Composite Material Laminate for Exterior Panels
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Solution Overview
Problem
Conventional metal plate materials used in exterior applications are heavy and prone to damage, necessitating a lightweight and durable alternative with improved weatherability and aesthetics.
Innovation Solution
A composite material laminate comprising a fiber-reinforced composite material with a thermoplastic resin and continuous reinforcing fibers, a weather-resistant coating layer made from an unsaturated polyester resin and hindered amine-based light stabilizer, and a non-woven fabric layer, which are laminated to provide enhanced strength, durability, and aesthetics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal plate material is used for exterior applications, then strength and durability are improved, but weight increases and susceptibility to damage increases
Solution Approach 1:
The invention uses a composite material structure consisting of a fiber-reinforced plastic plate (with continuous fibers oriented in one direction), a weather-resistant coating layer, and a non-woven fabric layer. This composite structure provides high strength and durability comparable to metal while significantly reducing weight, directly resolving the contradiction between strength and weight.
2Strength
If metal plate material is used for exterior applications, then strength is improved, but susceptibility to external damage increases
Solution Approach 1:
The composite structure with fiber-reinforced plastic provides high strength while the layered construction (including non-woven fabric and coating layers) enhances resistance to external damage such as nicks and impacts, improving reliability without sacrificing strength.
Solution Approach 2:
The non-woven fabric layer and weather-resistant coating layer serve as protective barriers that cushion and absorb external impacts before they reach the structural fiber-reinforced core, preventing damage beforehand.
3Ease of manufacture
If conventional materials are used for exterior applications, then manufacturing simplicity is maintained, but weatherability and aesthetics deteriorate
Solution Approach 1:
The multi-layer composite structure integrates weather-resistant coating containing light stabilizers and non-woven fabric layers that provide excellent weatherability and aesthetics. The manufacturing process remains relatively simple through lamination and curing operations, balancing ease of manufacture with improved reliability.
4Weight of moving object
If fiber-reinforced composite material is used to replace metal, then weight is reduced, but binding force with insulating material deteriorates
Solution Approach 1:
The non-woven fabric layer serves as an intermediate layer that enhances binding force with insulating materials through its porous structure and surface properties, while the overall composite structure maintains lightweight characteristics. This resolves the contradiction by improving interfacial adhesion without adding significant weight.
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 composite material laminate achieves high strength, reduced weight, excellent weatherability, and improved aesthetics, making it a suitable replacement for metal plate materials in exterior applications, while also providing enhanced binding force when laminated with insulating materials.
Implementation Method 1
a sheet-shaped composite material in which a thermoplastic resin is impregnated in a reinforcing fiber
Implementation Method 2
a surface-treated layer which is plasma or corona-treated on a surface
Implementation Method 3
a surface-treated layer which is plasma or corona-treated on a surface
Implementation Method 4
a composition including an unsaturated polyester resin and a hindered amine-based light stabilizer
Implementation Method 5
a hindered amine-based light stabilizer
Implementation Method 6
laminating a non-woven fabric on one surface of a fiber-reinforced composite material
Data Source
AI summary
A composite material laminate, replaceable with a metal panel for an exterior material, comprises a fiber-reinforced composite material including a sheet-shaped composite material in which a thermoplastic resin is impregnated in a reinforcing fiber which is continuous and oriented in one direction; a weather-resistant coating layer disposed on one surface of the fiber-reinforced composite material; and a non-woven fabric layer disposed on the other surface of the fiber-reinforced composite material, which is present invention disclosure has light, high strength, low surface roughness to have excellent aesthetics, and excellent durability and weatherability.