Thermoplastic Profile Cold Spray Metal Coating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing metal plastic composite profiles for window, door, and facade elements face challenges in achieving strong mechanical connections and long-term stable adhesive bonds between thermoplastic and metal components, particularly under varying environmental conditions and in providing adequate corrosion resistance and electrical conductivity.
Innovation Solution
The application of a supersonic cold spray process to deposit an inorganic containing layer, such as aluminum or tin, onto thermoplastic profiles, enhancing mechanical connection strength and allowing for thicker, more adherent metal layers with varying surface roughness for improved contact or sliding properties, while providing UV and weather protection and electrical conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional coating methods (spray, dip, powder coating) are used on thermoplastic profiles, then the coating process is simple and fast, but the mechanical connection strength and adhesive bond stability are insufficient under varying environmental conditions
Solution Approach 1:
The patent replaces conventional mechanical coating methods (spray, dip, powder coating) with a supersonic cold spray process. This substitution uses supersonic gas flow to accelerate metal particles to high velocities, enabling deep penetration into the thermoplastic surface and creating strong mechanical interlocking. The result is significantly improved mechanical connection strength and adhesive bond stability without requiring complex surface preparation or multiple coating layers.
Solution Approach 2:
The patent changes the physical parameters of the coating process by using supersonic cold spray technology. The metal particles are accelerated to supersonic velocities and deposited at low temperatures, preventing thermoplastic degradation while achieving deep surface penetration. This parameter change enables thicker, more adherent metal layers with varying surface roughness, directly addressing the insufficient mechanical connection strength of conventional methods.
2Reliability
If thin metal coatings (1-30 μm aluminum) are applied to improve electrical conductivity, then the coating is simple, but the corrosion resistance and long-term stability are inadequate
Solution Approach 1:
The patent replaces conventional thin-film deposition methods with supersonic cold spray, enabling the application of thicker metal layers (exceeding 30 μm) with superior adhesion. The supersonic particle impact creates deep mechanical interlocking and strong metallurgical bonds, ensuring long-term corrosion resistance and stability. The thicker layers provide enhanced protection against environmental degradation while maintaining electrical conductivity.
Solution Approach 2:
The patent creates a composite structure consisting of a thermoplastic profile body with a thick metal-containing layer deposited by supersonic cold spray. This composite material combination leverages the corrosion resistance and electrical conductivity of metals while maintaining the formability and insulation properties of thermoplastics. The strong interfacial bond between the two materials ensures long-term reliability under varying environmental conditions.
3Strength
If the thermoplastic profile surface is made rough to improve mechanical bonding, then the adhesion increases, but the sliding properties and contact quality deteriorate
Solution Approach 1:
The patent applies local quality by creating different surface characteristics in different regions of the metal-containing layer. The supersonic cold spray process enables control over layer thickness and surface roughness at different locations. Areas requiring strong bonding (e.g., connection zones) have rougher surfaces with deeper particle penetration, while areas requiring sliding contact have smoother surfaces. This spatial variation in surface quality simultaneously satisfies both adhesive bond strength and sliding property requirements.
4Reliability
If thick metal layers are deposited to improve corrosion resistance, then the protection increases, but the mechanical connection strength and adhesion to thermoplastic decrease
Solution Approach 1:
The patent replaces conventional coating methods with supersonic cold spray, which uses supersonic gas flow to accelerate metal particles to extremely high velocities. This mechanical energy enables thick metal layers to be deposited with strong adhesion to thermoplastic surfaces. The high-velocity particles penetrate deep into the thermoplastic surface, creating robust mechanical interlocking that maintains adhesive bond strength even as layer thickness increases for enhanced corrosion protection.
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 achieves significant improvements in mechanical connection strength, corrosion resistance, and electrical conductivity, enabling long-term stable adhesive bonds between thermoplastic and metal components, and facilitates the creation of electrical circuits, while providing enhanced durability against environmental factors like UV radiation, rain, and extreme temperatures.
Implementation Method 1
The application of a supersonic cold spray process to deposit an inorganic containing layer, such as aluminum or tin, onto thermoplastic profiles
Implementation Method 2
achieves significant improvements in mechanical connection strength, corrosion resistance, and electrical conductivity, enabling long-term stable adhesive bonds
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A profile for window, door, facade or cladding elements is disclosed, which comprises a profile body (2) made from thermoplastic material and extending in a longitudinal direction (z) with an essentially constant cross-section (x-y) along the longitudinal direction (z) and having at least one outer surface (2a), and a inorganic containing layer (4) deposited on at least part of the at least one outer surface (2a),wherein the thermoplastic material comprises at least one thermoplastic selected from the group containing polyamide, polyethylene, polybutylene terephthalate, acrylonitrile styrene acrylate,wherein the inorganic containing layer(4)is deposited directly on the profile body (2) using a cold spray technology, and wherein the inorganic containing layer (4) has a thickness in the range from 30µm to 450µm.