Epoxy Fiber Composite With Internal Release for Molded Surface Adhesion
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Solution Overview
Problem
Existing fiber-reinforced resin materials face challenges in achieving high productivity and quality due to the need for frequent application of external mold release agents, which increase costs and labor, and internal mold release agents require large amounts that can decrease mechanical properties and adhesion, while current mold release agents struggle with releasability and adhesion issues, especially with epoxy resins.
Innovation Solution
A fiber-reinforced composite molded article containing a silicone oil as an internal mold release agent, with a fragment ion intensity ratio of 3≤A/B≤20 (A: silicone oil, B: epoxy resin) and a contact angle of 90 degrees or more, ensuring effective releasability without external agents and allowing high adhesion with minimal surface treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an external mold release agent is applied to the mold surface, then releasability is secured, but frequent application is required which increases molding cost and labor
Solution Approach 1:
The mold release agent is incorporated into the resin composition itself, allowing the molded article to self-release from the mold without requiring external application. The internal mold release agent automatically migrates to the interface between the molded article and mold during curing, providing sustained releasability across multiple molding cycles without additional labor or cost.
Solution Approach 2:
The mold release agent is pre-mixed into the resin composition before molding, so that the releasability function is already prepared in advance. This eliminates the need for post-molding or pre-molding application steps, reducing both labor and time while ensuring consistent releasability performance.
2Reliability
If a large amount of internal mold release agent is added to the resin composition, then releasability is improved, but the physical and mechanical properties of the molded article may decrease
Solution Approach 1:
The invention optimizes the concentration of the internal mold release agent within a specific range (0.1-10 parts by mass per 100 parts of resin) to achieve the balance between releasability and mechanical properties. By precisely controlling this parameter, sufficient mold release performance is obtained while minimizing the negative impact on the molded article's strength and physical properties.
Solution Approach 2:
The mold release agent is formulated as a composite system combining silicone oil with specific additives and modifiers that enhance both releasability and mechanical performance. This composite approach allows the mold release function to be achieved without sacrificing the structural integrity of the final product.
3Strength
If epoxy resin is used, then high strength is achieved, but strong adhesion to metal mold causes burr formation and quality issues
Solution Approach 1:
The internal mold release agent acts as an intermediary substance between the epoxy resin and the metal mold surface. It creates a release layer that prevents direct contact and strong adhesion between the epoxy resin and mold, thereby eliminating burr formation and surface defects while maintaining the high strength characteristics of the epoxy resin.
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 enables high productivity and quality by ensuring releasability from molds with a small addition of internal mold release agent, allowing high adhesion without special surface treatments like sanding, and forming a stable bond with adhesives.
Implementation Method 1
when the resin composition is cured in the mold, the mold release agent component is bled out onto the surface of the molded article
Implementation Method 2
a contact angle of 90 degrees or more
Data Source
AI summary
A fiber-reinforced composite molded article which is obtained by molding reinforcing fibers and an epoxy resin, while containing a silicone oil as an internal mold release agent, and which is characterized in that the fragment ion intensity ratio A/B as detected in case where the molded article surface is analyzed by time-of-flight secondary ion mass spectrometry is expressed by the relationship of 3≤A/B≤20. A: The intensity of a fragment ion that has the highest intensity among the fragment ions derived from the silicone oil. B: The intensity of a fragment ion that has the highest intensity among the fragment ions derived from the epoxy resin. A fiber-reinforced resin molded article according to the present invention is capable of achieving high productivity and high quality by effectively exhibiting releasability from a mold with a small addition amount of a mold release agent without using an external mold release agent, while being capable of exhibiting high adhesion to other members without requiring a special surface treatment such as sanding.