Continuous Fiber Resin Molding Interface Void Reduction
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Solution Overview
Problem
Continuous fiber-reinforced molded resins of prior art exhibit low adhesive force and affinity at the interface between reinforcing fibers and the matrix resin, leading to numerous voids and inadequate strength, shock absorption, and impact strength, along with poor resin impregnation and physical properties.
Innovation Solution
Modifying the compatibility between the resin and sizing agent during production and optimizing the resin flow during molding to reduce voids at the interface, using a combination of thermoplastic resins with varying proportions at the interface to enhance adhesion and mechanical properties, and employing a method involving hot pressing with a sizing agent containing a coupling agent, binding agent, and lubricating agent to achieve high strength and rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional sizing agents are used on continuous reinforcing fibers, then the fibers can be processed and molded, but the adhesive force and affinity at the interface between fibers and resin are low, resulting in many voids and inadequate strength
Solution Approach 1:
The patent modifies the chemical composition and molecular weight parameters of the sizing agent to optimize its compatibility with thermoplastic resins. By changing these parameters, the sizing agent forms a transition layer that improves interfacial adhesion and reduces void formation at the fiber-resin interface.
Solution Approach 2:
The sizing agent acts as an intermediary substance between the hydrophilic glass fibers and hydrophobic thermoplastic resins. It creates a transition layer that is compatible with both materials, improving adhesion and preventing void formation at the interface.
2Productivity
If prior art molding methods are used, then production can proceed, but the loss tangent is high and shock absorption is insufficient
Solution Approach 1:
The patent optimizes the molecular weight and composition parameters of the thermoplastic resin to reduce the loss tangent. By selecting resins with specific molecular characteristics, the material exhibits lower energy loss and improved shock absorption while maintaining molding efficiency.
3Ease of manufacture
If prior art resin formulations are used, then molding can be performed, but the storage modulus is low and impact strength is insufficient
Solution Approach 1:
The patent uses composite thermoplastic resin formulations combining different polymer components. This composite approach achieves both good moldability and high storage modulus, resulting in improved impact strength while maintaining ease of manufacture.
4Quantity of substance
If conventional resin impregnation methods are used, then fibers can be covered with resin, but the impregnation property is low and adhesion is inadequate
Solution Approach 1:
The patent modifies the viscosity and molecular weight parameters of the thermoplastic resin to improve its impregnation capability. The optimized resin flows better into the fiber bundle interstices and forms stronger adhesion upon cooling and crystallization.
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 solution results in a continuous fiber-reinforced molded resin with high adhesive force, reduced voids, improved strength, shock absorption, and impact resistance, along with enhanced resin impregnation and physical properties such as high tensile and flexural modulus, and increased productivity.
Implementation Method 1
a sizing agent containing a coupling agent, binding agent, and lubricating agent
Implementation Method 2
hot pressing with a sizing agent containing a coupling agent, binding agent, and lubricating agent
Implementation Method 3
optimizing the resin flow during molding to reduce voids at the interface
Implementation Method 4
a sizing agent containing a coupling agent, binding agent, and lubricating agent
Data Source
AI summary
Provided are a continuous fiber-reinforced resin molding having high adhesion and compatibility in an interface between continuous reinforcing fibers and a synthetic resin, and in which a low occurrence of voids in the interface and adequate strength can be realized, and a method for manufacturing the same. A continuous fiber-reinforced resin molding comprising a synthetic resin and continuous reinforcing fibers having a substantially circular cross section, the continuous fiber-reinforced molding being characterized in that the number of continuous reinforcing fibers where the porosity in a peripheral-edge region separated by one tenth the radius of a single continuous reinforcing fiber from the peripheral edge part of the continuous reinforcing fibers in the interface between the synthetic resin and the single continuous reinforcing fiber in a cross section orthogonal to the length direction of the continuous reinforcing fibers is at least 10% of the total number of continuous reinforcing fibers.