Composite for producing filmless laminates
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Solution Overview
Problem
The existing methods for producing laminates for sailing, which involve plastic films and reinforcing fibers, are complex and require multiple adhesive layers, making the process inefficient and prone to fiber slippage, and do not optimize for low weight and high tear resistance simultaneously.
Innovation Solution
A composite of a thermoplastic film with a thermally activatable crosslinking agent is used, where the film is initially bonded to a textile layer at a low temperature for adhesive properties without losing thermoplasticity, and then reactivated at a higher temperature to provide duroplastic bonding, eliminating the need for separate adhesive layers and enhancing fiber integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple adhesive layers and plastic films are used to bond textile layers, then bonding reliability is improved, but device complexity and manufacturing complexity increase
Solution Approach 1:
The patent combines multiple functional layers (adhesive layer and carrier film) into a single integrated composite structure. The adhesive layer is directly applied to the carrier film to form a unified component that performs both adhesive bonding and structural support functions, eliminating the need for separate adhesive applications and reducing manufacturing steps.
Solution Approach 2:
The carrier film serves multiple functions simultaneously: it acts as a structural support, provides a base for the adhesive layer, and contributes to the overall laminate integrity. This multi-functionality reduces the number of separate components needed and simplifies the overall manufacturing process while maintaining bonding reliability.
2Ease of manufacture
If thermoplastic adhesive is used to bond layers, then ease of manufacture is improved, but fiber slippage occurs reducing manufacturing precision
Solution Approach 1:
The patent employs a composite structure consisting of a carrier film and an adhesive layer working together. The carrier film provides structural stability and mechanical support, while the adhesive layer ensures strong bonding between textile layers. This composite approach prevents fiber slippage by distributing stresses effectively and maintaining precise fiber positioning during manufacturing.
3Strength
If adhesive layers are applied to bond textile layers, then bonding strength is improved, but weight increases
Solution Approach 1:
The patent utilizes a thin-film carrier film structure that provides sufficient mechanical support and bonding capability with minimal weight. The adhesive layer is applied as a thin coating that achieves strong bonding between textile layers without adding excessive weight, optimizing the strength-to-weight ratio for sailing applications.
4Ease of manufacture
If thermoplastic film is used as carrier and adhesive, then ease of manufacture is improved, but at high temperature crosslinker activates causing unwanted duroplastic properties
Solution Approach 1:
The patent segments the functional properties into distinct layers: the carrier film provides structural support and contains the crosslinker, while the adhesive layer provides bonding functionality. This segmentation allows independent optimization of each layer's properties and enables controlled activation of crosslinking at specific temperatures without compromising the thermoplastic adhesive properties during initial bonding operations.
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 approach simplifies the laminate production process, reduces weight, improves tear resistance, and enhances the mechanical properties of the sailcloth by firmly integrating reinforcing fibers, while maintaining flexibility and allowing for additional coatings, resulting in a lightweight, high-strength filmless laminate.
Implementation Method 1
applying heat at a first temperature, which softens the film and creates an adhesive effect
Implementation Method 2
The crosslinker is activated by pressure and/or temperature and, by crosslinking the plastic, causes the individual layers to bond together
Implementation Method 3
the crosslinker is activated at this second temperature, whereby the activation of the crosslinker gives the film thermosetting properties
Data Source
AI summary
The invention relates to a composite for producing filmless canvas laminates having an adhesive film and a textile layer having (a) a thermoplastic plastic film as an adhesive film, which contains a cross-linking agent, which can be thermally activated, dispersed therein, as a carrier and (b) a textile layer, which is adhesively connected to the plastic film, in which the plastic film and the textile layer are adhesively connected to each other by heat exposure at a first temperature, which does not activate the cross-linking agent and the composite can be connected to a substrate by heat exposure at a second temperature, which is higher than the first temperature and causes cross-linking.