Composite Pre-bonding Treatment Method for Bonded Parts
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Solution Overview
Problem
Existing composite pre-bonding treatment methods, such as sanding and the peel ply method, suffer from variability in quality due to worker skill, potential damage to fibers, and residual contaminants that reduce adhesive strength.
Innovation Solution
A composite pre-bonding treatment method involving the use of an absorber to remove contaminants from the prepreg surface, followed by a non-transfer release member to prevent silicone and fluorine residue, and optional hydrophilic treatment to enhance adhesive strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If sanding is performed manually to remove dirt from panel surface, then the surface can be cleaned, but the quality varies in accordance with worker skill level and may cause damage to fibers
Solution Approach 1:
The patent replaces manual mechanical sanding with a chemical cleaning system using solvent-impregnated wipes. This substitution eliminates variability associated with worker skill while maintaining effective surface cleaning capability, thereby improving quality stability without sacrificing surface cleanliness.
Solution Approach 2:
The patent introduces a solvent-impregnated wipe as an intermediary between the cleaning agent and the panel surface. This intermediary consistently delivers a controlled amount of solvent to the surface, ensuring uniform cleaning results regardless of operator skill level, thus resolving the contradiction between surface cleanliness and quality stability.
2Manufacturing precision
If peel ply is used to form clean surface, then the surface can be cleaned, but polyester component may remain on FRP surface and reduce adhesiveness of bonded part
Solution Approach 1:
The patent extracts the cleaning function from the peel ply and assigns it to a dedicated solvent-impregnated wipe applied after peel ply removal. This separation allows the peel ply to be completely removed without leaving polyester residue, while the solvent wipe provides the necessary cleaning action, thereby maintaining both surface cleanliness and adhesive strength.
Solution Approach 2:
The patent uses a disposable solvent-impregnated wipe that is applied and then discarded after use. This single-use cleaning method ensures that no reusable material (like peel ply) remains on the surface, eliminating the risk of polyester residue while maintaining effective cleaning capability.
3Ease of manufacture
If release agent or release film is used in molding, then the molding process can be facilitated, but contaminant is transferred to surface of composite material and reduces adhesive force
Solution Approach 1:
The patent implements a continuous cleaning action using solvent-impregnated wipes at multiple stages: before bonding operations and after peel ply removal. This continuous cleaning ensures that any contaminants transferred during molding (from release agents or films) are systematically removed, maintaining adhesive force while preserving the molding facilitation benefits.
Solution Approach 2:
The patent employs organic solvents that chemically interact with and dissolve contaminant substances transferred from release agents or films. This chemical cleaning action effectively removes hydrocarbon-based contaminants that would otherwise reduce adhesive force, while leaving the composite material surface ready for bonding.
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 stabilizes the quality of bonded parts by reducing surface contamination, preventing residue from peel ply components, and improving adhesive strength through enhanced surface treatment.
Implementation Method 1
attaching an absorber adapted to absorb a contaminant to a surface of a prepreg laminate
Implementation Method 2
vacuuming the packaging material
Implementation Method 3
heating the prepreg laminate at a temperature lower than a curing temperature of a prepreg
Implementation Method 4
Since heating reduces the viscosity of a matrix resin contained in the prepreg, contaminants can be effectively absorbed
Implementation Method 5
attaching, to a surface of the prepreg laminate with the absorber peeled off, a release member that does not transfer silicone or fluorine to a resin
Data Source
AI summary
An object is to provide a composite pre-bonding treatment method that stabilizes quality of a bonded part. The present disclosure provides a composite pre-bonding treatment method performed when bonding a composite material to a member. The method includes: (S2) attaching an absorber adapted to absorb a contaminant to a surface of a prepreg laminate that is a precursor of the composite material; (S3) covering the prepreg laminate with a packaging material from above the absorber; (S4) vacuuming the packaging material and heating the prepreg laminate at a temperature lower than a curing temperature of a prepreg; (S5) then removing the packaging material; (S6) peeling off the absorber; (S7) attaching, to a surface of the prepreg laminate with the absorber peeled off, a release member that does not transfer silicone or fluorine to a resin, and then (S9) curing the prepreg laminate to mold the composite material; and (S11) peeling off the release member from the composite material before bonding the member.