Thermoset Composite Intermediate Layer Staged Curing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Composite materials with thermoset intermediate layers face challenges in forming components due to brittleness, difficulty in controlling partial curing, and high manufacturing costs, leading to unreliable process reliability and compromised component properties.
Innovation Solution
A composite material with an intermediate layer comprising multiple thermosets at different polymerization temperatures, where at least one is cured and others are uncured, allowing controlled polymerization during production and forming, ensuring reliable forming properties and cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a thermoset intermediate layer is used to bond metal sheets, then bonding strength is improved, but forming properties deteriorate due to brittleness
Solution Approach 1:
The intermediate layer is segmented into multiple thermoset polymers with different curing temperatures. The first thermoset polymer cures at lower temperature providing initial bonding, while the second thermoset polymer remains uncured during forming and cures later at higher temperature, enabling both strong bonding and good forming properties
Solution Approach 2:
The curing temperature parameter is differentiated between multiple thermoset polymers. By selecting polymers with different curing temperature characteristics, the system achieves staged curing: initial bonding at lower temperature and final strengthening after forming at higher temperature, resolving the contradiction between bonding strength and formability
2Ease of manufacture
If partial curing of thermoset is controlled during production, then forming properties are improved, but process reliability deteriorates due to difficulty in control
Solution Approach 1:
The first thermoset polymer acts as an intermediary that cures at lower temperature to provide initial structural stability and bonding. This intermediary layer enables the second thermoset polymer to remain uncured during forming, achieving good forming properties while the first polymer ensures process reliability through early bonding
3Ease of manufacture
If multiple thermosets with different polymerization temperatures are used, then forming properties are improved, but manufacturing complexity increases
Solution Approach 1:
Multiple thermoset polymers with different curing temperatures are merged into a single intermediate layer. This combination allows the layer to exhibit complex staged curing behavior (initial bonding followed by final strengthening) while maintaining a simple single-layer structure, avoiding the need for multiple separate layers or complex manufacturing processes
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 improved forming properties, prevents contamination of forming tools, maintains component properties, and allows for repair by adjusting polymerization temperatures, enhancing process reliability and component quality.
Implementation Method 1
an intermediate layer which is made of at least a first duromer and a second duromer with a higher polymerization temperature than the first duromer
Implementation Method 2
at least the first thermoset in a cured state and the second thermoset in an uncured state
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The invention relates a composite material (1) consisting of a metallic bottom flat element (2), a metallic top flat element (2') and an intermediate layer of thermosetting plastic arranged between the bottom flat element (2) and the top flat element (2'). In order to provide a composite material (1) comprising an intermediate layer of thermosetting plastic that has improved shaping properties and moreover can be produced at low cost and by a reliable process, it is proposed that the intermediate layer consists of three or more thermosetting materials (3, 4, 5), wherein one thermosetting material (3) is in a set state and the other thermosetting material (4) is in a non-set state and the first thermosetting material (3) has a polymerization temperature of between 50 and 100°C, the second thermosetting material (4) has a polymerization temperature of between 170 and 220°C and a third thermosetting material (5) has a polymerization temperature of between 230 and 260°C. The invention also relates to a method for producing such a composite material and a method for producing a shaped component from it.