Fiber-Reinforced Composite Surface Smoothing via Resin Coating
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Solution Overview
Problem
Fiber-reinforced resin molded articles exhibit surface irregularities due to reinforcement fiber morphology and resin shrinkage, leading to inferior surface smoothness, which is not adequately addressed by existing methods, particularly in applications requiring high-quality surfaces like automobile exterior components.
Innovation Solution
A molded article with a fiber-reinforced composite material coated with a film formed from a resin composition comprising an aliphatic epoxy resin, a thiol compound, and a quaternary phosphonium salt, cured at a temperature lower than the molding temperature to reduce thermal shrinkage and improve surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a fiber-reinforced resin molded article is produced by conventional molding methods (SMC, BMC, RTM), then productivity and mechanical properties are improved, but surface smoothness deteriorates due to surface irregularities from reinforcement fiber morphology and resin shrinkage
Solution Approach 1:
The invention applies a covering resin composition to the fiber-reinforced resin molded article before final curing, performing the surface smoothing action in advance. The covering resin fills the surface irregularities caused by fiber morphology and resin shrinkage, creating a smooth surface that is then cured to form a durable protective layer.
2Manufacturing precision
If mending and polishing treatments are applied to improve surface smoothness, then surface quality is improved, but labor time and process complexity increase considerably
Solution Approach 1:
The invention replaces mechanical mending and polishing processes with a chemical solution - applying a covering resin composition that chemically fills and smooths surface irregularities. This substitution eliminates the need for manual or automated mechanical surface treatment equipment and reduces process complexity while achieving superior surface smoothness.
3Manufacturing precision
If mending and polishing treatments are applied to improve surface smoothness, then surface quality is improved, but production time increases significantly for large surface area or complicated shaped articles
Solution Approach 1:
The invention replaces time-consuming mechanical mending and polishing operations with a rapid-curing covering resin composition. The resin can be applied and cured in a single continuous process, dramatically reducing production time for articles with large surface areas or complicated shapes while achieving consistent surface smoothness across all geometries.
4Manufacturing precision
If a covering resin composition is applied to conceal fiber patterns and pinholes, then surface quality is improved, but additional curing time and process steps are required
Solution Approach 1:
The invention uses a covering resin composition with specifically adjusted curing parameters - a slow-curing agent system that allows adequate time for the resin to flow and fill surface irregularities before curing begins, followed by a curing accelerator that speeds up the final curing process. This parameter optimization achieves smooth surface quality without excessive curing time.
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 solution significantly reduces surface irregularities and enhances the surface quality of fiber-reinforced composite materials, enabling their broader use in applications such as automobiles, thereby improving fuel efficiency and reducing greenhouse gas emissions.
Implementation Method 1
a resin composition comprising an aliphatic epoxy resin, a thiol compound, and a quaternary phosphonium salt
Implementation Method 2
a resin composition comprising an aliphatic epoxy resin, a thiol compound, and a quaternary phosphonium salt
Implementation Method 3
forming a film on its surface to markedly reduce the surface irregularity of the molded article
Data Source
AI summary
The present invention addresses the problem of providing a fiber-reinforced composite material molded article which exhibits excellent viscosity stability with regards to a resin composition for coating at a low temperature (50°C) after mixing, takes a short period of time to cure when forming a coating, and has excellent surface appearance. This molded article has a coating formed by having a resin composition cure on the surface of a fiber-reinforced composite material. The resin composition contains [A] an aliphatic epoxy resin, [B] a thiol compound, and [C] a quaternary phosphonium salt.