Fiber Reinforced Resin Sheet Production Method
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Solution Overview
Problem
Conventional methods for producing fiber reinforced resin sheet materials using thermoplastic resins face issues such as resin adhesion to conveying belts or sheets, fiber misalignment, and uneven impregnation, leading to increased production costs and reduced productivity due to the high viscosity of thermoplastic resins and difficulties in peeling off the resin sheet material without damaging it.
Innovation Solution
A production method involving the superimposition of a fiber sheet material and a resin sheet material, where the fiber sheet material is conveyed with tension across its entire width, and the resin sheet material is integrated and solidified within the fiber sheet material using heating and pressing, with specific steps to ensure uniform thickness and impregnation, including fluid spreading and lateral vibration of the fiber bundles to prevent adhesion and maintain fiber alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermoplastic resin is used as matrix resin, then toughness and recyclability are improved, but viscosity increases making impregnation difficult
Solution Approach 1:
The resin sheet material is pre-heated to a temperature above its melting point before impregnation, reducing its viscosity in advance to facilitate easier penetration into the fiber sheet material during the subsequent impregnation process
Solution Approach 2:
The temperature of the thermoplastic resin is changed from ambient temperature to above its melting point, transforming its physical state and dramatically reducing viscosity to enable effective impregnation into the fiber bundle
2Manufacturing precision
If resin sheet material is heated and pressed for impregnation, then impregnation is achieved, but resin adheres to conveying belt
Solution Approach 1:
A release agent is introduced as an intermediary substance between the heated resin sheet material and the conveying belt, preventing direct adhesion while allowing the resin to be conveyed and impregnated effectively
Solution Approach 2:
A disposable release paper or film is placed between the resin and conveying belt for each production cycle, serving as a sacrificial barrier that prevents resin adhesion to the expensive conveying belt while being discarded after single use
3Ease of operation
If fiber sheet material is conveyed without tension, then handling is easier, but fiber alignment deteriorates
Solution Approach 1:
The conveying system dynamically adjusts tension application, applying tension during critical stages such as superimposition and impregnation to maintain fiber alignment, while reducing or releasing tension during handling and transport stages
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 enables continuous and stable production of fiber reinforced resin sheet materials with improved impregnation uniformity and reduced adhesion issues, enhancing productivity and cost-effectiveness by preventing resin adhesion to conveying materials and maintaining fiber alignment.
Implementation Method 1
a first heating roll 1A and a second heating roll 1B... heating and pressing while conveying the superimposed fiber sheet material Ts and resin sheet material Js... melting the resin sheet material Js
Implementation Method 2
a first cooling roll 2A and a second cooling roll 2B... cooling while conveying the composite sheet material... solidifying step of solidifying a resin by cooling
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The purpose of the present invention is to provide a production method for a fiber reinforced resin sheet material, the method being capable of continuously and stably obtaining the fiber reinforced resin sheet material by using a fiber sheet material and a resin sheet material and melting the resin sheet material and impregnating or semi-impregnating the same into the fiber sheet material. The method includes the steps of: superimposing a fiber sheet material Ts and a resin sheet material Js, sandwiching these materials between conveying belts 7 and conveying the same; heating and pressing these materials between the heating rolls 1; and after the above steps, cooling and pressing the resulting material between cooling rolls 2 and thereby melting and impregnating or semi-impregnating the resin sheet material Js into the fiber sheet material Ts and thereby obtaining a fiber reinforced resin sheet material Ps, in which side end portions 8, 9 of the fiber sheet material Ts are arranged outside side end portions 10, 11 of the resin sheet material Js, respectively, and the fiber sheet material Ts and the resin sheet material Js are superimposed.