Fiber-Reinforced Resin Composite Material Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for manufacturing fiber-reinforced resin composite materials with complex shapes are costly due to the use of expensive polyamide particles, which increases the production costs while aiming to maintain a predetermined level of impact resistance.
Innovation Solution
A method involving a prepreg with reinforcing fibers and a preform with alternating layers of second and third fibers, where the second fibers are impregnated with a resin composition common to the first resin, and the preform is heated to melt the first polyamide resin, allowing the second resin composition to cure and form a second member on the surface of the first member, reducing manufacturing costs while maintaining high impact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyamide particles are used to improve impact resistance, then impact resistance is improved, but manufacturing cost increases
Solution Approach 1:
The invention changes the melting point parameter of the polyamide resin from conventional low melting point (e.g., PA6 at 220°C) to high melting point (e.g., PA11 at 230°C or higher). This parameter change allows the polyamide resin to maintain its impact-resistant properties while enabling proper impregnation and curing at the resin injection temperature, thereby reducing manufacturing cost by eliminating the need for expensive polyamide particles.
Solution Approach 2:
The invention utilizes the phase transition (melting) of the high melting point polyamide resin at a controlled temperature range (higher than conventional polyamide but lower than the reinforcing fiber melting point). This phase transition enables the polyamide resin to flow and impregnate the fiber preform properly, creating a void-free composite structure that provides inherent impact resistance without requiring additional polyamide particles.
2Manufacturing precision
If high melting point polyamide resin is used, then impregnation and void elimination are improved, but resin injection temperature must be increased
Solution Approach 1:
The invention changes the melting point parameter of the polyamide resin to a high melting point range (230°C or higher), which allows the resin to maintain structural integrity at injection temperatures while still enabling proper impregnation. This parameter change resolves the contradiction by allowing improved impregnation quality without excessively increasing the resin injection temperature beyond practical limits.
Solution Approach 2:
The invention creates a composite system combining high melting point polyamide resin with thermosetting resin and reinforcing fibers. This composite material system allows the polyamide resin to provide void elimination and impregnation benefits at controlled temperatures, while the thermosetting resin provides structural integrity. The composite approach enables achieving good impregnation quality without requiring excessively high injection temperatures.
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 enables the production of fiber-reinforced resin composite materials with complex shapes at lower costs while achieving comparable or higher impact resistance, stabilizing the quality and reducing voids within the composite material.
Implementation Method 1
heating the preform and the second resin composition at a temperature that is higher than the melting point of the first polyamide resin and lower than the melting point of the second polyamide resin to melt the first polyamide resin of the fourth fiber
Implementation Method 2
curing, after the heating, the first resin composition and the second resin composition to form a first member and to integrally form a second member on a surface of the first member
Data Source
AI summary
A fiber-reinforced resin composite material includes first and second members. The first member includes a first fiber and a first matrix resin. The first fiber includes a reinforcing fiber and is impregnated with the first matrix resin. The reinforcing fiber has a melting point and a tensile strength higher than those of an aliphatic polyamide fiber. The second member includes a stack and a second matrix resin. The stack includes a second fiber and a third fiber filled with the second matrix resin. The second fiber includes the reinforcing fiber. The second matrix resin includes a component common to that of the first matrix resin, and includes a first polyamide resin that includes an aliphatic polyamide resin. The third fiber includes a second polyamide resin that includes an aliphatic polyamide resin and has a melting point higher than that of the first polyamide resin by 7 to 50 degrees centigrade.