Thermally Bonded Composite Materials for Resin Infusion
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Solution Overview
Problem
Existing polymeric netting materials used in various applications lack sufficient protection and performance enhancement, particularly in resin infusion processes where uniform resin flow and thermal stability are crucial.
Innovation Solution
A composite material comprising a first layer of netting with intersecting strands and a second layer of nonwoven fibers, where the fibers have a melting point at least 20 degrees Celsius higher than the netting, allowing for thermal bonding and enhanced protection and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polymeric netting materials are used without outer protective layers, then the netting provides good resin infusion performance and controlled resin flow, but the netting lacks sufficient protection and thermal stability
Solution Approach 1:
The patent applies composite materials by combining polymeric netting with outer protective layers made of different polymer materials. The netting layer provides resin infusion performance while the outer layers provide protection and thermal stability, creating a multi-layer composite structure that integrates the advantages of both components.
Solution Approach 2:
The patent segments the protective function from the resin infusion function by separating the netting layer (resin infusion) from the outer protective layers. This segmentation allows each layer to be optimized for its specific function without compromising the other, resolving the contradiction between protection and structural simplicity.
2Temperature
If outer protective layers are added to polymeric netting, then thermal stability and protection are improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent utilizes parameter changes in melting points to control the thermal bonding process. By selecting outer protective layer materials with higher melting points than the netting material, the process parameters (temperature and pressure) can be controlled to bond the layers together without damaging the netting structure, simplifying the manufacturing process.
Solution Approach 2:
The patent employs phase transitions (melting and solidification) of polymer materials during the bonding process. The outer protective layers are heated to a temperature below their melting point but above the netting's melting point, allowing thermal bonding while maintaining the structural integrity of both layers, thus simplifying manufacturing.
3Temperature
If fibers with higher melting points are used in the outer layer, then thermal stability is enhanced, but the bonding process requires precise temperature control
Solution Approach 1:
The patent changes the temperature parameter during the bonding process to a specific range below the melting point of the outer protective layer material. This parameter change enables thermal bonding while preventing damage to the netting, achieving both thermal stability enhancement and manageable manufacturing precision requirements.
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 composite material achieves a controlled and predictable resin flow, improved thermal stability, and enhanced protection of the netting layer, making it suitable for diverse applications including resin infusion, filtration, and insulation.
Implementation Method 1
The second layer comprises first and second fiber components. The first fiber components have a melting point at least about 20 degrees Celsius higher than the melting point of the netting. The second fiber components have a melting point within about 20 degrees Celsius of the strands in the netting layer. This allows the second fiber components to thermally bond with the netting strands at contact points upon the application of heat and pressure.
Data Source
AI summary
The present disclosure provides composite materials comprising nettings, mattings or meshes thermally bonded to outer layers of nonwoven fibers that may be configured for use in a variety of applications and products. A composite material comprises a first layer of netting comprising intersecting strands and a second layer in contact with the first layer. The second layer comprises first and second fiber components. The first fiber components have a melting point at least 20 degrees higher than the melting point of the netting. The second fiber components have a melting point within 20 degrees Celsius of the fibers in the netting layer. This allows the second fiber components to thermally bond with the netting at contact points upon the application of heat and pressure. The first fiber components do not substantially thermally bond to the netting and thus form an outer layer, such as a sock, that protects the netting layer.