Cleaning Utensil Handle Adhesion via Surface Prep and Thermal Control
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Solution Overview
Problem
The existing methods for manufacturing handles for cleaning utensils face issues with adhesion of adhesive layers to metal surfaces, leading to deficient layer adhesion, matte finish, and an unpleasant touch due to the use of co-extrusion systems.
Innovation Solution
A method involving degreasing, brushing, deformation, and controlled temperature application of adhesive and plastic layers on a metal tube, followed by a co-extrusion process to ensure better adhesion and a pleasant touch, using a sequence of cleaning, heating, and cooling steps to achieve a stable and smooth finish.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If co-extrusion systems are used to apply adhesive and plastic layers, then the manufacturing process is simplified, but adhesion between layers and metal surface deteriorates
Solution Approach 1:
The metal strip surface undergoes preliminary cleaning by degreasing to remove cutting fluids and industrial oils, followed by brushing to eliminate residues and condition the surface. This preliminary surface preparation ensures optimal adhesion conditions before the adhesive layer is applied, resolving the contradiction by preparing the surface in advance rather than relying solely on the co-extrusion process.
Solution Approach 2:
The metal tube is heated to a temperature between 125-150°C before adhesive application, and the adhesive is applied at a hot temperature between 225-230°C. This temperature control modifies the physical parameters of both the substrate and adhesive, enhancing adhesion properties and resolving the contradiction between simplified manufacturing and reliable layer bonding.
2Productivity
If adhesive layers are applied to metal surface without proper surface preparation, then the manufacturing process is faster, but adhesion quality deteriorates
Solution Approach 1:
The metal strip surface undergoes preliminary cleaning by degreasing to remove cutting fluids and industrial oils, followed by brushing to eliminate residues and condition the surface. This preliminary surface preparation ensures optimal adhesion conditions before the adhesive layer is applied, resolving the contradiction by preparing the surface in advance rather than relying solely on the co-extrusion process.
Solution Approach 2:
The metal tube is heated to a temperature between 125-150°C before adhesive application, and the adhesive is applied at a hot temperature between 225-230°C. This temperature control modifies the physical parameters of both the substrate and adhesive, enhancing adhesion properties and resolving the contradiction between simplified manufacturing and reliable layer bonding.
3Ease of manufacture
If the third layer of plastic material has high fluidity, then the coating process is easier, but the finish quality deteriorates
Solution Approach 1:
The fluidity of the third layer of plastic material is precisely controlled within the range of 55-65 degrees, while the second layer has lower fluidity between 5-8 degrees. This controlled parameter variation optimizes both the coating process ease and the final surface finish quality, resolving the contradiction between manufacturing ease and finish quality.
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 ensures a strong and aesthetically pleasing handle with improved adhesion and surface quality, providing a pleasant touch and brighter finish by maintaining the metal tube's temperature during layer application and using polypropylene materials for the second and third layers.
Implementation Method 1
the longitudinal edges of the open tubular structure of the metal strip are heated by means of a first induction device
Implementation Method 2
applying a first layer of adhesive on the outer face of the metal tube
Implementation Method 3
applying a second layer of plastic material on the first layer of adhesive, also at a hot temperature delimited between 200 and 250 °C. applying a third layer of plastic material on the second layer of plastic material
Implementation Method 4
Cooling the set of the metal tube (2) with its three layers in a first cooling pond. Cooling the set of the metal tube with its three layers in a second cooling pond after being in the first cooling pond
Data Source
AI summary
The method begins with a metal strip deformed to form a tube, which outer face has been previously cleaned and conditioned to facilitate the adhesion of a first layer of adhesive material, on which a second layer of plastic material is applied and which is finally covered with a third layer, also of plastic material. The method used ensures the correct attachment of the different elements of the handle while providing a handle with a pleasant touch for the hands of the user. The handle obtained is more durable because it is perfectly protected against corrosion thanks to the three layers, each one of which is approximately 90 microns thick.