Fiber-Reinforced Resin Pellets Core-Shell Structure
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Solution Overview
Problem
Conventional methods for producing fiber-reinforced resin products often result in insufficient fiber opening and uneven distribution, leading to inadequate mechanical strength and unstable product quality.
Innovation Solution
A method involving the production of a fiber-containing particulate resin structure by dispersing fibers in a molten resin, followed by extrusion through a discharge port and cutting off the resin composition after it has expanded to a required diameter, ensuring fibers are evenly distributed and aligned for enhanced mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If pellets obtained by solidifying long fibers with resin are used as raw material, then fiber length is maintained for mechanical strength, but fiber opening becomes insufficient and distribution becomes uneven
Solution Approach 1:
The invention segments the fiber-resin pellet structure by introducing a core-shell configuration where the resin is divided into a core portion and a shell portion, with fibers positioned at the interface. This segmentation allows fibers to be released more effectively during molding while maintaining length, resolving the contradiction between strength and distribution uniformity.
Solution Approach 2:
The invention performs preliminary action by pre-positioning fibers at the interface between core and shell portions during pellet formation, and pre-heating the mold cavity before injection. This preliminary preparation ensures that fibers are properly oriented and the mold is at optimal temperature, achieving both fiber opening and uniform distribution while maintaining mechanical strength.
2Ease of manufacture
If conventional compression molding or transfer molding is used, then manufacturing process is simple, but fiber opening is insufficient and product quality is unstable
Solution Approach 1:
The invention introduces a specially designed fiber-containing resin pellet as an intermediary material that bridges the gap between simple molding processes and high product quality. The pellet's core-shell structure with fibers at the interface acts as a mediator that enables effective fiber opening and uniform distribution even in conventional molding processes, thereby improving reliability without complicating the manufacturing process.
3Strength
If long fibers are used to enhance mechanical strength, then tensile strength and impact resistance improve, but fiber distribution uniformity deteriorates
Solution Approach 1:
The invention applies local quality by concentrating fibers at the specific location of the interface between core and shell portions, rather than uniformly distributing them throughout the entire pellet. This localized positioning ensures that long fibers are concentrated where they can most effectively enhance mechanical strength while the core-shell structure prevents clumping, thereby achieving both strength enhancement and distribution uniformity.
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 results in a cured fiber-reinforced resin product with improved mechanical strength and stable product quality, as evidenced by increased compressive strength, flexural strength, and Charpy impact resistance.
Implementation Method 1
a molten mixture of a resin composition in which fibers are dispersed in an opened state in a molten resin is obtained
Implementation Method 2
discharging the molten mixture through a discharge port
Implementation Method 3
after the diameter of the resin composition that has been discharged through the discharge port has expanded to reach a required range with respect to the diameter of the discharge port
Data Source
Figure 1~3
Figure 4
AI summary
A fiber-containing particulate resin structure (S) is a particulate resin structure including a resin (1) and fibers (2), in which the fibers (2) are dispersed in the resin (1) in an opened state, and an average density of the resin structure is in a range of 0.20 to 1.00 (g/cm3).