Fiber-Reinforced Resin With Gradient Elongation
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Solution Overview
Problem
Conventional fiber-reinforced plastic materials using thermosetting resins are prone to brittleness and cracking, necessitating the development of a fiber-reinforced resin material with improved impact resistance and strength characteristics.
Innovation Solution
A fiber-reinforced resin material with a laminated structure comprising alternately stacked fiber assembly layers and thermoplastic resin layers, where the fiber assembly layers consist of continuous fibers with thermoplastic resin particles attached to their surfaces, and the thermoplastic resin layers can differ in composition and fiber content rate on each surface side, enhancing elongation and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermosetting resin is used as matrix resin, then fluidity and ease of impregnation are improved, but brittleness and crack resistance deteriorate
Solution Approach 1:
The patent changes the fundamental parameter of matrix resin from thermosetting to thermoplastic type. This parameter change transforms the material's behavior from brittle and crack-prone to ductile and crack-resistant, while still achieving good impregnation through controlled melting and pressing processes during manufacturing.
Solution Approach 2:
The patent creates a composite structure combining continuous fibers with thermoplastic matrix resin. This composite approach leverages the high strength of continuous fibers while the thermoplastic matrix provides ductility and crack resistance, achieving both structural integrity and toughness.
2Strength
If thermoplastic resin is used as matrix resin, then impact resistance is improved, but interfacial adhesion with fibers deteriorates
Solution Approach 1:
The patent introduces thermoplastic resin particles as an intermediary substance on the fiber surfaces. These particles act as a bridge between the continuous fibers and the thermoplastic matrix, improving interfacial adhesion through mechanical interlocking and chemical bonding while maintaining the ductility and impact resistance of the thermoplastic matrix.
Solution Approach 2:
The patent employs a multi-component composite system including continuous fibers, thermoplastic resin particles on fiber surfaces, and thermoplastic matrix resin. This hierarchical composite structure addresses both interfacial adhesion and impact resistance by combining materials with complementary properties at different scales.
3Ease of manufacture
If uniform fiber assembly structure is used, then manufacturing simplicity is improved, but elongation gradient and toughness deteriorate
Solution Approach 1:
The patent applies local quality by creating a gradient in fiber content rate from the center to the surface of the molded object. The center region has higher fiber content for strength, while the surface region has lower fiber content and higher resin content for elongation and toughness. This spatial variation in composition optimizes both mechanical properties.
Solution Approach 2:
The patent transitions from a uniform one-dimensional fiber assembly to a three-dimensional gradient structure. By controlling fiber distribution in the thickness direction (z-axis), the patent creates differential elongation properties across different regions, with the surface exhibiting higher elongation than the center, thereby enhancing overall toughness.
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
The resulting material exhibits significantly higher bending stress and bending elastic modulus, along with improved resistance to cracking, by gradient-treating elongation properties across the surface sides, thereby enhancing toughness and mechanical characteristics.
Implementation Method 1
carbon fiber having thermoplastic resin particles adsorbed on a surface thereof
Implementation Method 2
a thermoplastic resin composition obtained by melt-kneading a polyamide resin, a polyolefin resin, and a compatibilizer
Implementation Method 3
a laminated structure in which fiber assembly layers and thermoplastic resin layers are alternately located
Data Source
AI summary
The fiber-reinforced resin material of the present invention is a fiber-reinforced resin material having a laminated structure in which fiber assembly layers and thermoplastic resin layers are alternately located, wherein the fiber assembly layers are each an assembly of continuous fibers having thermoplastic resin particles attached to surfaces thereof, and the fiber-reinforced resin material has a higher elongation on one surface side than that on the other surface side. The fiber-reinforced resin structure is made of the present fiber-reinforced resin material. A method for manufacturing the present fiber-reinforced resin material includes: a stacking step of stacking a sheet-shaped product of the continuous fibers that serves as the fiber assembly layer and a resin sheet that serves as the thermoplastic resin layer so as to obtain the laminated structure; and a hot-pressing step of heating and compressing a stacked product obtained through the stacking step in a stacking direction.