Acrylate Adhesive Bonding Composite Materials
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Solution Overview
Problem
Existing adhesives fail to provide sufficient bond strength, processability, and durability for joining composite parts, particularly in wind turbine applications, where they must withstand centrifugal forces and environmental conditions for up to 25 years.
Innovation Solution
An adhesive formulation comprising an acrylate or methacrylate monomer, a vinyl ester resin with a weight average molecular weight between 450 and 3000, and a catalyst, which is applied between composite materials and cured to achieve enhanced lap shear strength and improved processability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If paste adhesive is used to join composite parts, then high strength joint is achieved, but processing difficulty increases due to high viscosity
Solution Approach 1:
The patent modifies the chemical composition parameters of the adhesive system by incorporating specific monomers (acrylate, methacrylate) and catalysts in controlled ratios. This changes the rheological properties to achieve optimal viscosity for processing while maintaining high bond strength through controlled polymerization reactions.
Solution Approach 2:
The adhesive formulation creates a composite chemical system combining monomers, vinyl ester resin, and catalysts. This composite formulation integrates the benefits of low initial viscosity for easy processing with high final strength through the synergistic polymerization reaction of multiple components.
2Strength
If epoxy adhesive is used to join composite parts, then high strength joint is achieved, but processing difficulty increases due to viscosity change during reaction
Solution Approach 1:
The patent controls the reaction kinetics by selecting specific catalysts and monomer types that provide a more gradual and predictable viscosity increase during curing. This allows workers to complete bonding operations before the adhesive becomes too viscous, while still achieving high ultimate bond strength.
Solution Approach 2:
The adhesive system exhibits dynamic properties during processing, transitioning from a low-viscosity state suitable for application to a high-strength cured state. The formulation is designed to maintain workability during the processing window while ensuring complete cure to achieve maximum bond strength.
3Speed
If epoxy adhesive is used at high temperature, then curing speed increases, but usability decreases due to rapid curing
Solution Approach 1:
The patent selects catalysts and monomer combinations with controlled reactivity that moderate the temperature dependence of curing speed. This allows the adhesive to cure at practical rates across a range of temperatures, maintaining usability even in warmer conditions while still achieving complete cure.
4Duration of action of moving object
If epoxy adhesive is used at low temperature, then curing speed decreases, but working time increases beyond practical limits
Solution Approach 1:
The formulation incorporates catalysts and monomer types that maintain adequate reaction kinetics at lower temperatures, ensuring that curing completes within a practical timeframe even in cooler environments, thus maintaining productivity without sacrificing bond quality.
5Strength
If adhesive formulation includes monomer, then lap shear strength increases by 20%, but formulation complexity increases
Solution Approach 1:
The patent creates a composite adhesive formulation where monomers are integrated with vinyl ester resin and catalysts in a unified system. This composite approach achieves enhanced lap shear strength through the polymerization network while managing formulation complexity through established配比 ratios and compatible component selection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The adhesive formulation provides a 20% increase in lap shear strength and improved workability, enabling durable bonding of composite parts under various conditions, including those encountered in wind turbine manufacturing.
Implementation Method 1
an adhesive formulation comprising an acrylate and/or methacrylate monomer, a vinyl ester resin having a weight average molecular weight ranging from about 450 to about 3000, and a catalyst
Implementation Method 2
an acrylate and/or methacrylate monomer, a vinyl ester resin... curing the adhesive formulation to provide a lap shear strength
Data Source
AI summary
Adhesive formulations generally including an acrylate and/or methacrylate monomer; a vinyl ester resin having a weight average molecular weight ranging from about 450 to about 3000; and a catalyst. Also disclosed is a method for forming a composite material employing the formulations.