remainder is polyurethane resin.

[0095] The pre-coated mesh substrate is placed in a reaction vessel and cured at a low temperature of 50~60℃ for 1.5~2 hours to obtain a cured mesh substrate.

[0096] A polishing slurry containing nano-alumina particles is coated onto the surface of the cured mesh substrate. The cured mesh substrate coated with the polishing slurry is then polished using a polishing device to obtain a coated substrate. The alumina particles have a size of 50~80nm, and the polishing pressure is 0.1~0.15MPa.

[0097] In this embodiment, the nano-coating spraying treatment on the surface of the mesh substrate requires the preparation of a composite solution. This solution consists of nano-titanium dioxide, a silane coupling agent, and polyurethane resin. The mass percentage of titanium dioxide is controlled at 6-8%, the silane coupling agent at 2-3%, and the remainder is polyurethane resin. Nano-titanium dioxide, due to its high catalytic activity and photochemical stability, can significantly enhance the antibacterial and self-cleaning properties of the coating. The silane coupling agent, through its active groups in its molecular structure, promotes the chemical bonding between the nanoparticles and the polyurethane resin, thereby improving the adhesion and stability of the coating. The polyurethane resin, as the matrix material, imparts excellent flexibility and weather resistance to the coating. To ensure effective spraying, the process must be carried out in a dust-free environment using high-voltage electrostatic spraying equipment. The spraying pressure is controlled at 0.2-0.3 MPa, the nozzle distance from the substrate surface is maintained at 15-20 cm, and the spraying speed is 0.5-0.8 m / s, to form a uniform initial coating on the mesh substrate. After spraying, the initial coated mesh substrate is placed in a reactor for low-temperature curing. The curing temperature is controlled at 50-60℃ for 1.5-2 hours. During curing, an inert gas mixture containing trace amounts of ozone (ozone concentration 0.01-0.02%) can be introduced into the reactor. Ozone, as a strong oxidant, can initiate a slight oxidation reaction of the coating surface molecules under low-temperature conditions, thereby promoting the interfacial bonding between the polyurethane resin and nano-titanium dioxide. After curing, the polishing stage begins. The polishing fluid contains nano-alumina particles with a size of 50-80 nm, and the polishing pressure is controlled at 0.1-0.15 MPa. The nano-alumina particles can effectively remove tiny protrusions and defects on the surface of the cured coating. A high-precision chemical mechanical polishing (CMP) system is used for polishing, with a polishing disc rotation speed of 50-80 rpm and a polishing fluid flow rate of 100-150 mL / min. To ensure uniformity in the polishing process, the contact angle between the polishing head and the substrate surface is controlled at 5~10°. Alternatively, 0.5~1% of a fluorinated silane modifier can be added to the polishing fluid to form a superhydrophobic film on the coating surface. The resulting coated substrate reduces the coefficient of friction of the coating surface and significantly improves its anti-fouling ability and chemical corrosion resistance, making the coated substrate perform better in harsh environments.

[0098] In one embodiment, the step of hot-pressing the coated substrate to obtain a gasket semi-finished product includes:

[0099] The coated substrate is placed in a reaction vessel and preheated and softened at a temperature of 120~130°C to obtain a preheated substrate.

[0100] A fluorinated non-stick coating is sprayed onto the surface of the pre-forming mold, and the preheated substrate is placed in the pre-forming mold and pre-shaped at 0.5~1MPa to obtain the pre-shaped substrate.

[0101] The pre-shaped substrate is transferred to a high-temperature and high-pressure hot press for high-temperature and high-pressure shaping to obtain a shaped substrate. The hot pressing temperature is set to 160~180℃ and the pressure is 2.5~3.5MPa.

[0102] The shaped substrate is subjected to gradient cooling treatment. In the first stage, the temperature is reduced from 180°C to 100°C at a rate of 5°C / min. In the second stage, the temperature is reduced from 100°C to 50°C at a rate of 3°C / min, resulting in a semi-finished gasket.

