Fluorinated Thermoplastic Prepreg for Fire-Resistant Composites
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Solution Overview
Problem
Current composite materials used in aircraft, train, and bus interiors face challenges such as toxicity, low mechanical performance, UV resistance, recyclability, and assembly difficulties, particularly with phenolic resin-based materials, and high costs and limitations with polyphenylene sulfide resins, necessitating the development of novel fire-resistant and mechanically robust materials.
Innovation Solution
A fluorinated thermoplastic polymer grafted with a polar carboxylic function and a fibrous reinforcer, specifically a unidirectional continuous inorganic or organic fiber, is used to create a flame-retardant composition, which is then processed into a prepreg for manufacturing fire-resistant composite materials through continuous lamination, vacuum molding, or thermo-compression, offering improved mechanical and fire-resistant properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If phenolic resin-based composite materials are used to meet fire safety standards, then fire resistance is improved, but mechanical performance and UV resistance deteriorate
Solution Approach 1:
The patent changes the chemical composition parameters of the thermoplastic resin from conventional materials to fluorinated polymers with specific chemical structures (containing F, H, C, and optionally O, N, Si, or B atoms). This parameter change enables the material to simultaneously achieve fire resistance comparable to phenolic resins while maintaining superior mechanical properties and UV resistance.
Solution Approach 2:
The patent uses composite materials consisting of fluorinated thermoplastic resin combined with reinforcing fibers (glass, carbon, aramid, or natural fibers). This composite structure allows the material to integrate the fire resistance required for transportation interiors with the mechanical strength provided by the fiber reinforcement, overcoming the limitations of both phenolic resins and simple thermoplastics.
2Reliability
If polyphenylene sulfide resins are used to achieve fire resistance, then fire safety is improved, but cost and molding temperature requirements worsen
Solution Approach 1:
The patent changes the thermal properties parameter by selecting fluorinated thermoplastic resins with lower melting points (typically 150-250°C) compared to polyphenylene sulfide (which requires >300°C). This parameter change enables fire-resistant composite materials to be manufactured at lower molding temperatures, reducing energy consumption and manufacturing complexity while maintaining fire resistance.
3Strength
If conventional thermoplastic composite materials are used for mechanical performance, then strength is improved, but fire resistance and smoke toxicity properties worsen
Solution Approach 1:
The patent changes the chemical composition parameter by incorporating fluorinated thermoplastic resins with specific molecular structures containing fluorine atoms. This parameter change fundamentally alters the combustion behavior of the material, resulting in fire-resistant properties and low smoke toxicity while preserving the mechanical performance enabled by the thermoplastic matrix and fiber reinforcement.
Data Source
AI summary
The present invention relates to the field of thermoplastic composite materials. Specifically, the invention relates to a fluorinated, flame-retardant thermoplastic composition, to the prepreg prepared from said composition, to the composite material containing said prepreg, to the methods enabling manufacture, and to the uses of said material. The invention also relates to the use of a thermoplastic prepreg for manufacturing fire-resistant composite materials.