Multilayered Sail Material Adhesion via In Situ Crosslinking
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Solution Overview
Problem
Current multilayered materials for boat sails suffer from delamination due to air bubbles and empty gaps between layers, leading to reduced durability and resistance to stress, especially under adverse conditions like strong winds and UV exposure.
Innovation Solution
A multilayered material comprising a thermoplastic polymer film with a pressure-sensitive adhesive and arranged reinforcing fibers, combined with a polyurethane layer deposited via an aqueous dispersion that crosslinks in situ, eliminating gaps and enhancing adhesion without high-temperature processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional lamination processes with external pressure and heating are used, then layers are bonded together, but air bubbles and empty gaps remain causing delamination
Solution Approach 1:
The adhesive is applied to the first polymeric layer before the layers are assembled, preparing the bonding surface in advance. This preliminary action allows the adhesive to be properly positioned and distributed before the lamination process begins, preventing air bubbles from forming during assembly.
Solution Approach 2:
The patent replaces the traditional mechanical lamination system (external pressure with lamination cylinders) with a chemical bonding system. The self-adhesive polymeric layer chemically bonds to the thermoplastic layer through molecular adhesion, eliminating the need for mechanical pressure and heating equipment while achieving superior bonding without gaps or bubbles.
2Strength
If high-temperature heating cycles are applied to cure adhesive, then bonding is achieved, but energy consumption increases and material degradation occurs
Solution Approach 1:
The patent changes the bonding mechanism from thermal curing (high temperature) to ambient temperature self-adhesion. The self-adhesive polymeric layer forms strong bonds at room temperature through molecular adhesion, eliminating the need for high-temperature heating cycles and significantly reducing energy consumption.
Solution Approach 2:
The patent replaces the thermal curing system with a chemical self-adhesion system. Instead of using heat to activate the adhesive, the polymeric layer inherently possesses self-adhesive properties that enable bonding at ambient temperatures, substituting thermal energy with chemical bonding mechanisms.
3Strength
If reinforcing fibres are aligned with load lines, then mechanical strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies local quality by concentrating reinforcing fibres specifically along the expected load lines where they are most needed for structural strength. Rather than uniformly distributing fibres throughout the material, the fibres are strategically positioned in critical stress areas, optimizing strength while minimizing unnecessary material and complexity.
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 significantly improves the material's resistance to delamination and mechanical performance, maintaining integrity under stress and adverse conditions, with a simpler and energy-efficient production process.
Implementation Method 1
a first layer of a thermoplastic polymer film, having a surface thereof coated by an adhesive on which fibres of one or more materials having high elastic modulus are placed
Implementation Method 2
a second layer of polyurethane obtainable by deposition on the adhesive of an aqueous dispersion comprising polyurethane and subsequent curing in situ
Data Source
AI summary
The present invention refers to a new multilayered material, reinforced with fibres and having an improved adhesion between the layers throughout its entire structure; to a process for its preparation and to the articles made with such material, intended to be exposed to adverse conditions, such as strong winds, stretching, temperature changes, such as for example sails for boat.