Silane Acid Treatment for Soft Cloth Septum Adhesion
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Solution Overview
Problem
Existing 2DoF composite panels with soft septums face challenges in achieving strong bonds between soft cloth septums and honeycomb panels using aerospace grade epoxy adhesives, leading to poor acoustic and mechanical performance due to issues with adhesion methods like corona or oxygen plasma treatments and chemical etching, which are inefficient or create latent flaws.
Innovation Solution
A method involving treating a soft cloth septum with a composition of silane and organic acid, followed by bonding it between two honeycomb panels using traditional aerospace adhesives, ensuring good acoustic and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If corona or oxygen plasma treatment is applied to the soft cloth septum to promote adhesion, then adhesion strength is improved, but the treatment is perishable and quickly loses effectiveness
Solution Approach 1:
The patent changes the chemical parameters of the cloth surface by applying silane and organic acid treatments, creating permanent chemical groups that provide lasting adhesion promotion without the perishable nature of plasma or corona treatments. This chemical modification permanently alters the surface properties of the polyester cloth to enhance epoxy adhesion.
2Strength
If chemical etching with hot sodium hydroxide is used to promote adhesion, then adhesion is improved, but the process is slow and residual sodium hydroxide can disrupt adhesive cure
Solution Approach 1:
The patent changes from alkaline chemical etching to acidic chemical treatment using organic acids. This parameter change in the chemical process avoids the formation of residual bases that interfere with epoxy curing, while still achieving effective adhesion promotion through controlled chemical modification of the cloth surface.
Solution Approach 2:
The patent uses a simple, inexpensive chemical treatment process that can be quickly applied and easily rinsed, replacing the complex, time-consuming sodium hydroxide etching process. The treatment is designed to be readily removable with water, avoiding residual issues.
3Strength
If primer coatings are applied to the cloth to promote adhesion, then adhesion is improved, but the coatings fill in and block the open area of the cloth, making acoustic performance unpredictable
Solution Approach 1:
The patent applies chemical treatment only to the surface of the cloth fibers, maintaining the local open structure of the fabric while modifying only the surface properties for adhesion. This localized treatment preserves the acoustic flow paths through the cloth while providing adequate bonding surface for the adhesive.
4Reliability
If a soft cloth septum is used instead of perforated hard septum, then acoustic performance is improved through laminar air flow, but adhesion to honeycomb panels becomes difficult
Solution Approach 1:
The patent changes the surface chemical parameters of the soft cloth through silane and organic acid treatment, creating a surface that is chemically compatible with epoxy adhesives. This allows the soft cloth to maintain its acoustic benefits while achieving reliable mechanical adhesion to the honeycomb panels.
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 treated composite panel achieves effective adhesion and maintains both excellent acoustic and mechanical properties, reducing material and labor costs while avoiding the drawbacks of previous methods.
Implementation Method 1
treating a septum having first and second opposed sides with a composition comprising silane and an organic acid; and adhesively bonding a first honeycomb panel to the first side of the treated septum and a second honeycomb panel to the second side of the treated septum
Data Source
AI summary
The invention describes a method for making a composite panel and the product made by the method. The composite panel is made from a soft septum treated with a composition containing silane and an organic acid. The treated soft septum is adhesively bonded between two honeycomb panels, forming a sandwich of the septum between the two honeycomb panels.