Flame-Retardant Laminate Structure That Preserves Mechanical Properties
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Solution Overview
Problem
Existing carbon-fiber-reinforced composite materials face challenges in achieving both high flame retardancy and maintaining mechanical properties, with previous methods either compromising on flame retardancy or moldability due to resin shrinkage differences.
Innovation Solution
A laminate and prepreg design where the flame-retardant filler is unevenly distributed on one surface, with a specific area ratio and particle size, and includes a matrix resin with a thermoplastic component, ensuring a balanced distribution of flame retardant and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flame-retardant filler is blended in thermosetting resin, then flame retardancy is improved, but mechanical properties deteriorate due to filler acting as fracture origin
Solution Approach 1:
The patent applies local quality by concentrating the flame-retardant filler in the surface layer portion (within 400 μm from the outermost surface) rather than uniformly distributing it throughout the laminate. This localized concentration achieves high flame retardancy at the surface where combustion would initiate, while maintaining better mechanical properties in the interior regions where the filler would otherwise act as fracture origins.
2Reliability
If flame-retardant filler is stacked on both surfaces, then flame retardancy is improved, but physical properties deteriorate from vicinity of both surface layers
Solution Approach 1:
The patent concentrates flame-retardant filler in the surface layer portion (within 400 μm from the outermost surface) of each prepreg, achieving high flame retardancy where needed while limiting the overall filler content to 1-20 wt% to maintain mechanical properties. The surface layer thickness is controlled to balance flame protection with structural integrity.
3Reliability
If different resins are used on both sides of prepreg, then flame retardancy and physical properties are achieved, but moldability deteriorates due to delamination from shrinkage difference
Solution Approach 1:
The patent uses the same thermosetting resin (epoxy resin) on both sides of the prepreg, ensuring uniform shrinkage behavior during curing. This homogeneity prevents delamination and maintains good moldability, while flame retardancy is achieved through localized filler concentration in the surface layer rather than through resin composition differences.
Data Source
AI summary
A lightweight laminate capable of maintaining mechanical properties while exhibiting excellent flame retardancy, a method for producing the laminate, and a prepreg are described, where the laminate includes fibers; a matrix resin; and a flame-retardant filler and satisfies 0.01<A/B<0.15 under the described conditions where A and B are as defined. The prepreg includes fibers; a matrix resin; and a flame-retardant filler and satisfies 0.01<A/B<0.15 under the described conditions where A and B are as defined.