[0103] In this embodiment, the coated substrate is placed in a reactor for preheating and softening treatment at a temperature controlled at 120-130°C to achieve appropriate flexibility and plasticity. During preheating, an inert gas mixture containing trace amounts of amino functionalized gas (amino gas concentration of 0.05-0.1%) is introduced into the reactor. The gas can undergo a slight chemical reaction with the active sites on the surface of the coated substrate at high temperature, forming trace amounts of amino functional groups, thereby improving the interfacial bonding ability of the substrate surface and providing a better molecular-level adhesion basis for subsequent pre-shaping and hot-pressing. After preheating and softening, low-pressure shaping lays the foundation for subsequent high-temperature and high-pressure shaping. The surface of the pre-shaping mold needs to be sprayed with a fluorinated non-stick coating to prevent the substrate from adhering to the mold surface during shaping and to reduce demolding resistance. The fluorinated non-stick coating is applied using plasma-enhanced chemical vapor deposition (PECVD) technology, with the coating thickness controlled at 0.5-1 μm to balance non-stick properties and mold surface wear resistance. Subsequently, the preheated substrate is placed in a pre-shaping mold and pre-shaped under a pressure of 0.5~1MPa. The mold temperature is set at 80~90℃, and the shaping time is 3~5 minutes. Then, it is transferred to a high-temperature, high-pressure hot press for high-temperature, high-pressure setting. The hot-pressing temperature is set at 160~180℃, the pressure at 2.5~3.5MPa, and the hot-pressing time is 10~15 minutes. Through high temperature and high pressure, the polymer molecular chains inside the substrate are further cross-linked and cured, while optimizing the interfacial bonding strength between the coating and the substrate. A progressive loading strategy is used to avoid microcracks caused by instantaneous high pressure on the substrate. After hot-pressing and setting, the shaped substrate undergoes gradient cooling to eliminate thermal stress and improve dimensional stability. The first stage cools from 180℃ to 100℃ at a rate of 5℃ / min; the second stage cools from 100℃ to 50℃ at a rate of 3℃ / min. The cooling process uses programmed cooling equipment, which precisely controls the flow rate and temperature of the cooling medium (nitrogen or air) to achieve a smooth temperature transition and obtain the gasket semi-finished product.

[0104] In one embodiment, the step of laser-cutting the semi-finished pad to a preset size to obtain a composite material pad includes:

[0105] The semi-finished pad is laser-cut according to a preset contour using a multi-wavelength laser to obtain a cut substrate, wherein the short-wavelength laser corresponds to the polyester film layer and the long-wavelength laser corresponds to the foam substrate.

[0106] The integrity of the marking lines on the surface of the cutting substrate is obtained based on optical inspection equipment to determine whether the cutting substrate meets the preset size requirements;

[0107] If it does not meet the requirements, the cut substrate is modified until the preset size requirements are met to obtain a composite material liner.

[0108] In this embodiment, a multi-wavelength laser is used for layered cutting. Short-wavelength lasers (e.g., ultraviolet lasers, approximately 355 nm) are used to cut the polyester film layer because their high energy density enables fine edge processing, preventing scorching or deformation due to thermal effects. Long-wavelength lasers (e.g., infrared lasers, approximately 1064 nm) are used for the foam substrate; their lower energy density effectively penetrates the porous structure while reducing thermal damage to the substrate. To improve cutting accuracy, computer-aided design (CAD) software can be used to generate the cutting contour, which is then imported into the laser control system. During the cutting process, the laser dynamically adjusts its focus and power based on the contour data to adapt to changes in material thickness and density. After the initial cutting is completed, the integrity of the marking lines on the surface of the substrate is obtained using an optical inspection device. This optical inspection device can include a high-resolution CCD camera and accompanying image processing software to capture the marking lines on the surface of the substrate, obtain the continuity and width data of the marking lines, and then analyze whether the marking lines are complete and whether they deviate from the preset contour using image processing algorithms (such as edge detection and geometric fitting). If the marking line is found to be broken or offset, it indicates that there may be problems such as uneven laser power or material positioning deviation during the cutting process. When the test results show that the cutting substrate does not meet the preset size requirements, the cutting substrate is corrected until the preset size requirements are met. The correction can include two aspects: first, secondary laser cutting to address the size deviation; and second, optimization of edge quality. In the secondary cutting, the laser parameters are readjusted based on the test feedback data, such as reducing the power to reduce the heat-affected zone or adjusting the cutting speed to improve accuracy. In another embodiment, after cutting and correction are completed, the composite material gasket undergoes surface functionalization treatment and performance verification testing. The surface functionalization treatment aims to improve the application performance of the gasket. Through plasma treatment technology, specific chemical groups (such as hydroxyl or amino groups) are introduced into the surface of the gasket to enhance its adhesion or water resistance. This is carried out in a vacuum environment, and by controlling the energy and gas composition of the plasma, the functionalization effect is ensured to be uniform and without damaging the material structure. Performance verification tests include a series of assessments of the mechanical properties and environmental adaptability of the liner, such as testing the compression resilience of the liner using a dynamic mechanical analyzer (DMA), or simulating extreme environments using a constant temperature and humidity chamber to verify its dimensional stability and durability, thereby obtaining composite material liners.

