Fibre-matrix semifinished product
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Solution Overview
Problem
Fibre-matrix semifinished products with layered constructions tend to delaminate when subjected to mechanical stress, leading to reduced flexural strength due to inadequate attachment of the matrix polymer to the fibre material, especially when flame retardant additives are used.
Innovation Solution
A single-layered fibre-matrix semifinished product is created using 1 to 100 semifinished fibre product plies of endless fibres with a polyamide matrix and organic phosphinic acid salts, ensuring uniform impregnation and consolidation to maintain fibre attachment and prevent delamination, with a volume fraction of fibre materials between 25% to 65% and air or gas less than 15%, and using specific additives like melamine polyphosphate and zinc borate for enhanced properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If flame retardant additives are used in the matrix resin, then flame resistance is improved, but attachment of the matrix polymer to the fibre material deteriorates
Solution Approach 1:
The patent changes the chemical parameters of the flame retardant system by using specific phosphorus-containing compounds (phosphoric acid, phosphonic acid, diphosphonic acid) with controlled concentrations (0.1-10 wt% each). This parameter optimization maintains flame resistance while minimizing negative effects on matrix-fibre attachment, resolving the contradiction between flame safety and mechanical bonding.
Solution Approach 2:
The patent employs a composite flame retardant system combining multiple phosphorus-containing compounds in specific ratios within the polyamide matrix. This composite approach creates synergistic effects that preserve both flame resistance and attachment strength, overcoming the limitation of single-additive systems that compromise mechanical properties.
2Device complexity
If layered construction is used in fibre-matrix semifinished products, then manufacturing complexity is reduced, but delamination occurs under mechanical stress
Solution Approach 1:
The patent applies local quality enhancement at the critical matrix-fibre interface by ensuring uniform distribution of phosphorus-containing flame retardants throughout the matrix polymer. This localized optimization of material composition at the bonding interface prevents delamination while maintaining the overall simplicity of the single-layer construction.
Solution Approach 2:
The patent incorporates flame retardant additives beforehand into the matrix resin composition before impregnation. This preliminary incorporation ensures that the matrix polymer maintains its bonding capabilities from the start, preventing delamination issues that would otherwise develop under mechanical stress, thus cushioning against future reliability problems.
3Object-affected harmful factors
If uniform impregnation with flame retardant additives is achieved, then flame resistance is improved, but flexural strength deteriorates due to reduced fibre attachment
Solution Approach 1:
The patent optimizes the concentration parameters of phosphorus-containing flame retardants (0.1-10 wt% for each compound) to achieve the minimum effective level for flame resistance while preserving flexural strength. This parameter control ensures uniform impregnation without excessive additive content that would compromise fibre-matrix attachment and mechanical performance.
Solution Approach 2:
The patent uses the same polyamide-based matrix resin composition for both the bulk matrix and the surface layer, ensuring chemical consistency throughout. This copying approach eliminates composition mismatches that could cause delamination or flexural strength reduction, while still achieving uniform flame retardant distribution for improved flame resistance.
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 effectively maintains the attachment of the matrix polymer to the fibre material, preventing delamination and achieving identical or better flexural strength compared to non-flame-retarded compositions, as demonstrated by flexural tests according to ISO178, while ensuring the fibre-matrix semifinished products are flame-retarded.
Implementation Method 1
the entirety of all semifinished fibre product plies is impregnated with a compound comprising as component A) at least one polyamide
Implementation Method 2
the attachment of the matrix polymer to the fibre material is maintained
Implementation Method 3
based on 100 parts by mass of component A) the compound further comprises as component B) 5 to 100 parts by mass of at least one organic phosphinic acid salt and/or a diphosphinic acid salt
Implementation Method 4
consolidation to maintain fibre attachment and prevent delamination, with a volume fraction of fibre materials between 25% to 65% and air or gas less than 15%
Data Source
AI summary
A flame-retardant single-, or multi-layered, fiber-matrix semi-finished product has a polyamide-based fiber-matrix that includes at least one organic phosphinic acid salt and/or a diphosphinic acid salt. A process for the production thereof includes impregnating a fiber ply, or plies, and consolidating the ply or plies into a composite.