Composite Sheet Material Scratch Resistance via Differential Melting
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Solution Overview
Problem
Composite materials with thermoplastic nonwoven surfaces suffer from poor scratch resistance, abrasion qualities, stain resistance, and color brilliance, along with undesirable appearance characteristics such as uneven surfaces, making them difficult to adhere to and print on.
Innovation Solution
A composite sheet material is formed by combining a substrate with a thermoplastic material and a matrix, where the matrix includes a support component with a higher melting point and a thermoplastic component with a lower melting point, which are laminated together in a thermo-pressure process, and optionally a cover sheet is used to impart surface characteristics during formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a thermoplastic nonwoven material is used as the outer surface, then the material provides ease of manufacture and flexibility, but it exhibits poor scratch resistance, poor abrasion qualities, poor stain resistance, and poor color brilliance
Solution Approach 1:
The patent applies composite materials by combining a thermoplastic nonwoven substrate with a thermoplastic polymer coating layer. The substrate provides ease of manufacture and flexibility, while the coating layer provides scratch resistance, abrasion resistance, and stain resistance. This composite structure resolves the contradiction by integrating materials with complementary properties.
Solution Approach 2:
The patent applies local quality by providing different properties at different locations within the composite material. The inner substrate layer maintains the ease of manufacture and flexibility characteristics, while the outer coating layer provides the protective qualities (scratch resistance, abrasion resistance, stain resistance). Each layer is optimized for its specific function.
2Ease of manufacture
If a thermoplastic nonwoven material is used as the outer surface, then the material provides ease of manufacture, but it has poor adhesion and does not accept pigment or print well
Solution Approach 1:
The patent uses a composite structure where the thermoplastic polymer coating layer is applied over the thermoplastic nonwoven substrate. The coating layer provides a surface that accepts pigments and printing well, while the substrate maintains ease of manufacture. This composite approach resolves the contradiction between manufacturability and printability.
Solution Approach 2:
The patent applies local quality by providing different surface properties at different locations. The outer coating layer has properties optimized for printability and pigment acceptance, while the inner substrate maintains properties optimized for ease of manufacture. This spatial differentiation of properties resolves the contradiction.
3Adaptability or versatility
If a thermoplastic nonwoven material is used as the outer surface, then the material provides flexibility, but it has undesirable appearance characteristics such as uneven surface finish
Solution Approach 1:
The patent applies composite materials by combining a flexible thermoplastic nonwoven substrate with a thermoplastic polymer coating layer. The substrate provides flexibility and adaptability, while the coating layer provides a uniform, desirable surface finish. This composite structure resolves the contradiction between flexibility and surface appearance.
Solution Approach 2:
The patent applies local quality by providing different properties at different locations within the composite. The inner substrate layer maintains flexibility and adaptability, while the outer coating layer provides a uniform surface finish with desirable appearance characteristics. Each layer is optimized for its specific function.
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 resulting composite sheet material exhibits enhanced durability, impact resistance, cleanability, and improved cosmetic appearance, addressing the shortcomings of existing materials by providing a flat, resistant, and printable surface.
Implementation Method 1
The matrix includes a support component having a first melting point, and a thermoplastic component having a second melting point. The second melting point is less than the first melting point.
Implementation Method 2
The cover sheet imparts one or more surface characteristics to the composite sheet material during thermo-pressure formation of the composite sheet material.
Data Source
AI summary
A composite sheet material and method for forming the same is provided that includes a substrate, a matrix, and a cover sheet. The substrate has a first face surface, a second face surface, and a plurality of edges, and includes a thermoplastic material. The matrix is attached to the substrate. The matrix includes a support component having a first melting point, and a thermoplastic component having a second melting point. The second melting point is less than the first melting point. The cover sheet imparts one or more surface characteristics to the composite sheet material during thermo-pressure formation of the composite sheet material.