[0109] It is worth noting that all the devices described in this application are achievable using existing technologies, the algorithms are all based on mature algorithms from the prior art, and the chemicals and conditions used in the preparation process are all within safe limits and will not cause harm to operators or the environment. Furthermore, the prepared composite material gasket exhibits excellent thermal conductivity and self-healing capabilities, demonstrating good reliability and stability.

[0110] This invention also discloses a composite material liner, manufactured using the production process of a composite material liner as described in any of the preceding claims. It includes a polyester film layer, a foam substrate, and a mesh structure disposed between the polyester film layer and the foam substrate. The mesh structure is composed of an optimized network substrate, the surface of which is covered with a nano-coating. Nano-titanium dioxide particles are uniformly dispersed in the nano-coating, giving the liner excellent antibacterial and self-cleaning properties. The polyester film layer, as the outer surface layer of the liner, provides good abrasion resistance and chemical stability, effectively resisting environmental erosion. The foam substrate provides the liner with excellent cushioning and sound absorption properties, enabling the liner to provide good comfort and sound insulation during application. Additionally, it includes marking lines, which are set on the semi-finished liner to indicate the cutting path and dimensional positioning.

[0111] The above-described embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application.

Claims

1. A process for the production of a composite material gasket, characterized in that, The method comprises the following steps: a foam substrate is subjected to plasma surface activation treatment to obtain an activated foam substrate; the activated foam substrate is subjected to modification and compounding treatment with a polyester film in an ultraviolet light irradiation device to obtain a composite substrate; a laser is used to irradiate the composite substrate row by row along a preset grid pattern to form a groove network structure on the surface of the composite substrate, thereby obtaining a grid substrate with grid identification lines; the grid substrate is subjected to nano-coating spraying treatment to obtain a coated substrate; the coated substrate is subjected to heat pressing and shaping treatment to obtain a gasket semi-finished product; the gasket semi-finished product is subjected to laser cutting treatment according to a preset size to obtain a composite material gasket; the step of irradiating the composite substrate row by row along a preset grid pattern with a laser to form a groove network structure on the surface of the composite substrate, thereby obtaining a grid substrate with grid identification lines, comprises the following steps: first surface topography data of the composite substrate is collected by a computer device, and a laser irradiation path is generated according to the first surface topography data, wherein the laser irradiation path comprises intersecting lines in different directions and a variation region with a preset depth; the composite substrate is subjected to incident irradiation treatment at multiple angles according to the laser irradiation path, thereby forming a primary network substrate, wherein the variation region with the preset depth is formed at the intersection points of the multiple angles; second surface topography data of the primary network substrate is collected, and the curvature of the intersection points is optimized according to the second surface topography data, specifically comprising analyzing the curvature distribution at the intersection points and the topography deviation of the groove edges, calculating the curvature parameters according to the topography deviation through a preset algorithm, and forming optimized curvature parameters; the primary network substrate is subjected to secondary laser irradiation treatment according to the optimized curvature parameters, thereby forming an optimized network substrate; the groove inner wall of the optimized network substrate is subjected to etching treatment by a laser, and the edge of the groove inner wall is subjected to local melting treatment, thereby obtaining a grid substrate with grid identification lines; the step of subjecting the primary network substrate to secondary laser irradiation treatment according to the optimized curvature parameters, thereby forming an optimized network substrate, comprises the following steps: the surface of the primary network substrate is divided into multiple energy partitions according to the second surface topography data of the primary network substrate and the optimized curvature parameters; each energy partition is set with corresponding laser power, and the primary network substrate is irradiated according to the laser power, thereby obtaining the optimized network substrate.

2. The process for producing a composite gasket according to claim 1, wherein The polyester film is one or a combination of PET film, PBT film and PEN film.

