Fiber-Reinforced Resin Composite Manufacturing via Pre-Coated Filament Foaming
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Solution Overview
Problem
Existing methods for manufacturing fiber-reinforced resin composites face challenges in efficiently impregnating resin into fiber strands, limiting the fiber content and dispersibility, and complicating the manufacturing process, which increases time and cost.
Innovation Solution
A method involving spinning fiber filaments, coating their surfaces with an impregnation resin emulsion, and forming fiber strands by bundling the coated filaments, thereby enhancing resin impregnation efficiency and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If fiber strands are bound by binder or binding agent to prevent scattering, then fiber dispersibility is improved, but resin impregnation efficiency deteriorates
Solution Approach 1:
The patent applies preliminary action by coating the fiber filament surface with impregnation resin emulsion during the spinning process, before the fiber strand is formed. This preliminary resin coating is then foamed to create space between fibers, enabling subsequent resin infiltration without requiring strong binding agents that would hinder impregnation.
2Strength
If binding agent content is increased to maintain fiber strand integrity, then fiber strand strength is improved, but impregnation efficiency deteriorates
Solution Approach 1:
The patent performs preliminary resin coating and foaming during the spinning stage, creating internal space structure before strand formation. This eliminates the need for high binding agent content, as the foamed resin structure provides both strand integrity and impregnation pathways.
Solution Approach 2:
The patent changes the physical state of resin from liquid emulsion to foamed structure, creating void spaces that facilitate subsequent resin infiltration while maintaining strand strength without requiring excessive binding agents.
3Productivity
If fiber strand is opened or widened to improve resin infiltration, then impregnation efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The patent creates the necessary internal space structure during the spinning process itself through resin coating and foaming, eliminating the need for subsequent opening or widening operations. The space for resin infiltration is prepared in advance during fiber formation.
4Productivity
If binding agent content is minimized to open fiber strands, then impregnation efficiency is improved, but fiber strand integrity deteriorates
Solution Approach 1:
The patent applies resin coating and foaming during spinning to create internal space structure before strand formation. This preliminary action provides both the space needed for impregnation and the structural framework to maintain strand integrity without relying on binding agents.
Solution Approach 2:
The patent transforms resin from a liquid coating to a foamed structure, creating a three-dimensional framework that maintains strand integrity while providing channels for resin infiltration, eliminating the trade-off between integrity and impregnation efficiency.
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 method allows for a higher fiber content and improved dispersibility, enabling the production of molded products with adjustable physical properties, such as tensile strength and impact strength, while reducing production time and cost.
Implementation Method 1
coating a surface of the fiber filament by spraying an impregnation resin emulsion onto the spun fiber filament
Implementation Method 2
foaming a fiber strand by bundling the surface-coated fiber filament
Data Source
AI summary
Provided are a method for manufacturing a fiber-reinforced resin composite, a fiber-reinforced resin composite manufactured by the manufacturing method, and a molded product, the method comprising the steps of: spinning a fiber filament; coating a surface of the fiber filament by spraying an impregnation resin emulsion onto the spun fiber filament; and forming a fiber strand by bundling the surface-coated fiber filament.