Moldable Composite with Non-Olefin Bonding Interface

Solution Overview

Problem

The surface character of olefin tape elements in existing moldable mat structures reduces adhesion between the mat and applied substrate layers, leading to delamination issues with materials like adhesives, resins, foams, plastics, and rubbers.

Innovation Solution

A composite material is developed with interwoven axially drawn tape fiber elements and non-olefin embedded fiber elements that form a secure bondable surface structure, allowing for secure bonding to adhesive or non-adhesive substrates by projecting outwardly and defining a partial surface covering across the mat structure, which is moldable to three-dimensional geometries through heat and pressure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If olefin tape elements are used to form moldable mat structures, then moldability and heat fusibility are improved, but adhesion to substrate layers deteriorates

Engineering Contradiction:

ImprovemoldabilityVSAvoidadhesion

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent applies local quality by creating distinct regions within the tape structure: the core layers maintain olefin properties for moldability, while the surface layers use non-olefin materials with enhanced adhesion properties. This allows different parts of the same material to have different functional characteristics - the interior provides heat fusibility and moldability, while the exterior provides bonding strength to substrates.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent employs composite materials by combining olefin and non-olefin layers within a single tape structure. The multi-layer construction integrates materials with complementary properties: olefin core layers for thermoplasticity and moldability, and non-olefin surface layers for improved adhesion. This composite approach resolves the contradiction by merging the advantages of different material classes in a unified structure.

Inventive Principle:

Principle #40Composite materials

2Temperature

If low melting point polyolefin covering layers are applied to facilitate heat bonding, then heat fusibility is improved, but adhesion and delamination resistance deteriorate

Engineering Contradiction:

Improveheat bonding temperatureVSAvoiddelamination resistance

Core Design Contradiction:

TemperatureVSStrength

Solution Approach 1:

The patent applies local quality by creating distinct regions within the tape structure: the core layers maintain olefin properties for moldability, while the surface layers use non-olefin materials with enhanced adhesion properties. This allows different parts of the same material to have different functional characteristics - the interior provides heat fusibility and moldability, while the exterior provides bonding strength to substrates.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent employs composite materials by combining olefin and non-olefin layers within a single tape structure. The multi-layer construction integrates materials with complementary properties: olefin core layers for thermoplasticity and moldability, and non-olefin surface layers for improved adhesion. This composite approach resolves the contradiction by merging the advantages of different material classes in a unified structure.

Inventive Principle:

Principle #40Composite materials

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 composite material provides enhanced adhesion and mechanical strength, preventing delamination while maintaining moldability and adaptability to complex three-dimensional shapes.

Implementation Method 1

The covering layer of the tape fiber elements is characterized by a softening point below that of the base layer to permit fusion bonding upon application of heat

Methodology Applied

Scientific EffectPhase change: Phase Change

Implementation Method 2

The composite of the mat with anchored non-olefin fiber elements is moldable to a three-dimensional geometry by application of heat and pressure following formation

Methodology Applied

Scientific EffectHeating: Heating

Data Source

PatentUS7300691B2Moldable construction incorporating non-olefin bonding interface

Publication Date: 2007.11.27 MILLIKEN & CO

AI summary

A composite construction incorporating one or more mat layers of interwoven axially drawn heat fusible tape fiber elements. The axially drawn tape fiber elements incorporate a central or base layer of a strain oriented polymer with a covering layer of a heat fusible polymer. The covering layer of the tape fiber elements is characterized by a softening point below that of the base layer to permit bonding fusion upon application of heat. An arrangement of embedded non-olefin fiber elements extends in anchored relation at least partially across the thickness dimension of the mat structure. The composite is adapted for bonding to a substrate layer. An optional covering layer may be utilized.