Molded body, composite material, and method for producing composite material
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Solution Overview
Problem
Molded articles made from poly(p-phenylene benzobisoxazole) fiber-based composite materials tend to undergo thermal expansion due to the presence of aggregates on the fiber surface, which are not effectively addressed by existing production methods.
Innovation Solution
The use of ultrasonically treated poly(p-phenylene benzobisoxazole) fibers, where surface particles are removed, and the fibers are partially or entirely covered with resin, forming a composition with a specific fiber proportion and width difference, to create a molded article resistant to thermal expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If poly(p-phenylene benzobisoxazole) aggregates are used as composite material, then fiber reinforcement is achieved, but thermal expansion occurs due to particle aggregation on fiber surface
Solution Approach 1:
The invention extracts and removes the harmful particles aggregated on the fiber surface through ultrasonic treatment. This separates the beneficial fiber reinforcement function from the harmful thermal expansion effect, allowing the fiber to provide strength without the aggregate-induced thermal expansion problem.
Solution Approach 2:
Ultrasonic vibration is applied to the composite material to remove particles from the fiber surface. The mechanical vibration energy disrupts and eliminates the aggregate structures that cause thermal expansion, while preserving the fiber's reinforcing capability.
2Object-affected harmful factors
If particles are removed from fiber surface by ultrasonic treatment, then thermal expansion is reduced, but manufacturing complexity increases
Solution Approach 1:
The ultrasonic treatment to remove particles is performed as a preliminary step before final composite formation. This preliminary action eliminates thermal expansion issues early in the process, preventing them from manifesting in the final product despite the added manufacturing step.
3Object-affected harmful factors
If fiber proportion is increased to 50% or more, then thermal expansion resistance is improved, but manufacturing difficulty increases
Solution Approach 1:
The invention changes the critical parameter of fiber proportion to 50% or more of total poly(p-phenylene benzobisoxazole) content. This parameter change ensures sufficient fiber reinforcement to resist thermal expansion while the ultrasonic treatment makes achieving this composition feasible by removing aggregates that would otherwise interfere with proper fiber distribution.
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 resulting molded article exhibits reduced thermal expansion and improved thermal conductivity through fiber dispersion and resin bonding, effectively suppressing thermal expansion during heating.
Implementation Method 1
a poly(p-phenylene benzobisoxazole) fiber (X) obtained by subjecting the poly(p-phenylene benzobisoxazole) aggregate described in Patent Literature 2, for example, to an ultrasonic treatment or the like to remove particles that are on the surface
Implementation Method 2
a composite material including a poly(p-phenylene benzobisoxazole) fiber (X) and a resin that covers all or a part of the fiber (X)
Data Source
Figure 1
Figure 2
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AI summary
Provided are a molded article, a composite material for producing the molded article, and a method for producing the composite material. The molded article formed from a composition containing a resin and poly(p-phenylene benzobisoxazole) fiber (X), wherein a proportion of the fiber (X) relative to 100% by mass of poly(p-phenylene benzobisoxazole) contained in the composition is 50% by mass or more.