Thermoplastic Insert Bonding for Thermoset Composites

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Solution Overview

Problem

Fiber-reinforced plastics with a thermoset matrix cannot be directly bonded using injection molding, limiting their application in visible areas and attachment to vehicle chassis or other components, as chemical bonding between thermoplastic and thermoset materials is challenging.

Innovation Solution

A process involving the use of thermoplastic layers between thermoset prepreg layers, where the thermoplastic layer is mechanically locked in place, allowing for bonding without chemical adhesion, enabling the use of components in visible areas by forming a cutout and inserting a thermoplastic structure through it, which can be secured via injection molding or welding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If injection molding is used for direct bonding on fiber-reinforced plastics with thermoset matrix, then bonding of thermoplastic components is achieved, but chemical bonding between thermoplastic and thermoset materials is challenging and applications in visible areas are excluded

Engineering Contradiction:

Improvebonding reliabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The component is segmented into a thermoset matrix layer and a separate thermoplastic layer. The thermoplastic layer is applied only in the region where bonding is required, rather than attempting to bond thermoplastic directly to the thermoset matrix. This segmentation allows each material to be used in its optimal application area while avoiding the chemical bonding compatibility issues between thermoplastic and thermoset materials.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The thermoplastic layer acts as an intermediary between the thermoset matrix and the thermoplastic components to be bonded. Instead of directly bonding thermoplastic components to the thermoset matrix (which has poor chemical bonding properties), the thermoplastic layer serves as a mediating interface that enables reliable bonding through standard thermoplastic bonding methods.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a thermoplastic layer is applied over the entire surface, then bonding is enabled, but material costs increase and production complexity increases

Engineering Contradiction:

Improvebonding capabilityVSAvoidmaterial consumption

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The thermoplastic layer is applied locally only in the region where bonding is required, rather than covering the entire surface. This localized application reduces material consumption while maintaining the bonding capability where needed. The method enables precise control over where the thermoplastic layer is present, optimizing both material usage and bonding performance.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If thermoplastic components are bonded to thermoset components, then attachment functions are achieved, but chemical bonding between different material types is challenging

Engineering Contradiction:

Improveattachment functionalityVSAvoidbonding process difficulty

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The method changes the bonding parameter from chemical bonding (which is difficult between thermoplastic and thermoset) to mechanical bonding through melting and adhesion (which is easy for thermoplastic materials). By applying the thermoplastic layer and then bonding thermoplastic components to it using standard thermoplastic bonding processes, the attachment functionality is achieved with simplified manufacturing.

Inventive Principle:

Principle #35Parameter changes

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 reliable and simple bonding of thermoplastic components to thermoset components, facilitating their use in visible areas without the need for chemical bonding, reducing material costs and simplifying production by localizing the thermoplastic layer only where needed.

Implementation Method 1

the thermoplastic layer is locked between the two thermoset layers

Methodology Applied

Scientific EffectMechanical locking: Mechanical Fastener

Implementation Method 2

applying the injection-molding composition for the connector clip, in liquid form, to both sides of the layer made of the fiber-reinforced plastic with the thermoset matrix

Methodology Applied

Scientific EffectInjection molding:

Data Source

PatentUS10981337B2Bonding of thermoplastic components to a thermoset component

Publication Date: 2021.04.20 DR ING H C F PORSCHE AG

AI summary

A process for producing a component from a fiber-reinforced plastic with a thermoset matrix. The process includes the steps providing a first and second thermoset prepreg layer, producing a cutout in the first thermoset prepreg layer, providing a thermoplastic layer in the semifinished product between the first and the second thermoset prepreg layer in the region of the cutout, and manufacturing the component with a first and second thermoset layer and a thermoplastic layer in the region of the cutout, where the thermoplastic layer is locked between the two thermoset layers. The component may be used in a vehicle, where the component has been produced from a fiber-reinforced plastic with a thermoset matrix by the abovementioned process.