Composite Prepreg Base Production for Complex FRP Shapes
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Solution Overview
Problem
Conventional fiber-reinforced plastic (FRP) production methods struggle to create complex shapes with continuous fibers, leading to poor mechanical properties and surface issues like warping and voids, especially in thin components.
Innovation Solution
A composite prepreg base production process involving cuts in continuous fibers and an additional resin layer with lower viscosity and higher fracture toughness than the matrix resin, allowing for improved flowability and adhesion, which facilitates the production of FRP with complex shapes and enhanced mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If continuous fibers are used in prepreg base, then mechanical properties are improved, but ability to form complicated shapes is worsened
Solution Approach 1:
The patent applies segmentation by cutting the continuous fibers into discontinuous fibers with specific length (1-300mm). This segmentation allows the fibers to bend and flow more easily during molding, enabling complicated three-dimensional shapes while maintaining adequate mechanical properties through the discontinuous fiber structure.
2Adaptability or versatility
If chopped strands are used in SMC process, then complicated shapes can be formed, but mechanical properties deteriorate due to uneven distribution and orientation
Solution Approach 1:
The patent changes the parameter of fiber length by controlling the cut length to be within 1-300mm. This parameter control ensures that the discontinuous fibers are long enough to maintain mechanical strength but short enough to flow and orient properly during molding, achieving both complicated shapes and good mechanical properties.
3Ease of operation
If deep cuts are put in prepreg base to increase flowability, then fiber flowability is improved, but mechanical properties vary largely
Solution Approach 1:
The patent optimizes the cut depth and cut length parameters to achieve the right balance. The cuts extend through the thickness but the cut length is controlled to be 1-300mm, which provides sufficient flowability while maintaining mechanical properties through proper fiber segmentation.
Solution Approach 2:
The patent performs preliminary cutting of fibers before molding to create the discontinuous structure. This preliminary action prepares the fiber structure in advance to flow properly during molding while maintaining the mechanical properties through controlled cut lengths.
4Strength
If thermoplastic resin with high melt viscosity is used as matrix, then structural integrity is improved, but flowability of prepreg base deteriorates
Solution Approach 1:
The patent segments the continuous fibers into discontinuous fibers, which reduces the viscosity of the prepreg base mixture. This segmentation allows the thermoplastic resin with high melt viscosity to still achieve adequate flowability during molding, as the discontinuous fiber structure creates more space for resin flow.
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 process enables the production of FRP with high quality stability, good mechanical properties, and improved appearance quality, suitable for structural elements with complicated shapes like transport equipment and sports equipment.
Implementation Method 1
an additional resin layer with lower viscosity and higher fracture toughness than the matrix resin
Implementation Method 2
an additional resin layer with lower viscosity and higher fracture toughness than the matrix resin
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A composite prepreg base which comprises: a raw prepreg base comprising a fiber sheet comprising discontinuous reinforcing fibers arranged in one direction and having a fiber length of 1-300 mm and a matrix resin infiltrated into the fiber sheet; and an additional resin layer formed on at least one surface of the raw prepreg base. The composite prepreg base is produced by a process comprising (i) the step of preparing the raw prepreg base and (ii) the step of forming an additional resin layer on at least one surface of the raw prepreg base prepared. Also provided are: a layered base comprising two or more sheets of the composite prepreg base which have been superposed so that the additional resin layer is present on at least one surface; and a fiber-reinforced plastic formed by heating and pressing the layered base.