Heat-Resistant Composite Sheet Surface Roughness Control
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Solution Overview
Problem
Existing heat-resistant composite sheets with glass fiber fabrics impregnated with fluorine-containing resins face issues with surface abrasion and uneven wear, leading to reduced service life, especially when used in heat sealing applications, and thickening the substrate to increase service life increases processing costs without optimal results.
Innovation Solution
A heat-resistant composite sheet with controlled surface roughness (Rz ≤ 21 µm and Ra ≤ 7.5 µm) and a fluorine-containing resin layer thickness of 3 to 30 µm, treated with a silicon-containing agent and repeatedly impregnated and heated to form a sheet with improved flatness and abrasion resistance, and an adhesive tape variant with an adhesive layer for enhanced sticking and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the substrate fluororesin layer is thickened to increase service life, then abrasion resistance is improved, but processing cost is greatly increased and handling becomes difficult
Solution Approach 1:
The invention changes the surface roughness parameter (Rz ≤ 21 μm, Ra ≤ 7.5 μm) to achieve better abrasion resistance. By optimizing the surface topology rather than increasing thickness, the patent reduces material consumption and processing costs while maintaining or improving service life.
Solution Approach 2:
The invention applies different properties to different parts of the composite sheet. The surface layer has controlled roughness for abrasion resistance, while the bulk material maintains its original properties. This localized optimization allows thin substrates to achieve the durability of thick substrates without the associated costs.
2Reliability
If the substrate fluororesin layer is thickened to increase service life, then abrasion resistance is improved, but the composite sheet becomes difficult to attach and handle
Solution Approach 1:
By changing the surface roughness parameters (Rz ≤ 21 μm, Ra ≤ 7.5 μm) and maintaining optimal thickness, the invention achieves a balance between durability and handleability. The controlled surface topology provides abrasion resistance without requiring excessive material thickness that would compromise flexibility and ease of application.
3Ease of manufacture
If the surface of the composite sheet is uneven, then manufacturing is simpler, but abrasion is uneven during use and glass fibers are easily exposed
Solution Approach 1:
The invention specifies precise surface roughness parameters (Rz ≤ 21 μm, Ra ≤ 7.5 μm) that optimize both manufacturability and performance. These controlled parameters ensure uniform abrasion resistance and prevent glass fiber exposure while remaining achievable through standard manufacturing processes.
Solution Approach 2:
The invention replaces reliance on thick material layers (mechanical solution) with controlled surface topology (geometric solution) to achieve abrasion resistance. This substitution allows for thinner, more cost-effective substrates that maintain durability through surface engineering rather than bulk material increases.
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 enhances abrasion resistance, production efficiency, and reduces costs by maintaining flatness and preventing glass fiber exposure, ensuring a longer service life and improved practical use performance.
Implementation Method 1
treating a glass fiber fabric with a silicon-containing agent
Implementation Method 2
impregnating the glass fiber fabric treated as above with a fluorine-containing resin
Implementation Method 3
heating the glass fiber fabric impregnated with the fluorine-containing resin to form the composite sheet
Data Source
Figure 1~3
AI summary
The disclosure provides a heat-resistant composite sheet and a method of producing the same. The composite sheet(10) is a glass fiber fabric(13) impregnated with a fluorine-containing resin, wherein, with the glass fiber fabric(13) as a center, the composite sheet(10) has two opposite surfaces in the thickness direction, at least one of which has a surface roughness of Rz ≤ 21 µm or Ra ≤ 7.5 µm. The heat-resistant composite sheet(10) of the disclosure has good flatness and a high abrasion resistance because of the adjustment of the surface roughness, and after the composite sheet is processed into an adhesive tape, the adhesive tape is easily attached and is not easily detached from the adherend, and the composite sheet(10) has a high production efficiency.