Composite Metal Sheet Vibration Damping via Elastomer Layer
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Solution Overview
Problem
Conventional lightweight sandwich steel sheets for automobiles face increased manufacturing costs and inadequate adhesion between the metal and plastic layers, which affects vibration damping characteristics.
Innovation Solution
A composite metal sheet comprising a metal sheet with a polyolefin and thermoplastic polyester polyether elastomer plastic layer, bonded via thermal compression without a separate adhesive layer, optimizing adhesion and vibration damping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a thin iron sheet (0.2 mm to 0.3 mm) is used to reduce weight, then weight reduction is achieved, but manufacturing costs increase and adhesion between plastic core and steel sheet is insufficient
Solution Approach 1:
The invention changes the chemical composition parameters of the plastic layer by incorporating specific polyolefin content (20-80 wt%) and thermoplastic polyester polyether elastomer content (20-80 wt%), which modifies the adhesion properties to the metal sheet surface, enabling strong bonding even with thin metal sheets of 0.2-0.3 mm thickness
Solution Approach 2:
The invention uses a composite plastic layer material consisting of polyolefin and thermoplastic polyester polyether elastomer in specific proportions, creating a multi-component material system that simultaneously provides both adhesion to the metal sheet and vibration damping performance
2Strength
If a separate adhesive layer is used to improve adhesion, then adhesion between metal sheet and plastic layer is enhanced, but device complexity and manufacturing cost increase
Solution Approach 1:
The invention merges the adhesive function into the plastic layer itself by formulating a composite material that inherently bonds to the metal sheet, eliminating the need for a separate adhesive layer and reducing the overall structure to just two layers: metal sheet and plastic layer
Solution Approach 2:
The plastic layer material is designed to be self-adhesive to the metal sheet through its specific composition of polyolefin and thermoplastic polyester polyether elastomer, allowing it to bond to the metal surface without requiring external adhesives or additional bonding processes
3Ease of manufacture
If conventional plastic core materials are used, then manufacturing simplicity is maintained, but vibration damping characteristics are insufficient
Solution Approach 1:
The invention changes the material composition parameters by incorporating thermoplastic polyester polyether elastomer (20-80 wt%) into the plastic layer, which fundamentally alters the vibration damping characteristics while maintaining the simplicity of the two-layer sandwich structure and existing manufacturing processes
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 solution provides high adhesion and excellent vibration damping characteristics, reducing manufacturing costs and eliminating the need for additional adhesives, while maintaining structural integrity and weight reduction.
Implementation Method 1
the metal sheet and the plastic layer may be bonded to each other by thermal compression without a separate adhesive layer
Implementation Method 2
The thermal compression may be performed at a temperature ranging from 170 to 240 and a pressure ranging from 60 kgf/cm2 to 150 kgf/cm2
Implementation Method 3
A composite metal sheet according to the present invention uses a thermoplastic polyester polyether elastomer in a plastic layer, and thus has high adhesion between a metal sheet and the plastic layer and, in particular, excellent vibration damping characteristics
Data Source
AI summary
The present invention relates to a lightweight composite metal sheet having excellent vibration damping characteristics and a method of manufacturing the same. Provided is a composite metal sheet including: a metal sheet; and a plastic layer disposed on one surface or both surfaces of the metal sheet and including a polyolefin and a thermoplastic polyester polyether elastomer.