Multilayer Composite Surface Finish and Recycling via Thermoplastic Layer
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Solution Overview
Problem
Thermoplastic composite materials used in mechanical or structured parts face challenges in achieving a decorative surface finish while maintaining mechanical performance, as the fibrous reinforcement is visible, and existing surface treatments like gelcoats or paints hinder recycling and thermoforming due to crosslinking.
Innovation Solution
A multilayer composition featuring a thermoplastic surface layer and a substrate layer with a polymeric thermoplastic (meth)acrylic matrix and fibrous reinforcement, where the fibrous material has a high aspect ratio or two-dimensional structure, combined with a manufacturing process involving thermoforming, impregnation, and polymerization of a (meth)acrylic syrup, allowing for adhesion and flexibility without additional adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a gelcoat or paint layer is applied to provide a quality finish on the visible surface, then the surface aspect is improved, but the multilayer composition cannot be recycled and thermoformed due to crosslinking
Solution Approach 1:
The patent changes the chemical parameter of the surface layer from crosslinked (thermoset) to non-crosslinked (thermoplastic) state. This allows the surface layer to maintain decorative quality while enabling recycling and thermoforming operations, as thermoplastic materials can be melted and reprocessed without chemical degradation
Solution Approach 2:
The patent creates a composite multilayer structure combining a thermoplastic composite substrate layer with a thermoplastic surface layer. This composite approach allows each layer to contribute its beneficial properties: the substrate provides mechanical strength and fiber reinforcement, while the surface layer provides decorative finish and enables recycling/thermoforming
2Adaptability or versatility
If a thermoplastic polymer is used for the composite material, then recycling and thermoforming are enabled, but the surface is not aesthetic or decorative due to visible fiber structure
Solution Approach 1:
The patent divides the composite structure into two distinct functional segments: a substrate layer containing the fibrous reinforcement and thermoplastic matrix, and a separate surface layer providing decorative finish. This segmentation allows the fibrous structure to remain visible in the substrate while the surface layer provides an aesthetic appearance, resolving the contradiction between structural functionality and surface quality
3Strength
If thermosetting polymer matrix is used, then mechanical performance is improved, but the matrix cannot be easily shaped and recycling is difficult due to rigidity and crosslinking
Solution Approach 1:
The patent changes the fundamental parameter of the matrix material from thermosetting (crosslinked, rigid) to thermoplastic (non-crosslinked, flexible) state. This parameter change enables the composite to be easily shaped during manufacturing through heating and molding, and allows for recycling by melting and reprocessing, while still achieving high mechanical performance through optimized fiber reinforcement
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 solution provides a decorative surface finish that hides the fibrous aspect, enables recycling, and allows for thermoforming and shaping, while maintaining mechanical performance, and is suitable for large-scale, cost-effective manufacturing.
Implementation Method 1
polymerising the liquid (meth) acrylic syrup impregnating said fibrous substrate
Implementation Method 2
thermoforming the surface layer comprising the thermoplastic polymer A
Data Source
Figure 1~2
AI summary
The present invention relates to a multilayer composition comprising a surface layer comprising a thermoplastic polymer A and a substrate layer comprising a polymeric composite material based thermoplastic (meth)acrylic matrix and a fibrous material as reinforcement.The multilayer composition is suitable for mechanical or structured parts or articles with a decorative surface aspect The present invention concerns also a manufacturing process for multilayer mechanical or structured parts or articles and three- dimensional mechanical or structured parts.