Fiber-Reinforced Resin Substrate With Fiber-Bridged Resin Interface
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Solution Overview
Problem
Fiber-reinforced composite materials with thermoplastic resins face challenges in joining members with different properties, leading to prolonged production times and reduced strength due to mechanical or adhesive methods, and limited design freedom in thermal welding methods.
Innovation Solution
A fiber-reinforced resin substrate is created by impregnating two different thermoplastic resins into continuous reinforcing fibers, with one resin exposed on each surface, forming a boundary region where reinforcing fibers cross, enhancing the joining strength between layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical joining methods (bolts, rivets, screws) are used to join fiber-reinforced composite members, then the members can be integrated, but the production step is prolonged and production cost increases due to processing steps like creating holes
Solution Approach 1:
The patent replaces mechanical joining methods (bolts, rivets, screws) with thermal welding of thermoplastic resin. The thermoplastic resin layer is heated to melt and bond the thermosetting resin members together, eliminating the need for mechanical fasteners and associated processing steps like hole creation, thereby reducing production time while maintaining joining strength
Solution Approach 2:
The patent changes the physical state of the thermoplastic resin from solid to molten state through temperature control. By heating the thermoplastic resin layer to its melting point and then cooling it, the resin transitions through phase changes to achieve bonding, enabling joining without mechanical processing steps
2Reliability
If adhesive joining methods are used to join fiber-reinforced composite members, then the members can be integrated, but the production process is prolonged due to bonding preparation, coating, and curing processes
Solution Approach 1:
The patent replaces adhesive bonding processes with thermal welding using thermoplastic resin. Instead of requiring adhesive preparation, coating, and curing steps, the thermoplastic resin layer is directly heated to melt and bond the members together, significantly reducing production time while achieving comparable or superior bonding strength
3Productivity
If thermal welding methods are used to join members made of different thermoplastic resins, then joining time is reduced, but the degree of freedom in design is limited due to requirements for high compatibility or low compatibility resin combinations
Solution Approach 1:
The patent introduces a thermoplastic resin layer as an intermediary between thermosetting resin members. This thermoplastic layer acts as a mediator that can be selectively heated and melted to join different thermosetting resin members together, enabling design freedom in selecting different resin combinations while maintaining efficient thermal welding processes
Solution Approach 2:
The patent applies local quality by having the thermoplastic resin layer positioned specifically at the joining interface between members. This localized thermoplastic layer is heated to melt and bond the members, while the bulk materials can be different thermosetting resins with various properties, thus enabling design freedom in material selection while achieving efficient joining
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 allows for strong, efficient joining of members with different thermoplastic resins, improving interlaminar shear strength and enabling complex shape production in a single molding process, while maintaining high dynamic characteristics.
Implementation Method 1
a fiber-reinforced resin substrate obtained by impregnating a thermoplastic resin (A) and a thermoplastic resin (B) into continuous reinforcing fibers
Implementation Method 2
both the thermoplastic resin (A) and the thermoplastic resin (B) are a crystalline resin having a melting point of 200° C. or higher
Data Source
AI summary
A fiber-reinforced resin substrate is described in which a plurality of resins having differing properties are strongly composited, wherein the fiber-reinforced resin substrate is obtained by impregnating a thermoplastic resin (A) and a thermoplastic resin (B) into continuous reinforcement fibers, wherein a thermoplastic resin (A) layer, which comprises the thermoplastic resin (A) and is exposed at one surface, and a thermoplastic resin (B) layer, which comprises the thermoplastic resin (B) and is exposed at the other surface, form a boundary region, where at least some of the continuous reinforcement fibers exist in a manner spanning across the boundary region and both the thermoplastic resin (A) and the thermoplastic resin (B) are crystalline resins having a melting point of not less than 200° C.