The COSADA project aims to develop a functional nonwoven-adhesive film for the structural bonding of metal-composite parts. Applying the thermoplastic nonwovens as a substrate, the epoxy adhesive will be fabricated as a ready-to-use product in a solid roll of material.

The innovative product will be manufactured by combining two products – an epoxy film developed by Adamant Composites from Greece and thermoplastic nonwovens manufactured by TMBK Partners Sp. z o.o. Thermoplastic nonwovens provide flexibility, while the selected epoxy film offers high bonding strength. The use of functional fillers embedded in the nonwovens expands the application.

Various types of polymers for nonwoven production will be tested, resulting in the most effective configuration of nonwoven and epoxy film with a bonding strength of 25 MPa. The nonwoven-epoxy adhesive film will be subjected to aging tests under variable temperatures and humidity to demonstrate the adhesive’s resistance. The effect of functional fillers such as carbon nanotubes will be studied to prove their contribution.

The developed technology will answer the structural need of the automotive sector for resistant adhesive films, but also having the potential to reach other markets where high-performance lightweight joining methods are required, such as in the aeronautic industry. The technology will allow consistent, lighter designs, and enhanced new functionalities.

TMBK Partners Sp. z o.o. will lead the task dedicated to the project coordination and will manufacture, using the pilot-line, various thermoplastic nonwovens from thermoplastic polymers with and without functional fillers, having different areal weights, as well as will perform material testing.