3. The process of producing a composite gasket according to claim 1, wherein The step of subjecting the foam substrate to plasma surface activation treatment to obtain an activated foam substrate comprises the following steps: a polyurethane foam substrate is placed in an ultrasonic cleaning device, and a mixed solution of deionized water and isopropyl alcohol is used as a cleaning medium to clean the polyurethane foam substrate, thereby obtaining a foam substrate; the foam substrate is placed in a low-pressure plasma treatment cavity, a mixed gas of argon and nitrogen is introduced, the volume ratio of argon to nitrogen is controlled to be 3:1, and the power is set to 200W, thereby obtaining a primary activated substrate; The exhaust gas is introduced into a mixed gas of oxygen and carbon tetrafluoride, the volume ratio of oxygen to carbon tetrafluoride is controlled to be 4:1, and the power is set to be periodically changed between 250W and 350W, so that the activated foam substrate is obtained.

4. The process of producing a composite gasket according to claim 1, wherein The step of modifying and compounding the activated foam substrate and the polyester film in the ultraviolet light irradiation device to obtain a composite substrate comprises: An acrylic ester prepolymer containing a photoinitiator and a nano zinc oxide particle-acrylate mixed solution are coated on the surface of the polyester film, and a pre-curing treatment is performed under the protection of inert gas to obtain an initial polyester film; The initial polyester film is placed in an ultraviolet light irradiation device for modification treatment, the wavelength of the ultraviolet light source is set to be 355-365nm, and the irradiation intensity is set to be 100-150mW / cm², so that a modified polyester film is obtained; An environmentally friendly polyurethane hot melt adhesive is coated on the surface of the activated foam substrate, and the coated foam substrate is flattened by a cooling roller to obtain a foam substrate with adhesive; The modified polyester film and the foam substrate with adhesive are subjected to hot melt compounding treatment, the compounding temperature is 120-140°C, and the compounding time is 30-60 seconds, so that a composite substrate is formed.

5. The process of producing a composite gasket according to claim 1, wherein The step of performing nano-coating spraying treatment on the grid substrate to obtain a coated substrate comprises: A composite solution containing nano-titanium dioxide, silane coupling agent and polyurethane resin is sprayed on the surface of the grid substrate to form a primary coated grid substrate, wherein the proportion of titanium dioxide in the composite solution is 6-8% by mass, the proportion of silane coupling agent is 2-3% by mass, and the rest is the polyurethane resin; The primary coated grid substrate is placed in a reaction kettle and subjected to curing treatment in a low-temperature environment of 50-60°C for 1.5-2 hours to obtain a cured grid substrate; A polishing liquid containing nano-aluminum oxide particles is coated on the surface of the cured grid substrate, and the coated cured grid substrate is subjected to polishing treatment based on a polishing device to obtain a coated substrate, wherein the size of the aluminum oxide particles is 50-80nm, and the polishing pressure is 0.1-0.15MPa.

6. The process of producing a composite gasket according to claim 1, wherein The step of performing hot-pressing shaping treatment on the coated substrate to obtain a gasket semi-finished product comprises: The coated substrate is placed in a reaction kettle and subjected to preheating and softening treatment at a temperature of 120-130°C to obtain a preheated substrate; A fluorinated non-stick coating is sprayed on the surface of a pre-shaping mold, and the preheated substrate is placed in the pre-shaping mold to perform pre-shaping treatment on the preheated substrate at a pressure of 0.5-1MPa to obtain a pre-shaped substrate; The pre-shaped substrate is transferred to a high-temperature and high-pressure hot press for high-temperature and high-pressure shaping treatment to obtain a shaped substrate, wherein the hot-pressing temperature is set to be 160-180°C, and the pressure is 2.5-3.5MPa; The shaped substrate is subjected to gradient cooling treatment, the first stage is from 180°C to 100°C, the cooling rate is controlled to be 5°C / min, the second stage is from 100°C to 50°C, and the cooling rate is slowed down to 3°C / min, so that a gasket semi-finished product is obtained.

7. The process of producing a composite gasket according to claim 1, wherein The step of performing laser cutting treatment on the gasket semi-finished product according to a preset size to obtain a composite material gasket comprises: The laser cutting process is performed on the semi-finished gasket based on a multi-wavelength laser according to a preset profile to obtain a cut base material, wherein a short-wavelength laser corresponds to a polyester film layer and a long-wavelength laser corresponds to a foam base; The integrity of the identification line on the surface of the cut base material is obtained based on an optical detection device to determine whether the cut base material meets preset size requirements; If not, the cut base material is subjected to a correction process until the preset size requirements are met to obtain a composite gasket.

8. A composite gasket, characterized by, The composite gasket is produced by using the production process according to any one of claims 1 to 7.

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