Commingled Yarn Prepreg Manufacturing for High-Strength Composite Parts
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Solution Overview
Problem
There is a lack of suitable composite materials and manufacturing methods for creating molded articles that require high mechanical properties, particularly for large or partially reinforced components, using commingled yarns containing continuous reinforcing fibers and thermoplastic resin fibers.
Innovation Solution
A method involving the disposition of commingled yarns with continuous reinforcing fibers and thermoplastic resin fibers on a prepreg surface, followed by heat-processing, where the prepreg contains unidirectionally or bidirectionally parallel reinforcing fibers with a thermosetting resin impregnated between them, and optionally fixing the yarns with a thread-like material, to produce a molded article with enhanced mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If commingled yarn stitch is used for entire portion of molded article, then mechanical strength is improved, but manufacturing complexity increases and productivity decreases for large or partially reinforced components
Solution Approach 1:
The patent applies local quality by selectively placing commingled yarn only in specific regions of the molded article where high mechanical strength is required, rather than using it throughout the entire structure. This allows different parts of the article to have different reinforcement levels, optimizing both strength where needed and manufacturing efficiency where full reinforcement is not necessary.
Solution Approach 2:
The patent segments the reinforcement strategy by dividing the molded article into zones with different reinforcement requirements. Commingled yarn is applied segmentally to specific areas needing enhanced mechanical properties, while other areas use standard materials, thereby improving overall productivity without compromising critical strength requirements.
2Ease of manufacture
If commingled yarn is disposed on prepreg surface without fixation, then manufacturing simplicity is improved, but yarn positioning accuracy deteriorates during heat processing
Solution Approach 1:
The patent applies preliminary action by fixing the commingled yarn to the prepreg surface before heat processing begins. This preliminary fixation step ensures that the yarn maintains its intended position and orientation throughout the subsequent heat treatment process, preventing displacement while adding only minimal complexity to the manufacturing process.
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 enables the production of molded articles with improved mechanical strength and high productivity, suitable for large or partially reinforced components, by effectively integrating commingled yarns into the prepreg structure, ensuring uniform fiber distribution and adhesion, while maintaining moldability.
Implementation Method 1
a melting point of a thermoplastic resin fiber constituting the continuous thermoplastic resin fiber is higher than a curing temperature of the thermosetting resin
Implementation Method 2
a curing temperature of the thermosetting resin
Data Source
AI summary
To provide a method for manufacturing a novel molded article using a commingled yarn and a composite material using a commingled yarn. The method for manufacturing a molded article, includes disposing a commingled yarn containing a continuous reinforcing fiber and a continuous thermoplastic resin fiber on a part of a surface of a prepreg, the prepreg containing continuous reinforcing fibers paralleling at least unidirectionally, and a thermosetting resin impregnated between the continuous reinforcing fibers, and heat-processing the prepreg with the commingled yarn.