Fiber-Reinforced Thermoplastic Film Composite for Stable Bonding
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Solution Overview
Problem
Existing fiber-reinforced plastics exhibit low stability transverse to the fiber direction and limited substrate bonding versatility due to the use of thermosetting resins with hardeners, leading to premature cross-linking and limited substrate compatibility.
Innovation Solution
A sheet-like semi-finished product with a latent reactive plastic composition forming a thermoplastic elastomer matrix and unidirectionally aligned continuous fibers, embedded in a thermoplastic film, providing enhanced stability and broad substrate bonding capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermosetting resin systems with hardeners are used as plastic matrix, then fiber reinforcement and structural performance are improved, but storage time is limited due to premature cross-linking and substrate bonding versatility is restricted
Solution Approach 1:
The patent changes the chemical state of the resin from reactive thermosetting to latent reactive, where the resin remains stable during storage but activates only during bonding. This parameter change allows the material to maintain both structural performance and bonding versatility without premature cross-linking.
Solution Approach 2:
The patent applies the resin to substrates in a latent reactive state before final bonding, allowing preparation and storage without cross-linking. The resin only becomes active during the actual bonding process, enabling versatile substrate selection and extended storage time while maintaining structural integrity.
2Strength
If unidirectional fiber alignment is used, then tensile strength in fiber direction is improved, but stability transverse to fiber direction deteriorates due to low viscosity matrix
Solution Approach 1:
The patent creates a composite structure combining unidirectionally aligned fibers with a latent reactive resin matrix. The fiber reinforcement provides tensile strength in the fiber direction while the latent resin matrix provides transverse stability without premature cross-linking, resolving the contradiction between directional strength and transverse stability.
3Strength
If reactive resin matrix is used for fiber reinforcement, then composite strength is improved, but storage time is limited due to cross-linking tendency
Solution Approach 1:
The patent applies the resin in a latent reactive state as a preliminary step, allowing extended storage time without cross-linking. The resin only becomes reactive during the bonding process, enabling both long storage duration and high composite strength after activation.
Solution Approach 2:
The patent changes the reactivity parameter of the resin from immediately reactive to latent reactive, allowing the material to remain stable during storage and only activate when needed. This parameter change enables extended storage time while maintaining the ability to form strong composites.
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 product achieves increased tensile strength and improved adhesion across various substrates, allowing for high stability transverse to the fiber direction and enabling diverse composite applications.
Implementation Method 1
a matrix comprising at least one latent reactive plastic composition, the plastic composition being curable to form an elastomer, in particular a thermoplastic elastomer
Implementation Method 2
The thermoplastic film is preferably essentially inseparably bonded to the matrix, i.e. the film cannot be removed and reused. Rather, there is a permanent adhesion between the film and the matrix.
Data Source
AI summary
A flat semi-finished product having-a matrix with at least one latently reactive plastic composition, which can be cured to form an elastomer, more particularly a thermoplastic elastomer,-continuous fibres embedded in the matrix. The fibres are aligned preferably unidirectionally. The flat semi-finished product further has a thermoplastic film. A method for producing a flat semi-finished product of this kind and the use of a flat semi-finished product of this kind.