Polyurethane Coated Metal Composite Adhesion
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Solution Overview
Problem
The bonding of cloth to shaped metal materials using double-sided tapes or adhesives increases the thickness, weight, and manufacturing time, and costs, while also requiring stabilization time for adhesive strength, which is inefficient and costly.
Innovation Solution
A composite is formed by coating a shaped metal material with a polyurethane resin containing a polycarbonate unit, followed by thermocompression bonding with a chemical fiber cloth, eliminating the need for adhesives and tapes, and ensuring excellent adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If double sided tape or adhesive is used to bond cloth to shaped metal material, then bonding strength is improved, but thickness and weight of composite increase
Solution Approach 1:
The invention extracts and eliminates the adhesive layer from the composite structure. Instead of using adhesive to bond the cloth to the metal substrate, the invention uses a coating formed directly on the metal substrate surface that provides both adhesion and design functionality, thereby removing the separate adhesive layer and reducing overall weight.
Solution Approach 2:
The invention merges the functions of the coating and adhesive into a single integrated coating layer. The coating on the metal substrate serves dual purposes: providing the desired surface design appearance and simultaneously bonding the cloth to the substrate, eliminating the need for a separate adhesive layer.
2Strength
If double sided tape or adhesive is used to bond cloth to shaped metal material, then bonding strength is improved, but manufacturing time is prolonged
Solution Approach 1:
The coating is applied to the metal substrate in advance during the manufacturing process, before the cloth bonding step. This preliminary coating formation integrates the adhesion function into the substrate preparation phase, eliminating the need for separate adhesive application and aging time.
Solution Approach 2:
The invention enables continuous processing by eliminating the aging time requirement. The coating provides immediate bonding capability upon application, allowing the manufacturing process to proceed without interruption or waiting periods for adhesive strength stabilization.
3Strength
If double sided tape or adhesive is used to bond cloth to shaped metal material, then bonding strength is improved, but manufacturing cost is increased
Solution Approach 1:
The coating on the metal substrate performs multiple functions simultaneously: it provides the desired surface design appearance, ensures corrosion protection, and provides adhesion for bonding the cloth. This multi-functionality eliminates the need for separate adhesive materials and simplifies the manufacturing process.
Solution Approach 2:
The invention discards the separate adhesive material and recovers its bonding function by integrating it into the coating system. The coating that would traditionally only provide design appearance now also provides the adhesion function previously requiring separate adhesive 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
This method allows for a lightweight, cost-effective composite with enhanced adhesion between the coated shaped metal material and the chemical fiber cloth, reducing manufacturing time and costs, and achieving strong bonding without the use of adhesives.
Implementation Method 1
joining the cloth containing a chemical fiber by compression to the coated side of the coated shaped metal material that is heated
Implementation Method 2
a mass ratio of the polycarbonate unit to mass of a total resin in the coating is 15 to 80 mass%, and a film thickness of the coating is 0.2 μm or more, the chemical fiber is a polyurethane fiber
Data Source
AI summary
Provided is a composite having a coated, shaped metal material, and cloth which includes chemical fibers and which is joined to the surface of the coated, shaped metal material. This coated, shaped metal material has a shaped metal material, and a coating film that includes a polycarbonate unit-containing polyurethane resin formed on the surface of the coated, shaped metal material. The proportion of the mass of polycarbonate units to the total mass of resin in the coating film is 15-80 mass%. The thickness of the coating film is 0.2 µm or thicker.