Micro Contoured Surface Layer on Composite Products
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Solution Overview
Problem
Current composite products made from polymer materials lack a natural feel and enhanced functionality, particularly in terms of heat conductivity, surface roughness, printability, and adhesive properties, which are essential for user experience and environmental considerations.
Innovation Solution
A method to produce composite products with a micro contoured surface layer using organic natural fiber-based materials, where the surface roughness can be adjusted by controlling process parameters, such as heating and cooling the primary surface layer to create a secondary surface layer with specific roughness characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a polymer surface is used in composite products, then the visual appearance is improved, but the natural feeling and functionality are worsened
Solution Approach 1:
The patent applies local quality by creating a micro contoured surface layer on the composite product that mimics natural wood grain patterns. This surface layer is applied to the polymer substrate to provide the visual appearance of natural materials while maintaining the underlying polymer structure. The micro contoured pattern creates localized variations in surface topology that enhance the natural feeling and functionality without compromising the overall visual appearance.
2Manufacturing precision
If a micro contoured surface layer is created by heating and cooling, then the surface roughness and natural feeling are improved, but the process complexity increases
Solution Approach 1:
The patent utilizes parameter changes by controlling the temperature parameters during the manufacturing process. The composite material is heated to a temperature above the glass transition temperature of the polymer matrix, allowing the material to become pliable and conform to the micro contoured mold surface. Subsequent cooling solidifies the desired surface morphology. This temperature parameter control enables precise adjustment of surface roughness and micro contour formation without requiring complex additional equipment.
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 micro contoured surface layer enhances the natural feel and functionality of composite products, improving heat conductivity, surface roughness, printability, and adhesive properties, while also meeting environmental standards and user preferences.
Implementation Method 1
softening said primary surface layer of said composite material by heating
Implementation Method 2
providing a secondary surface layer of said composite material surface with a secondary surface roughness by cooling said softened surface layer
Data Source
AI summary
Providing composite structures with micro contoured surface layer. There is provided a method to adjust roughness level of micro contoured surface layer when manufacturing a composite and products thereof. The micro contoured surface layer may cover all or at least part of the surface area of the composite product. The roughness level of micro contoured surface layer may be increased or decreased by controlling the process parameters. In particular, there is provided a method to increase the roughness level of composite material having a primary surface layer with a primary surface roughness by softening the primary surface layer of the composite material by heating and providing a secondary surface layer of the composite material surface with a secondary surface roughness by cooling the softened surface layer. Further, there are provided methods to determine and visualize the level of micro contoured surface layer roughness on a composite product surface.