Composite Material Curing with Diluent-Assisted Fiber Wetting
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Solution Overview
Problem
Current methods for producing fiber-reinforced plastic composite materials face challenges in achieving high strength-to-weight ratio, durability under repeated and long-term stress, and cost-effective production, often resulting in materials with low durability and high production complexity.
Innovation Solution
A method involving mixing a plastic matrix substance with a diluent to form a mixture, which is then brought into contact with a reinforcement fiber structure, where the diluent is separated from the matrix substance during curing, using energy addition methods like electrical current through conductive fibers or microwaves to accelerate the process, reducing the need for heated molds and improving wetting and adhesion between fibers and matrix.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional methods are used to produce fiber-reinforced plastic composite materials, then production complexity is reduced, but the strength-to-weight ratio and durability are low
Solution Approach 1:
The patent extracts and removes voids and gas pockets from the composite material during the curing process through vacuum application. This extraction of defects improves the strength-to-weight ratio by ensuring dense fiber-matrix bonding without voids, while the vacuum system represents a relatively simple device compared to complex autoclave systems.
Solution Approach 2:
The patent changes the physical parameters of the resin system by using a low-viscosity resin that can thoroughly impregnate the fiber structure. This parameter change allows complete fiber wetting and void elimination without requiring complex heating equipment, thereby improving strength-to-weight ratio while maintaining simple production processes.
2Reliability
If complex production methods with heated molds and autoclaves are used, then material properties are improved, but production costs and time increase
Solution Approach 1:
The patent employs a self-curing resin system that cures at ambient or moderate temperatures without requiring external heating from complex mold systems or autoclaves. The resin's own chemical properties enable curing, eliminating the need for energy-intensive heated equipment and significantly reducing production time while maintaining durability through complete fiber impregnation and void elimination.
Solution Approach 2:
The patent uses vacuum application to extract air and volatiles from the composite during curing. This simple extraction process eliminates voids and ensures complete resin-fiber bonding, achieving high durability without the need for time-consuming autoclave cycles or complex heated mold systems.
3Strength
If resin viscosity is high, then material strength is maintained, but fiber wetting and adhesion are insufficient
Solution Approach 1:
The patent changes the viscosity parameter of the resin system by selecting or formulating a low-viscosity resin. This parameter change enables the resin to flow thoroughly through and wet the fiber structure completely, ensuring adequate adhesion between matrix and reinforcement. The low viscosity allows complete impregnation without requiring high pressure or complex injection systems, achieving both good wetting and maintaining strength through proper fiber-matrix bonding.
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 approach enables the production of composite materials with high fiber volume fraction, high strength-to-weight ratio, and improved durability, while reducing production costs and time, and eliminating the risk of voids and gas pockets, leading to enhanced material properties and increased production efficiency.
Implementation Method 1
adding energy to diluent from within the intermediate material, in particular by conducting electrical current through said electrically conductive reinforcement fibers
Implementation Method 2
exerting microwaves on the intermediate material
Implementation Method 3
exerting sound waves on the intermediate material
Implementation Method 4
separating diluent from matrix substance to form a composite material
Data Source
AI summary
A method according to an aspect of the invention comprises a step of bringing a plastic matrix substance in contact with a reinforcement fiber structure to form an intermediate material. Further, the method comprises a step of curing the matrix substance of the intermediate material to form a composite material. Before the plastic matrix substance is brought into contact with the reinforcement fiber structure, it is mixed with a diluent to form a mixture.