Fiber-containing prepregs and methods and systems of making
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Solution Overview
Problem
Conventional methods face challenges in evenly distributing resin compositions within fibers, particularly with high viscosity melts and powdered resins, which can lead to inefficient processing and potential damage to fibers, and require complex and costly steps to achieve homogeneous mixtures.
Innovation Solution
The use of prepregs with reactive fibers and resin compositions, including monomers and oligomers that polymerize to form a low-viscosity matrix, which are applied to fibers and then cured to create a polymerized resin matrix, reducing the need for time-consuming mixing and dispersal steps and minimizing fiber damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If high viscosity thermoplastic polymer melt is used as resin composition, then the resin material can be applied to fibers, but it becomes difficult to impregnate into the bulk of the fibers
Solution Approach 1:
The patent changes the physical state parameter of the resin from a high-viscosity melt to a low-viscosity suspension in a liquid carrier medium (such as water). This parameter change allows the resin to easily penetrate and impregnate the fiber bulk without requiring high pressure or temperature that could damage the fibers.
2Ease of operation
If temperature is increased to reduce resin viscosity, then the resin becomes easier to apply, but unwanted reactions or decomposition occur in the resin material
Solution Approach 1:
Instead of changing temperature to reduce viscosity, the patent changes the resin formulation by creating a suspension in a liquid carrier medium. This allows the resin to maintain low viscosity at lower temperatures, preventing thermal decomposition and unwanted reactions while still achieving easy application and impregnation.
3Ease of manufacture
If pressure is increased using a double belt press to drive high-viscosity melt into fibers, then resin impregnation improves, but fibers are damaged and distorted
Solution Approach 1:
The patent changes the resin rheology by formulating it as a suspension in a liquid carrier medium, which dramatically reduces viscosity. This allows the resin to flow into and impregnate the fiber bulk under minimal pressure, eliminating the need for high-pressure belt pressing that would damage and distort the fibers.
4Quantity of substance
If powdered resin composition is applied to fibers, then resin can be distributed on fiber surface, but significant difficulty exists distributing particles beyond the surface into the bulk
Solution Approach 1:
The patent changes the physical form of the resin from a powder to a suspension in a liquid carrier medium. This parameter change allows the resin to be applied as a liquid that can easily penetrate and distribute throughout the fiber bulk, rather than remaining as surface-level particles that are difficult to disperse internally.
5Ease of manufacture
If particle size is reduced to fit through interstitial spaces between fibers, then resin distribution improves, but complex and expensive processing is required
Solution Approach 1:
The patent changes the resin formulation from a powder requiring size reduction to a suspension in a liquid carrier medium. This eliminates the need for complex milling processes to reduce particle size, as the liquid suspension can already penetrate through fiber interstices without requiring further size reduction.
6Ease of manufacture
If fine-grained particles are mixed in air to distribute resin, then resin can be applied to fibers, but explosion hazard is created
Solution Approach 1:
The patent uses a liquid carrier medium (such as water) as the base for the resin suspension, eliminating the need to handle fine resin particles in air. This inherently creates a safe processing environment without explosion hazards, as the resin is dissolved or suspended in a non-flammable liquid medium throughout the application process.
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 simplifies the process of creating fiber-reinforced composite articles by eliminating the need for extensive resin application and dispersal, enhancing the efficiency and integrity of the final product while reducing processing time and costs.
Implementation Method 1
The reactive resin composition may include monomers and/or oligomers capable of polymerizing into a polymerized resin matrix
Implementation Method 2
The mixture may be heated to a polymerization temperature where the monomers, oligomers, or both polymerized to form a fiber-resin amalgam
Data Source
AI summary
Methods of making fiber-containing prepregs are described. The methods may include the steps of providing a plurality of fibers, and applying a reactive resin composition to the plurality of fibers to make a mixture of the plurality of fibers and the resin composition. The reactive resin composition may include at least one of monomers and oligomers capable of polymerizing into a polymerized resin matrix. The mixture may be heated to a polymerization temperature where the monomers, oligomers, or both polymerize to form a fiber-resin amalgam that includes the polymerized resin matrix. The fiber-resin amalgam may be formed into the fiber-containing prepreg. Also described are methods of forming a fiber-reinforced composite that includes the prepreg.