Composite Component Adhesion via Mold Surface Finish
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Solution Overview
Problem
Conventional methods for producing fiber-reinforced composite materials with functional layers, such as thermal spraying, often result in poor adhesive strength, surface damage, and high production costs due to surface activation and coating processes, which can lead to mechanical strength deterioration and reduced component lifespan.
Innovation Solution
A method involving the use of a negative form with a smooth surface finish treated to achieve Sa≤5 μm and Sz≤80 μm roughness, followed by thermal spraying of a functional layer and application of a fiber-reinforced plastic layer with a hardenable matrix, allowing for improved adhesion and cost-effective production of high-quality composite components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If surface activation is performed to improve adhesive strength, then adhesive strength between functional layer and substrate is improved, but mechanical strength of fiber-reinforced plastic component deteriorates due to fiber damage
Solution Approach 1:
The negative form is pre-treated with a release agent before the fiber-reinforced plastic layer is applied. This preliminary action creates a release layer that prevents adhesion between the negative form and the plastic layer, allowing easy removal without damaging the fibers or requiring aggressive surface activation of the finished component.
2Reliability
If thorough surface activation is performed to ensure mechanical clamping, then adhesive strength is improved, but surface defects and fiber damage increase
Solution Approach 1:
The negative form surface is pre-coated with a release agent before composite layering. This preliminary coating prevents the plastic matrix from adhering to the negative form, ensuring that the fiber-reinforced plastic surface remains intact and free from defects during the manufacturing process.
3Productivity
If conventional thermal spraying is used to apply functional layer, then coating efficiency is improved, but production costs increase due to multiple process steps
Solution Approach 1:
The patent combines the negative form removal step with the functional layer application. The negative form is removed after the fiber-reinforced plastic layer is applied but before the functional layer is sprayed. This merging of steps eliminates the need for separate surface activation and cleaning operations, reducing production costs while maintaining coating efficiency.
Solution Approach 2:
The negative form is pre-treated with a release agent that allows for easy removal without requiring subsequent surface activation. This preliminary action eliminates the need for sand blasting, chemical etching, or other surface preparation steps before thermal spraying, thereby reducing both time and cost.
4Reliability
If surface activation is performed to prepare for coating, then adhesive strength is improved, but component lifespan is reduced due to surface damage
Solution Approach 1:
A release agent is applied to the negative form surface before the fiber-reinforced plastic layer is applied. This preliminary action ensures that the plastic layer does not adhere to the negative form, allowing clean removal without surface damage. The fiber-reinforced plastic component surface remains intact, free from the micro-cracks and defects that would otherwise reduce component lifespan.
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 method enables the production of composite components with enhanced adhesive strength (>10 MPa) and reduced surface damage, facilitating the creation of lightweight, temperature-resistant, and corrosion-resistant components with improved tribological characteristics, suitable for various applications including wheel rims and thermal insulation.
Implementation Method 1
finish treating of the negative form at the surface thereof so that the surface of the negative form has a surface characteristic Sa≤5 μm and a surface roughness characteristic of Sz≤80 μm
Implementation Method 2
applying at least one functional layer by means of thermal spraying onto the negative form
Implementation Method 3
applying at least one fiber-reinforced plastic layer including a hardenable matrix material
Implementation Method 4
hardening of the matrix material
Data Source
AI summary
The invention relates to a method for producing a composite material component, comprising the following steps: providing a negative mold, fine machining of the negative mold, applying at least one functional layer by means of thermal spraying to the negative mold, applying at least one fiber-reinforced plastic layer with a curable matrix material, curing the matrix material, and detaching the composite material component from the negative mold.