Fiber-Reinforced Foam Particle Molded Article Without Adhesives
Solution Overview
Problem
Existing methods for producing fiber-reinforced expanded particle molded articles require adhesives, leading to increased costs and complexity, and often result in density gradients and warping due to heating, which complicates thickness control and reduces mechanical strength.
Innovation Solution
A fiber-reinforced expanded particle molded article is produced by integrating a fabric or braided reinforcing material made from a linear composite material comprising low-temperature and high-temperature melting thermoplastic fibers, which is fused with the surface of expanded molded articles during in-mold molding, using a method that eliminates the need for adhesives and allows for precise control of thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is used to bond expanded molded article and FRTP layer, then adhesion between layers is improved, but weight increases and cost increases
Solution Approach 1:
The invention extracts and eliminates the adhesive layer from the composite structure, achieving direct bonding between the expanded molded article and FRTP layer through heat fusion alone, thereby removing the source of additional weight and cost
Solution Approach 2:
The invention uses a composite material system where the expanded molded article surface and FRTP layer are directly fused through heat, creating a strong bond without requiring an intermediate adhesive material
2Strength
If heating is applied to integrate reinforcing material with expanded molded article, then integration is achieved, but warping occurs and thickness control becomes difficult
Solution Approach 1:
The invention changes the heating parameters by using lower temperatures and shorter heating times during in-mold molding, preventing excessive thermal expansion and warping while still achieving sufficient integration of the reinforcing material with the expanded molded article
Solution Approach 2:
The reinforcing material is pre-placed on the mold surface before molding, and the in-mold molding process simultaneously expands the beads and fuses the reinforcing material to the surface, preventing warping by establishing the final geometry before cooling
3Manufacturing precision
If control device is added for thickness control, then thickness precision is improved, but device complexity increases
Solution Approach 1:
The invention enables the expanded molded article to self-regulate its thickness through the inherent properties of the expanded beads and the molding process, eliminating the need for external control devices such as spacers or thickness control mechanisms
4Productivity
If in-mold molding is used to produce expanded molded article with skin layer, then production efficiency is improved, but reinforcing effect is insufficient and cost increases
Solution Approach 1:
The invention uses a composite material system where the expandable beads are combined with a thermoplastic resin skin layer that contains reinforcing fibers, creating a unified composite structure that provides both structural integrity and reinforcing effect
Solution Approach 2:
The invention merges the skin layer formation and reinforcing material integration into a single in-mold molding process, where the thermoplastic resin melts and bonds the reinforcing fibers to the expanded bead surface, achieving both functions simultaneously
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 enhances mechanical strength, reduces production costs, and simplifies the process by integrating the reinforcing material directly with the expanded molded article during molding, achieving a uniform density and improved geometric design flexibility.
Implementation Method 1
introducing a heating medium into the cavity through vent holes open on the mold surface of the mold to thermally expand the filled particles
Implementation Method 2
the matrix component of the reinforcing material (2) and the surface of the expanded molded article (3) are fused and integrated during in-mold molding
Implementation Method 3
produced by melting and integrating a thermoplastic fiber comprising a low-temperature melting component fiber as a matrix component and a high- temperature melting component fiber as a fiber reinforcement
Data Source
Figure 1~2(B)
Figure 3(A)~3(C)
Figure 4(A)~4(D)
AI summary
The present invention can provide a fiber-reinforced expanded particle molded article having a reinforcing material fused and integrated with the surface of an expanded molded article, wherein the reinforcing material is a fabric or a braided product produced by weaving a linear composite material produced by melting and integrating a thermoplastic fiber comprising a low-melting component fiber and a high-melting component fiber, as two or more threads selected from the group consisting of a warp, a weft and a slant thread, the fiber-reinforced expanded particle molded article exhibiting an excellent reinforcing effect; and a method for economically producing the molded article by in-mold molding with a small number of steps.