Metal-Plastic Composite Sheet for Thin-Gauge Coil Coating
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Solution Overview
Problem
Existing methods struggle to produce lightweight metal/plastic composites with metal layers thinner than 0.4 mm, as they are difficult to coat uniformly, and conventional metal sandwich panels used in vehicle bodies cannot be made thinner due to stability concerns, limiting weight reduction potential.
Innovation Solution
A method involving a metal/plastic composite with a metal layer up to 1.5 mm thick, preferably 0.5 mm, combined with a temperature-resistant plastic layer, allowing easy coil coating and potential texturing or embossing to enhance appearance and stability, while using steel layers for cost-effectiveness and ease of processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If metal layer thickness is reduced to achieve lightweight construction, then mass is reduced, but coating quality and structural stability deteriorate
Solution Approach 1:
The patent applies composite materials by combining a thin metal layer (0.1-1.5mm) with a plastic layer (0.2-3.0mm) to create a metal-plastic composite. This composite structure enables significant mass reduction compared to solid metal while maintaining coating quality, as the plastic layer provides a stable substrate for the coil coating process even when the metal layer is thin.
Solution Approach 2:
The patent utilizes thin film technology by employing a thin metal layer (up to 1.5mm, preferably up to 0.5mm) that is fully bonded to a plastic layer. This thin film approach allows the structure to be lightweight while the plastic layer compensates for the reduced metal thickness, ensuring both coating feasibility and structural integrity.
2Weight of moving object
If metal layer thickness is reduced below 0.4mm for lightweight construction, then mass is reduced, but processability in coil coating lines deteriorates
Solution Approach 1:
The patent uses composite materials where the plastic layer (0.2-3.0mm thick) serves as a stable substrate for the thin metal layer (0.1-1.5mm). This composite structure enables the thin metal layer to be processed in coil coating lines despite its reduced thickness, as the plastic layer provides the necessary structural stability and coating surface quality.
Solution Approach 2:
The plastic layer acts as an intermediary between the thin metal layer and the coating process. It provides a stable, coating-friendly surface that enables the coil coating process to proceed successfully with metal layers thinner than 0.4mm, effectively mediating between the lightweight requirement and manufacturing feasibility.
3Stability of the object's composition
If metal sandwich panels use minimum thickness for stability, then structural integrity is maintained, but weight reduction potential is limited
Solution Approach 1:
The patent applies composite materials by combining thin metal layers (0.1-1.5mm) with plastic layers (0.2-3.0mm) to create metal-plastic composites. This composite approach achieves significant weight reduction compared to traditional solid metal sandwich panels while maintaining structural stability, as the plastic layer provides the necessary rigidity and strength.
Solution Approach 2:
The patent changes the material composition parameters by replacing solid metal with a metal-plastic composite structure. This parameter change allows the structure to achieve the required stability with significantly reduced metal content, enabling weight reduction while maintaining structural integrity through the synergistic combination of materials.
Data Source
Figure 1~2b
Figure 3
AI summary
The invention relates to a plate-shaped or ribbon-shaped semi-finished product (7, 7') comprising at least one first metal layer (8, 8') and at least one plastic layer (10, 10'), which are connected together over the entire surface to form a metal/plastic composite (7), wherein the material thickness of the metal layer (8, 8') is at most 1.5 mm, and the material thickness of the plastic layer (10, 10') is at least 0.2 mm. The invention further relates to a method for the production and use thereof. The object the present invention, which is to provide a semi-finished product which is significantly lighter than the semi-finished products found in the prior art, is achieved for a semi-finished product having the features of claim 1.