Fiber-Reinforced Resin Molding Material with Split and Unsplit Aggregates
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Solution Overview
Problem
Fiber-reinforced resin forming materials face a trade-off between achieving good fluidity during the forming process and excellent mechanical properties in the final product, with existing technologies either prioritizing one over the other.
Innovation Solution
A fiber-reinforced resin forming material comprising a bundled aggregate of discontinuous reinforcing fibers, including a split fiber aggregate A and an unsplit or partially split fiber aggregate B, with a controlled weight ratio of 50-95% for aggregate B, to balance fluidity and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If fiber bundles with many single yarns are used, then fluidity in forming process is improved, but mechanical properties of formed product deteriorate
Solution Approach 1:
The invention applies local quality by creating two distinct types of fiber aggregates with different properties: Aggregate A (completely split) provides good fluidity and dispersion, while Aggregate B (partially or unsplit) provides high mechanical strength. Each aggregate type is placed in the composite material according to its functional advantage, allowing different regions of the material to have different fiber configurations optimized for their specific roles.
Solution Approach 2:
The invention uses composite materials by combining two different types of fiber aggregates (A and B) with different split ratios in a single forming material. This composite approach allows the material to simultaneously achieve good fluidity (from Aggregate A) and high mechanical properties (from Aggregate B), resolving the contradiction between these two opposing requirements.
2Strength
If fiber bundles with less single yarns are used, then mechanical properties of formed product are improved, but fluidity in forming process is suppressed
Solution Approach 1:
The invention applies local quality by creating two distinct types of fiber aggregates with different properties: Aggregate A (completely split) provides good fluidity and dispersion, while Aggregate B (partially or unsplit) provides high mechanical strength. Each aggregate type is placed in the composite material according to its functional advantage, allowing different regions of the material to have different fiber configurations optimized for their specific roles.
Solution Approach 2:
The invention uses composite materials by combining two different types of fiber aggregates (A and B) with different split ratios in a single forming material. This composite approach allows the material to simultaneously achieve good fluidity (from Aggregate A) and high mechanical properties (from Aggregate B), resolving the contradiction between these two opposing requirements.
3Productivity
If completely split fiber bundles are used, then fluidity and productivity are improved, but stress concentration occurs at fiber ends
Solution Approach 1:
The invention applies local quality by creating two distinct types of fiber aggregates with different properties: Aggregate A (completely split) provides good fluidity and dispersion, while Aggregate B (partially or unsplit) provides high mechanical strength. Each aggregate type is placed in the composite material according to its functional advantage, allowing different regions of the material to have different fiber configurations optimized for their specific roles.
Solution Approach 2:
The invention uses composite materials by combining two different types of fiber aggregates (A and B) with different split ratios in a single forming material. This composite approach allows the material to simultaneously achieve good fluidity (from Aggregate A) and high mechanical properties (from Aggregate B), resolving the contradiction between these two opposing requirements.
Data Source
Figure 1(A)~2
AI summary
The present invention is a fiber-reinforced resin forming material containing at least a matrix resin and bundled aggregates of discontinuous reinforcing fibers, wherein: the bundled aggregates of reinforcing fibers include both reinforcing fiber aggregates A having a shape formed by cutting after having performed a splitting treatment to completely split the strands of continuous reinforcing fibers into a plurality of bundles of strands, and reinforcing fiber aggregates B1 having a shape that includes unsplit parts where splitting treatment was inadequate and/or reinforcing fiber aggregates B2 having a shape not subjected to splitting treatment; and both the ratio of the weight of the reinforcing fiber aggregates B1 with respect to the total weight of reinforcing fibers in the fiber-reinforced resin forming material, and the ratio of the total weight of the reinforcing fiber aggregates B1 and the reinforcing fiber aggregates B2 with respect to the total weight of reinforcing fibers in the fiber-reinforced resin forming material, are within a range of 50-95%. Provided are a fiber-reinforced resin forming material with which it is possible to achieve a good balance of excellent fluidity during forming and exceptional mechanical properties of the formed article, and a method for producing the same.