Composite Material Conjugate Adhesion via Surface Activation
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Solution Overview
Problem
Existing methods for joining composite materials without adhesives result in low adhesive strength, and methods like sanding are costly and prone to variability, while the peel ply method can leave residual components that reduce strength.
Innovation Solution
A method involving the use of a non-transfer release member made of a material that does not transfer silicone and fluorine, combined with surface treatment to impart polar functional groups, allowing for bonding of composite materials without adhesives while maintaining high adhesive strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the peel ply method is used to remove release material, then the surface is cleaned for bonding, but residual components from the peel ply remain and reduce adhesive strength
Solution Approach 1:
The invention extracts and removes the harmful release material components from the composite material surface through a dedicated cleaning step using a solvent-wipe or cleaning cloth, separating the cleaning function from the peel ply removal process to ensure no residual contamination remains that would interfere with adhesive bonding
Solution Approach 2:
The invention performs preliminary surface cleaning and activation treatments (such as plasma treatment or corona discharge) before bonding to ensure the surface is completely free of release material residues and properly activated for optimal adhesive bonding, preventing any potential contamination issues
2Manufacturing precision
If sanding is used to remove release material, then the surface is cleaned, but the process is costly and prone to variability in quality
Solution Approach 1:
The invention replaces the mechanical sanding process with chemical cleaning methods using solvents and cleaning cloths, eliminating the need for manual or automated sanding equipment while achieving consistent surface cleanliness and removing the associated costs and quality variability
Solution Approach 2:
The invention changes the cleaning approach from mechanical removal (sanding) to chemical removal (solvent wiping), fundamentally altering the process parameters to achieve the same cleaning objective with better cost-effectiveness and consistency
3Weight of moving object
If adhesive bonding is applied to structural members, then weight reduction is achieved, but reliability and safety of fixation must be ensured
Solution Approach 1:
The invention performs preliminary surface activation treatments (plasma treatment, corona discharge, or flame treatment) to enhance the surface energy and chemical reactivity of the composite material, ensuring optimal adhesive bonding strength and reliability while maintaining weight reduction benefits
Solution Approach 2:
The invention utilizes plasma or corona discharge (gas-phase treatments) to activate the composite material surface, creating a highly reactive surface state that dramatically improves adhesive bonding strength and reliability without adding weight
4Strength
If bolt joining is used to join composite materials, then fixation is achieved, but joint strength is low and plate thickness must be increased
Solution Approach 1:
The invention replaces mechanical bolt joining with chemical adhesive bonding, eliminating the need for holes, bolts, and associated sealing components, thereby achieving superior joint strength while reducing the overall weight of the assembled structure
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 method achieves adhesive strength comparable to adhesive-based methods without using adhesives, stabilizes the bonding process, and reduces the risk of fiber damage and residual contamination.
Implementation Method 1
surface treatment for imparting a polar functional group to a surface of the first composite material, to which the release member has been attached, to activate the surface
Implementation Method 2
surface treatment for imparting a polar functional group to a surface of the first composite material, to which the release member has been attached, to activate the surface
Implementation Method 3
surface treatment for imparting a polar functional group to a surface of the first composite material, to which the release member has been attached, to activate the surface
Data Source
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AI summary
The purpose of the present invention is to provide a method for producing a composite material conjugate having adhesive strength comparable to when an adhesive is used by a conventional method, even without using an adhesive. The present disclosure is a method for producing a composite material conjugate in which a first composite material and a second composite material are adhered without using an adhesive, wherein (S2 to S4) a first prepreg laminate to which a release member is attached is cured to form the first composite material, the release member being made of a material that does not transfer silicone and fluorine to the first prepreg laminate, (S6) after detaching the release member from the first composite material, (S7) surface treatment that imparts polar functional groups to the surface of the first composite material to which the release member was bonded is carried out to activate the surface, (S8) a second prepreg laminate is placed directly on the activated surface of the first composite material, and (S10) the second prepreg laminate is cured to form a second composite material adhered to the first composite material.