Flame-Resistant Layered Molded Article Using Infusible Fiber Sheet
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Solution Overview
Problem
Existing resin molded articles face challenges in achieving high flame resistance and flame shielding properties on their surface, while also maintaining desired strength, stiffness, and moldability.
Innovation Solution
A flame-resistant layered molded article is created by exposing one surface of a fiber sheet material containing infusible fibers to the outside and joining at least a part of the other surface to a thermoplastic resin forming a molded article body, thereby achieving high flame resistance and flame shielding properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a chemical having a flame-retardant effect is kneaded into the resin to impart flame retardance to the molded article itself, then the flame retardance of the molded article is improved, but the degree of flame retardance is limited and high flame resistance or flame shielding property cannot be achieved
Solution Approach 1:
The invention divides the molded article into two distinct layers: a flame-resistant fiber sheet material layer and a molded article body layer. The fiber sheet material layer containing infusible fibers is positioned on the surface to provide high flame resistance and flame shielding property, while the molded article body provides structural integrity. This segmentation allows each layer to specialize in its function, with the surface layer dedicated to flame protection and the body to structural requirements.
Solution Approach 2:
The invention uses a composite structure combining infusible flame-resistant fibers with thermoplastic resin. The fiber sheet material comprises infusible fibers (such as aramid, glass, or carbon fibers) that do not melt or burn, combined with a thermoplastic resin that provides moldability and strength. This composite material approach allows the surface layer to exhibit high flame resistance while maintaining desired mechanical properties and moldability.
2Object-affected harmful factors
If non-woven fabric or paper made of composite comprising infusible fibers and fibers made of polyphenylene sulfide is used to achieve high flame resistance, then the flame shielding property is improved, but it is difficult to form a molded article having desired strength and stiffness and good moldability
Solution Approach 1:
The invention separates the flame protection function from the molding function by using two distinct layers. The fiber sheet material layer provides flame shielding property, while the molded article body made of thermoplastic resin provides moldability and structural strength. This segmentation resolves the contradiction by allowing each layer to optimize for its specific function without compromising the other.
Solution Approach 2:
The invention creates a composite structure where a fiber sheet material layer (containing infusible fibers and thermoplastic fibers) is joined to a molded article body made of thermoplastic resin. The fiber sheet material provides flame resistance and flame shielding property, while the thermoplastic resin body provides excellent moldability, strength, and stiffness. The combination achieves both high flame shielding property and good moldability that neither material could achieve alone.
3Object-affected harmful factors
If non-woven fabric or paper is made fairly thick to achieve high flame resistance, then the flame shielding property is improved, but the cost becomes extremely expensive and desired strength and stiffness cannot be secured
Solution Approach 1:
The invention divides the structure into a thin flame-resistant fiber sheet material layer and a separate molded article body layer. The fiber sheet material layer, being thin, provides sufficient flame shielding property without requiring excessive thickness. The molded article body provides the necessary strength and stiffness. This segmentation allows achieving high flame shielding property and mechanical strength without increasing overall thickness or cost.
Solution Approach 2:
The invention uses a composite structure combining a thin fiber sheet material layer with a molded thermoplastic resin body. The fiber sheet material layer (containing infusible fibers) provides high flame shielding property even at thin thickness due to the flame-resistant properties of infusible fibers. The thermoplastic resin body provides the required strength and stiffness. This composite approach achieves flame shielding, strength, and stiffness without requiring thick material or incurring extreme costs.
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 provides high flame resistance and flame shielding properties to the surface of the molded article, while ensuring desired strength, stiffness, and good moldability at a low cost.
Implementation Method 1
a thermal conductivity of the infusible fibers A determined based on ISO22007-3 (2008) is 0.060 W/m·K or less
Implementation Method 2
a part of the thermoplastic fibers B and a part of the thermoplastic resin C are fused to each other
Implementation Method 3
the fiber sheet material containing the infusible fibers A and the thermoplastic fibers B is thermally welded with the thermoplastic resin C
Implementation Method 4
the fiber sheet material containing the infusible fibers A and the thermoplastic fibers B is formed as a fiber sheet material capable of exhibiting a flame shielding property by forming a film between the infusible fibers A by melting the thermoplastic fibers B and carbonizing the film under an oxygen blocking condition
Data Source
AI summary
The present invention is a flame-resistant layered molded article in which one surface of a fiber sheet material containing at least infusible fibers A, particularly a fiber sheet material containing infusible fibers A and thermoplastic fibers B, is exposed to the outside of a molded article, and in which at least a part of the other surface side is joined to a thermoplastic resin C forming a molded article body. As a flame-resistant layered molded article, the present invention can realize to exhibit the high flame resistance and flame-shielding property that are required, and to ensure the desired strength and stiffness and good moldability that are required overall.