Composite Material Web Adhesion
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Solution Overview
Problem
Existing methods for achieving adhesion between carrier materials and coating materials in composite materials, such as those used in textile architecture, are complicated and expensive, often requiring adhesion promoters or corona treatments that can be short-term and prone to migration, especially in large-area applications where high tensile and compressive forces are involved.
Innovation Solution
A composite material is created where the carrier material is coated with a first and second coating material, forming a web-like connection between the two surfaces without the need for adhesives or corona treatments, ensuring intimate adhesion and stabilization of the carrier material, with the coating material penetrating through the carrier material to form a strong bond.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesion promoters are used to achieve adhesion between carrier material and coating material, then adhesion is improved, but the complexity and cost of the manufacturing process increases
Solution Approach 1:
The patent removes adhesion promoters from the system entirely. Instead of adding chemical additives to improve adhesion, the invention uses purely physical methods - specifically, forming a mechanical interlocking structure where the coating material is embedded into the carrier material through a process that creates anchoring points without any chemical bonding agents.
Solution Approach 2:
The patent introduces a physical intermediary structure - a three-dimensional anchoring structure formed within the carrier material that mechanically connects the coating material to the carrier. This physical intermediary replaces the chemical intermediary (adhesion promoter) that would otherwise be needed to bridge the two materials.
2Strength
If corona treatment is used to improve adhesion between carrier material and coating material, then adhesion is improved, but the manufacturing process becomes more expensive and less flexible
Solution Approach 1:
The patent removes corona treatment from the manufacturing process entirely. Instead of using electrical plasma treatment to activate the carrier material surface, the invention employs a mechanical embedding process where the coating material is physically pressed into and bonded with the carrier material structure, eliminating the need for complex plasma generation equipment and process controls.
Solution Approach 2:
The patent replaces the electrical/chemical corona treatment system with a purely mechanical embedding system. The coating material is applied and then mechanically embedded into the carrier material through pressure and heat, creating physical interlocking rather than surface activation, which simplifies the manufacturing equipment and process.
3Strength
If adhesion promoters are used to ensure adhesion, then adhesion is improved, but the risk of component detachment and migration increases
Solution Approach 1:
The patent removes adhesion promoters from the system, eliminating the source of potential detachment and migration. By using purely physical embedding and mechanical interlocking, there are no chemical additives that could detach, migrate, or degrade over time. The connection between carrier material and coating material is formed through the physical structure itself, which remains stable.
Solution Approach 2:
The carrier material and coating material create their own adhesion through their physical interaction. The embedding process causes the coating material to become mechanically interlocked with the carrier material structure, creating a self-sustaining bond that does not require external chemical promoters and cannot detach or migrate.
4Strength
If corona treatment is applied to improve adhesion, then adhesion is improved, but the short-term effect requires immediate coating which reduces manufacturing flexibility
Solution Approach 1:
The patent removes corona treatment from the process sequence, eliminating the time-sensitive step that requires immediate coating. The embedding process can be performed at any stage of manufacturing, allowing for flexible scheduling and processing times without compromising adhesion, since the physical embedding mechanism does not depend on time-sensitive surface activation.
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 provides a stable and strong adhesion between the carrier and coating materials, preventing shrinkage or crimping of the carrier material, and is suitable for large-area applications, including those in textile architecture and food technology, without the drawbacks of adhesion promoters or corona treatments.
Implementation Method 1
The carrier material is coated on a first surface with a first coating material and on a second surface with a second coating material. The first coating material creates a first coating layer on the first surface of the carrier material, which is advantageously connected to a second coating layer (formed by the second coating material) by the webs. The carrier material consequently lies between the two coating layers and is at least partially penetrated by the coating material (through the webs).
Implementation Method 2
In addition, the invention has the advantage that the carrier material is stabilized by the webs within the carrier material. For example, the webs prevent the carrier material from shrinking or crimping, as a result of which, for example, the dimensions of the carrier material (for example length or width of the carrier material) also remain stabilized.
Data Source
Figure 1~3
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AI summary
The invention relates to a composite material, at least consisting of a carrier material (3), wherein the carrier material (3) is coated on a first surface with a first coating material (2) and on a second surface with a second coating material (2'), wherein the composite material has webs (4) of coating material which extend from the first surface of the carrier material to the second surface of the carrier material, wherein webs of coating material emanate from 1 to 90% of at least one of the surfaces of the carrier material. Furthermore, the invention relates to a method for producing a composite material of this type.