Methods of coating fiber containing materials and coated fiber containing materials
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Solution Overview
Problem
Fiber-containing materials, such as woven carbon fibers, often dislodge or deform during coating processes, and lose flexibility, necessitating a more effective coating method that maintains fiber integrity and flexibility.
Innovation Solution
A method involving applying a liquid solution with dispersed polymers, followed by drying to form a network of discontinuous polymeric particles, and then applying a film-forming resin coating that interacts with the dried polymeric material to enhance adhesion and prevent fiber deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional coating processes are applied to fiber-containing materials, then coating coverage is achieved, but fibers dislodge or deform and flexibility is lost
Solution Approach 1:
The patent applies a liquid solution containing dispersed polymer particles to the fiber-containing material before the main coating process. This preliminary treatment creates a protective layer that prevents fiber dislodgment and deformation during subsequent coating operations, while the discontinuous particle network maintains fiber flexibility. The polymer particles are applied and dried to form this protective underlayer before the actual coating is applied.
2Strength
If a continuous polymeric coating is applied to fibers, then adhesion is improved, but fiber flexibility is reduced
Solution Approach 1:
The patent creates a coating structure with local quality variations by using discontinuous polymeric particles rather than a continuous film. The polymer particles are distributed sparsely across the fiber surface, creating localized adhesion points that bond the coating to fibers while leaving gaps that preserve fiber flexibility. This discontinuous particle network provides sufficient adhesion without forming a rigid continuous layer that would restrict fiber movement.
3Reliability
If coating is applied to maintain fiber structure, then fiber dislodgment is prevented, but coating complexity increases
Solution Approach 1:
The patent introduces an intermediary substance - dispersed polymer particles in a liquid solution - that acts as a mediator between the fiber-containing material and the main coating. This intermediary layer is applied first, dried to form discontinuous particles, and then the main coating is applied over it. The intermediary polymer particles facilitate coating application and fiber protection without requiring complex equipment or multi-step processes, simply needing sequential application and drying steps.
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 method achieves improved adhesion and flexibility of coated fibers, preventing dislodgment and deformation, while maintaining a 3D structure and allowing for good visible appearance and thermal stability.
Implementation Method 1
drying at least a portion of the liquid solution applied over the fibers of the material to obtain a dried polymeric material that forms a network of discontinuous dried polymeric particles over the fibers
Implementation Method 2
a first coating composition comprising a film-forming resin that interacts with the dried polymeric material to improve at least adhesion of the first coating layer over the plurality of fibers
Data Source
AI summary
A method for coating a material having a plurality of fibers includes treating at least a portion of the fibers by applying a liquid solution over at least a portion of the fibers of the material in which the liquid solution includes a polymer dispersed in a liquid medium, drying at least a portion of the liquid solution applied over the fibers of the material to obtain a dried polymeric material that forms a network of discontinuous dried polymeric particles over the fibers, applying to at least a portion of the fibers a first coating composition comprising a film-forming resin that interacts with the dried polymeric material, and drying the first coating composition to form a first coating layer over at least a portion of the fibers. A coated material is also included.