Composite Thermoplastic Laminate Adhesion Promoting Layer
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Solution Overview
Problem
Composite sheet materials with thermoplastic and nonwoven layers often suffer from surface defects such as poor scratch resistance, uneven surface finish, and difficulty in adhering paint or print, due to issues like air entrapment and fiber distribution patterns.
Innovation Solution
The use of a composite sheet material structure that includes a cover sheet, a substrate, and an adhesion promoting layer, where the adhesion promoting layer has affinities to bond with both the cover sheet and substrate materials, and a thermoplastic layer with a support thermoplastic membrane component that prevents thermal combination with the substrate and reduces surface imperfections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a thermoplastic layer is combined with a nonwoven substrate, then the composite material achieves structural integrity and flexibility, but surface defects such as air entrapment and fiber distribution patterns cause poor scratch resistance and uneven surface finish
Solution Approach 1:
An adhesion promoting layer is introduced as an intermediary between the thermoplastic layer and the nonwoven substrate. This intermediate layer has affinity to bond with both the cover sheet material and the substrate material, eliminating direct contact between incompatible materials and preventing surface defects caused by air entrapment and fiber distribution issues.
Solution Approach 2:
The patent employs a multi-layer composite structure consisting of a cover sheet, an adhesion promoting layer, and a substrate. This composite configuration combines materials with different properties to achieve both structural integrity and improved surface finish, resolving the contradiction between strength and manufacturing precision.
2Ease of manufacture
If a thermoplastic layer is directly applied to a substrate, then the manufacturing process is simple, but adhesion is poor and the surface does not accept paint or print well
Solution Approach 1:
The adhesion promoting layer serves as a mediator that enhances bonding between the thermoplastic layer and the substrate. This intermediate layer provides chemical or physical affinity to both materials, significantly improving adhesion quality while maintaining manufacturing simplicity through a standardized lamination process.
3Strength
If the thermoplastic layer is heated to combine with the substrate, then the layers bond together, but thermal combination causes surface imperfections and defects
Solution Approach 1:
The adhesion promoting layer acts as a thermal buffer and bonding intermediary. During heating, this intermediate layer facilitates controlled bonding between layers while preventing direct thermal combination that causes surface imperfections. The layer absorbs and distributes thermal energy evenly, preventing localized overheating and surface defects.
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 configuration enhances the surface quality of the composite sheet materials by reducing surface defects, improving adhesion, and allowing for a smoother, more uniform finish that can accept paint or print effectively.
Implementation Method 1
A first side of the adhesion promoting layer disposed towards the cover sheet has an affinity to bond with the cover sheet material. A second side of the adhesion promoting layer disposed towards the substrate has an affinity to bond with the substrate material.
Implementation Method 2
The first thermoplastic layer and the support thermoplastic membrane component together provide a laminate having a region where the first thermoplastic material and the thermoplastic membrane material are intermixed.
Implementation Method 3
applying a second temperature and second pressure for a second time period as part of a second formation process that combines the matrix and a substrate. The applying the second temperature and second pressure for a second time period provides a larger amount of energy to the matrix and the substrate than the applying the first temperature and first pressure for the first time period provides to the matrix.
Data Source
AI summary
A composite sheet material includes a cover sheet, a substrate and an adhesion promoting layer. The cover sheet has a cover sheet material. The substrate has a substrate material. The adhesion promoting layer is disposed between the cover sheet and the substrate. A first side of the adhesion promoting layer disposed towards the cover sheet has an affinity to bond with the cover sheet material. A second side of the adhesion promoting layer disposed towards the substrate has an affinity to bond with the substrate material.