Fiberglass-Mat Thermoplastic Substrates With Low Thermal Expansion
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Solution Overview
Problem
Conventional thermoplastic composites face challenges in achieving low thermal expansion coefficients without compromising other properties like weight, flexibility, and cost, particularly with polymers like polyolefins and PVC, which are difficult to fill effectively with fillers to reduce thermal expansion.
Innovation Solution
Embedding a fiberglass mat with an open weave into a thermoplastic polymer using thermal compression bonding, specifically through a continuous double belt press, allows for the production of thermoplastic composites with significantly reduced thermal expansion coefficients while maintaining mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If excessive filler or fibers are added to reduce thermal expansion coefficient, then thermal expansion coefficient is reduced, but other properties such as weight, flexibility, cost, and impact strength are compromised
Solution Approach 1:
The invention changes the physical state parameters of the thermoplastic polymer by heating it to a molten state, enabling it to penetrate and impregnate the fiberglass mat structure. This parameter change allows the polymer to flow into the mat's voids and bond with fibers, creating a composite with reduced thermal expansion without requiring excessive filler content that would compromise mechanical properties.
Solution Approach 2:
The invention creates a composite material system combining thermoplastic polymer and fiberglass mat, where the polymer impregnates the mat structure to form an integrated composite. This composite approach reduces thermal expansion coefficient through the fiberglass reinforcement while maintaining impact strength through proper fiber-matrix bonding, avoiding the need for excessive filler that would degrade mechanical properties.
2Stability of the object's composition
If high amounts of fillers are incorporated into thermoplastics to reduce thermal expansion, then thermal expansion coefficient is reduced, but it becomes very difficult to mix and process the material
Solution Approach 1:
The invention performs preliminary action by pre-forming the fiberglass mat structure before polymer impregnation. The mat is prepared in advance with its fibrous network structure, and then the molten polymer is applied to impregnate it. This sequential approach avoids the mixing difficulties of incorporating high amounts of filler into the polymer, as the reinforcement structure is established separately before composite formation.
Solution Approach 2:
The molten thermoplastic polymer acts as an intermediary medium that facilitates bonding between the fiberglass fibers and the final composite structure. By heating the polymer to a molten state, it becomes a fluid intermediary that can penetrate the mat structure, wet the fibers, and create strong interfacial bonding, enabling easy processing without requiring high filler loading that would complicate mixing.
3Stability of the object's composition
If thermoplastic polymers with high thermal expansion coefficients (such as polyethylene and polypropylene) are used, then density and flexibility are maintained, but it is difficult to modify them into thermoplastic composites with very low thermal expansion coefficient
Solution Approach 1:
The invention applies parameter changes by heating the thermoplastic polymer to its melting point, transforming it from a solid state to a molten state. This parameter change enables the polymer to flow and impregnate the fiberglass mat structure effectively. Even polymers with high thermal expansion coefficients like polyethylene and polypropylene can be successfully modified into composites with very low thermal expansion through this thermal parameter change and subsequent impregnation process.
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 thermoplastic composites exhibit thermal expansion coefficients at least three times lower than the neat thermoplastic resin, achieving values as low as 8*10^-6 m/(m*°C), suitable for applications requiring low thermal expansion without sacrificing mechanical strength or increasing density.
Implementation Method 1
heating the thermoplastic polymer to a molten state
Implementation Method 2
thermal compression bonding method
Implementation Method 3
applying a compressive force to the fiberglass mat and thermoplastic polymer
Data Source
Figure 1
AI summary
A substrate and method for providing a thermoplastic composite having a fiberglass mat embedded within a thermoplastic polymer. The characteristics of the fiberglass mat combined with a thermal compression bonding method allow for a substantially improved and desirable thermal expansion coefficient over conventionally filled thermoplastic substrates or other fiberglass reinforced thermoplastics.