Sandwich Composite Plastic Layer Activation
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Solution Overview
Problem
Existing methods for producing sandwich composite materials risk delamination due to excessive heat input, which causes the plastic layer to melt and separate from the metal layer, especially in the border area, leading to unreliable connections and potential delamination issues.
Innovation Solution
Activating the plastic layer directly from its surface, using methods such as heat, radiation, or plasma, to create a negative temperature gradient that prevents excessive heating of the metal-plastic connection, ensuring a stable bond between the layers and reducing the risk of delamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heat is introduced into the metallic cover layer to activate the plastic layer, then the plastic layer can be activated for bonding, but the metal layer becomes excessively hot causing the plastic to melt and delaminate
Solution Approach 1:
Instead of heating the metal layer from its original side to activate the plastic, the invention inverts the approach by heating the plastic layer directly from the bonding side. This reversal allows activation of the plastic at the interface without transferring excessive heat to the metal layer, preventing delamination while achieving reliable bonding.
Solution Approach 2:
The invention applies heat locally only to the plastic layer at the bonding interface rather than heating the entire metal layer. This localized heating approach activates the plastic where needed for bonding while keeping the metal layer temperature controlled, avoiding the harmful effects of excessive heat on the plastic-metal connection.
2Temperature
If higher temperatures are used to compensate for heat transport losses, then the targeted temperature can be reached in the border area, but the plastic layer near the metal melts and delaminates
Solution Approach 1:
The invention reverses the heating direction to apply temperature directly to the plastic layer at the bonding interface. This eliminates the need to compensate for heat transport losses through the metal layer, achieving the required bonding temperature locally without causing excessive heat buildup that would lead to delamination.
3Reliability
If discontinuous processes are used to activate and connect semi-finished products, then activation can be controlled, but production efficiency is reduced
Solution Approach 1:
The invention enables continuous production by maintaining the plastic layer in an activated state through controlled heating from the bonding side. This continuous activation allows for uninterrupted bonding operations, eliminating the need to stop and re-activate the plastic between connections, thereby significantly improving production efficiency while maintaining process control.
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 approach allows for the production of sandwich composite materials with consistent properties and improved reliability, as the plastic layer is activated only to the extent necessary for bonding, minimizing the risk of delamination and enabling efficient, continuous production of high-quality materials.
Implementation Method 1
the plastic layer is activated directly from the plastic-coated side of the semi-finished product... the activation takes place from the plastic surface side... a negative temperature gradient is generated in the plastic layer in the direction of the metallic cover layer
Implementation Method 2
Activation by heat is a particularly simple method of activating a plastic layer... by radiation and/or by the action of a plasma
Implementation Method 3
by the action of an activation medium, by radiation and/or by the action of a plasma
Data Source
Figure 1
Figure 2a~2b
Figure 3~4
AI summary
The invention relates to a method for producing a sandwich composite material (9, 9'), comprising at least two outer metal cover layers (4a, 5a, 4a', 5a', 9a, 9b) and at least one plastic layer (4b, 5b, 4c', 5c', 9c) arranged between the cover layers, wherein: at least two metal semi-finished products (4a, 5a, 4a', 5a') coated with plastic (4b, 5b, 4c', 5c') on one side are provided; in order to establish a connection between the plastic layers of the semi-finished products, at least one of the sides of the metal semi-finished products coated with the plastic is activated before the connecting occurs; and the semi-finished products are connected to each other by means of the sides of the semi-finished products coated with plastic in order to form a sandwich composite material. The problem of providing a method that ensures an improvement in the process reliability in the production of sandwich composite materials from semi-finished products coated with at least one plastic layer on one side is solved by activating the plastic layer of the semi-finished products directly from the side of the semi-finished product coated with plastic.