Continuous-Fiber PPS Substrate for Gelation-Resistant Molding
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Solution Overview
Problem
Conventional fiber-reinforced polyphenylene sulfide (PPS) resin substrates suffer from brittleness, residual stress during molding, and insufficient mechanical properties due to high temperature processing, leading to gelled products and unstable production processes, with undisclosed molecular weight, ash content, and carboxyl group content.
Innovation Solution
A fiber-reinforced thermoplastic resin substrate with polyphenylene sulfide resin having a weight average molecular weight of 75,000 to 150,000, ash content of 0.001 to 0.30 wt%, and carboxyl group content of 5 to 25 μmol/g, optimized for improved mechanical properties and adhesion with reinforcing fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional PPS resin is used with high temperature processing, then molding is achieved, but the resin becomes gelled and mechanical properties are insufficient
Solution Approach 1:
The patent changes the molecular weight parameter of PPS resin from conventional high molecular weight (≥150,000) to a specific range (75,000-150,000), which fundamentally alters the resin's thermal and mechanical behavior during processing, enabling successful molding without gelation while achieving superior mechanical properties
Solution Approach 2:
The patent creates a composite material system by combining PPS resin with controlled molecular weight (75,000-150,000) and specific ash content (0.001-0.30 wt%) with reinforcing fibers, where the controlled resin properties allow effective fiber reinforcement without the negative effects of conventional high molecular weight resin
2Strength
If conventional PPS resin with high molecular weight is used, then resin strength is maintained, but toughness is insufficient and residual stress increases
Solution Approach 1:
The patent optimizes the molecular weight parameter to a specific range (75,000-150,000) which balances resin strength with toughness and reduces residual stress during molding, fundamentally improving the mechanical behavior compared to conventional high molecular weight resin
3Ease of manufacture
If high temperature heating is applied to PPS resin, then molding processability is improved, but gelled products are generated and production stability deteriorates
Solution Approach 1:
The patent changes the molecular weight parameter of PPS resin to (75,000-150,000), which fundamentally alters the resin's thermal behavior, allowing high-temperature molding processing without gelation and ensuring production stability
Solution Approach 2:
The patent eliminates the need for complex post-molding heat treatment processes by using PPS resin with optimized molecular weight that can be directly molded at high temperatures without gelation, simplifying the manufacturing process and improving stability
4Ease of manufacture
If conventional PPS resin is used, then basic molding is achieved, but mechanical properties such as flexural strength and interlayer shear strength are insufficient
Solution Approach 1:
The patent optimizes the molecular weight parameter to (75,000-150,000) and ash content to (0.001-0.30 wt%), which fundamentally enhances the resin's ability to provide mechanical strength while maintaining molding capability
Solution Approach 2:
The patent creates an optimized composite material system with PPS resin (Mw: 75,000-150,000, ash content: 0.001-0.30 wt%) combined with reinforcing fibers, where the controlled resin properties maximize the mechanical properties of the composite while maintaining processability
Data Source
AI summary
A fiber-reinforced thermoplastic resin substrate has good mechanical properties. The fiber-reinforced thermoplastic resin substrate includes a plurality of continuous reinforcing fibers and a polyphenylene sulfide resin with which the plurality of continuous reinforcing fibers are impregnated, wherein the polyphenylene sulfide resin has a weight average molecular weight of 75,000 or more and 150,000 or less, and the polyphenylene sulfide resin has an ash content of 0.001 wt % or more and 0.30 wt % or less.