Thermosetting Laminate Adhesion via Post-Curing
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Solution Overview
Problem
The bonding between thermoplastic and thermosetting materials in composite laminates is often weak, leading to structural integrity issues and potential delamination, especially when exposed to water, limiting the selection of materials and increasing production costs.
Innovation Solution
A post-curing process at elevated temperatures is applied to the cured composite laminates, which improves the adhesion between thermoplastic and thermosetting materials, allowing the use of various types of thermosetting resins, including high DCPD unsaturated polyester resins, without the need for special surface treatments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional bonding methods are used to combine thermoplastic and thermosetting materials, then the composite structure can be manufactured, but the adhesion between layers is weak leading to delamination and structural integrity issues
Solution Approach 1:
The patent applies parameter changes by adjusting temperature and time parameters during the curing process. Specifically, it employs a two-stage curing method: initial curing at ambient temperature followed by post-curing at elevated temperatures (90-200°C) for a specific duration. This temperature parameter change enhances the adhesion between thermoplastic and thermosetting materials, resolving the weak bonding issue while maintaining structural integrity.
Solution Approach 2:
The patent implements preliminary action through the initial curing stage performed before the final post-curing. The composite is first cured at ambient temperature to establish basic bonding, then subjected to post-curing at elevated temperatures to enhance and stabilize the adhesion. This staged approach ensures reliable bonding while preventing delamination, addressing the structural integrity concern.
2Strength
If special surface treatments are applied to improve adhesion, then bonding strength increases, but manufacturing complexity and production costs increase
Solution Approach 1:
The patent extracts the adhesion enhancement function from complex surface treatment processes. Instead of applying primers, coatings, or mechanical surface modifications, the invention achieves improved bonding through a simple thermal post-curing process. This eliminates the need for additional surface treatment equipment and procedures, reducing manufacturing complexity while maintaining high bonding strength.
Solution Approach 2:
The patent replaces mechanical surface treatment methods with a thermal field-based approach. Rather than using mechanical means such as sandblasting, chemical etching, or primer coatings, the invention uses controlled heating during post-curing to enhance adhesion. This substitution simplifies the manufacturing process and reduces equipment requirements while achieving the same bonding improvement.
3Productivity
If conventional curing processes are used, then production time is reasonable, but production speed is limited and manufacturing efficiency is reduced
Solution Approach 1:
The patent applies continuity of useful action by making the post-curing process an integral part of the manufacturing workflow. The elevated temperature curing is performed continuously after the initial curing, ensuring that the adhesion enhancement occurs without interrupting production. This continuous thermal treatment accelerates the overall curing process and improves production speed while maintaining manufacturing efficiency.
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 process enhances the bonding strength between thermoplastic and thermosetting materials, enabling faster production, lower material costs, and reduced VOC emissions, while allowing the use of MACT compliant thermosetting resins, thereby improving the structural integrity and manufacturing efficiency of composite laminates.
Implementation Method 1
A post-curing process at elevated temperatures is applied to the cured composite laminates, which improves the adhesion between thermoplastic and thermosetting materials
Data Source
AI summary
The present invention related to a process to improve the adhesion between a thermosetting laminate and a thermoplastic shell in making reinforced plastic laminates for sanitary fixtures, such as shower receptors, spas, bathtubs, sinks, lavatories and the like, and composites laminates for transportation, marine, and construction applications. The adhesion improvement is through a designed post-curing process of the cured composites laminates. The thermosetting resin used in the construction of composites laminate can be unsaturated polyester resin of any kind, vinyl ester resin, or combination of both.