Fiber-Reinforced Resin Intermediate Material Void Reduction
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Solution Overview
Problem
Existing fiber-reinforced resin intermediate materials face challenges in shaping ability and void formation, particularly with thermoplastic resin sheets and prepregs, where air release is difficult and voids are easily formed due to high resin viscosity and complex shapes.
Innovation Solution
A fiber-reinforced resin intermediate material is created by attaching a resin powder to an opened reinforcing fiber substrate, heating it to impregnate the substrate in a semi-impregnated state with void spaces on the surface, allowing for improved shaping and impregnation while minimizing voids, using a combination of thermoplastic and thermosetting resins with controlled fiber volume content and apparent density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a thermoplastic resin non-woven fabric is melted to impregnate the reinforcing fiber bundle, then the impregnation is improved, but void spaces remain where impregnation is insufficient
Solution Approach 1:
The patent utilizes the porous structure of the thermoplastic resin non-woven fabric to facilitate resin flow and impregnation. The porous nature allows the resin to penetrate the reinforcing fiber bundles more effectively while maintaining pathways for air evacuation, thereby reducing void formation during the molding process.
Solution Approach 2:
The patent employs a composite structure combining thermoplastic resin non-woven fabric with thermosetting resin composition. The thermoplastic fabric provides structural support and initial impregnation, while the thermosetting resin fills remaining voids and provides final curing, creating a multi-phase composite system that addresses both impregnation uniformity and void reduction.
2Adaptability or versatility
If the fiber-reinforced resin intermediate material is used for complex shape molding, then shaping ability is improved, but air release becomes difficult and voids are easily formed
Solution Approach 1:
The patent performs preliminary impregnation of the reinforcing fiber substrate with thermoplastic resin before final molding. This preliminary action prepares the material for complex shape molding by pre-distributing resin in areas that will become difficult-to-reach zones, ensuring better impregnation uniformity while maintaining air release pathways through the non-woven fabric structure.
Solution Approach 2:
The patent controls the physical and chemical parameters of the resin system, including the glass transition temperature of the thermoplastic resin, the viscosity of the thermosetting resin composition, and the curing conditions. By optimizing these parameters, the material achieves both the flexibility needed for complex shaping and the flow characteristics necessary for complete impregnation without void formation.
3Strength
If the resin is fully impregnated into the reinforcing fiber substrate, then mechanical strength is improved, but shaping flexibility is reduced
Solution Approach 1:
The patent employs partial impregnation rather than complete saturation of the reinforcing fiber substrate. The thermoplastic resin non-woven fabric provides sufficient resin content for mechanical strength while leaving portions of the fiber substrate relatively dry, maintaining flexibility and shaping capability. The thermosetting resin is then applied to provide additional strength without compromising the flexibility gained from partial impregnation.
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 method enables the production of fiber-reinforced resin molded articles with complex shapes and reduced defects, achieving high fiber volume content and low void ratios through controlled impregnation and pressurization.
Implementation Method 1
heating the resin to a temperature equal to or higher than the melting point of the resin to the resin to the fibre tow
Implementation Method 2
by laminating the fiber-reinforced resin intermediate material and performing heating and pressurization
Data Source
Figure 1(a)~1(b)
Figure 2
Figure 3~4
AI summary
The present invention provides a fiber-reinforced resin intermediate material, including not only a thermoplastic resin but also a thermosetting resin, in which defects such as voids are difficult to be generated and which is excellent in shaping ability; and a method for manufacturing the same. The fiber-reinforced resin intermediate material according to the present invention is a fiber-reinforced resin intermediate material formed by attaching a resin to an outer surface part of a reinforcing fiber substrate formed of reinforcing fibers subjected to opening and heating the resin to a temperature equal to or higher than the melting point of the resin to impregnate the reinforcing fiber substrate with the resin, wherein the reinforcing fiber substrate has void space that is opened on an outer surface thereof and the resin is in a semi-impregnated state.