Amorphous Thermoplastic Lightning Protection Layer for Composite Adhesion

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Solution Overview

Problem

The existing methods for preparing surfaces of thermoplastic composite materials for primer application are time-consuming and costly, and the use of solvent-based primers has environmental drawbacks, particularly for large components.

Innovation Solution

A component with a lightning protection layer based on amorphous thermoplastic resin, which eliminates the need for surface preparation and allows the use of water-based primers and coatings, enhancing attachment and reducing environmental impact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If surface preparation is performed to increase wettability of thermoplastic composite material, then attachment of primer layer is improved, but manufacturing time and cost increase significantly

Engineering Contradiction:

Improveattachment of primer layerVSAvoidsurface preparation time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The invention changes the chemical parameter of the primer layer by using a water-based primer instead of traditional solvent-based primers. This parameter change allows direct application on thermoplastic composite surfaces without requiring surface preparation to increase wettability, thereby resolving the contradiction between attachment strength and preparation time

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention introduces a tie layer as an intermediary between the thermoplastic composite surface and the water-based primer layer. This tie layer acts as a mediator that ensures effective attachment without requiring surface preparation, thus resolving the contradiction by providing a chemical bridge that enables direct bonding

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If surface preparation is performed to increase wettability, then attachment of primer layer is improved, but manufacturing cost increases

Engineering Contradiction:

Improveattachment of primer layerVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The invention changes the chemical composition parameter of the primer layer to water-based formulation, which eliminates the need for surface preparation steps. This parameter change directly reduces manufacturing cost while maintaining or improving attachment quality

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The tie layer serves as a cost-effective intermediary that enables direct application of water-based primers on thermoplastic composites. By introducing this intermediate layer, the invention eliminates expensive surface preparation processes while ensuring reliable attachment

Inventive Principle:

Principle #24Intermediary (Mediator)

3Strength

If solvent-based primer layer is used, then attachment is achieved, but environmental impact increases

Engineering Contradiction:

Improveattachment of primer layerVSAvoidenvironmental impact

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The invention changes the solvent parameter of the primer layer from organic solvents to water-based formulation. This parameter change eliminates harmful volatile organic compounds while maintaining effective attachment, directly resolving the environmental harm issue

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The tie layer acts as an intermediary that enables the use of environmentally friendly water-based primers on thermoplastic composite surfaces. By providing chemical compatibility between the composite and water-based primer, it allows elimination of harmful solvents while maintaining attachment quality

Inventive Principle:

Principle #24Intermediary (Mediator)

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

This solution simplifies the surface preparation process, reduces costs, and minimizes environmental impact by enabling the use of water-based primers and coatings, while maintaining effective attachment and adhesion properties.

Implementation Method 1

the matrix of the lightning protection layer is based on at least one amorphous thermoplastic resin... it is no longer necessary to prepare the surface to which the primer layer or the coating is applied so as to increase its wettability and thus the attachment of said layers

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

it is no longer necessary to prepare the surface to which the primer layer or the coating is applied so as to increase its wettability and thus the attachment of said layers

Methodology Applied

Scientific EffectWetting: Wetting

Data Source

PatentUS20230011370A1Component made of thermoplastic composite material comprising at least one tie layer based on at least one amorphous thermoplastic resin

Publication Date: 2023.01.12 AIRBUS OPERATIONS (SAS)

AI summary

A component including a body having a first surface and a matrix made of semicrystalline thermoplastic resin, a coating at least partially covering the first surface and a lightning protection layer having a matrix, positioned against the surface, between the body and the coating. The matrix of the lightning protection layer is based on at least one amorphous thermoplastic resin.